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WA R DEPAR TMENT
31 JANUARY 1944 \
WAR DEPARTMENT TECHNICAL MANUAL
TM 9-808
^/■TON 4x4 TRUCK
(DODGE)
WAR DEPARTMENT
31 January 1944
"^iKis manual supersedes TM 9-808, 12 May 1943, and includes pertinent informa-
tion from TB 700-1, 1 January 1942; TB 700-20, 13 October 1942; TB 700-33,
11 February 1943; TB 700-37, 4 March 1943; TB 700-43, 17 April 1943; TB
800-4, 29 December 1942, and OFSB 6-11, 1 November 1943. For the super-
session of Quartermaster Corps (10-series) manuals see paragraph 1 d.
1
WAR DEPARTMENT
Washington 25, D. C, 31 January 1944
TM 9-808, ^-ton 4x4 Truck (Dodge), is published
for the information and guidance of all concerned
[A.G. 300.7 (20 Oct. 43)]
By Order of The Secretary of War:
G. C. MARSHALL,
Chief oi Staff.
Official: S=-''^ .
^ "^ -' ^^ ' «.^ '
I^^A. l^IO. _^ 'y0^%
$ Si -. Maior,:G^BBral, : „ ^
^ i- '^ ^ The ^djutaht-C^neral.
DistSfpvjToN: B and^^j#); B18 (2); R9 (4); Bn 6, 7, 9 and 18
' '^ - - (^>;.^e§^Vnd 18 (2), 9 (5).
(For explanation of symbols, see FM 21-6)
•• ^i944
TM 9-808
%-TON 4x4 TRUCK
(DODGE)
CONTENTS
PART ONE-VEHICLE OPERATING INSTRUCTIONS
Paragraphs Pagat
Section I Introduction 1 5
II Description and tabulated data. . 2-4 6-14
III Driving controls and operation. . 5-9 15-33
IV Auxiliary equipment controls and
operation 10-11 34-38
V Operation under unusual condi-
tions 12-17 39-46
VI First echelon preventive main-
tenance services 18-22 47-56
VII Lubrication 23-24 57-67
VIII Tools and equipment stowage on
the vehicle 25 68-69
PART TWO-VEHICLE MAINTENANCE INSTRUCTIONS
Section IX Record of modifications 26 70
X New vehicle run-in test .. 27-28 71-75
XI Second echelon preventive main-
tenance . 29 76-97
XII Organization tools and equipment 30-31 98
XIII Trouble shooting 32-53 99-132
XIV Engine— description, maintenance,
and adjustment in vehicle .... 54—65 133-153
XV-. Engine removal and installation. 66-67 154—162
XVI Fuel system 68-75 163-176
XVII Exhaust system 76-79 177-178
XVIII Cooling system 80-86 179-189
XIX Battery 87-89 190-194
3
TM 9-808
3/4 -TON 4x4 TRUCK (DODGE)
Paragraphs Paget
Section XX Starting system 90-93 195-197
XXI Generating system 94-97 198-201
XXII Ignition system 98-102 202-208
XXIII Radio interference suppression. . 103 209-219
XXIV Lighting system 104-113 220-230
XXV Instruments, gages, and miscel-
laneous electrical equipment . 114-123 231-240
XXVI Wiring 124-128 241-251
XXVII Clutch 129-131 252-255
XXVIII Transmission and power take-off 132-134 256-261
XXIX Transfer case 135-137 262-264
XXX Propeller shafts 138-139 265-267
XXXI Front axle 140-145 268-280
XXXII Rear axle 146-149 281-286
XXXIII Foot brakes 150-155 287-297
XXXIV Hand brake 156-160 298-302
XXXV Wheels and tires 161-165 303-309
XXXVI Steering 166-169 310-315
XXXVII Frame 170-171 316-318
XXXVIII Springs and shock absorbers .... 172-176 319-325
XXXIX Body and sheet metal 177-187 326-333
XL Winch 188-193 334-337
PART THREE-STORAGE AND SHIPMENT
Section XLI Storage and shipment 194-198 338-343
References 344-346
Index 347
TM 9-808
1
PART ONE-VEHICLE OPERATING INSTRUCTIONS
Section I
INTRODUCTION
Paragraph
Scope 1
1. SCOPE.
a. This technical manual is published for the information and
guidance of the using arm personnel charged with the operation and
maintenance of this materiel.
b. In addition to a description of the %-ton 4x4 truck (Dodge),
this manual contains technical information required for the identifica-
tion, use, and care of the materiel. The manual is divided into three
parts. Part One, section I through section VIII, contains vehicle
operating instructions. Part Two, section IX through section XL,
contains vehicle maintenance instructions for using arm personnel
charged with the responsibility of doing maintenance work within
their jurisdiction. Part Three, section XLI, contains instructions for
the shipment and limited storage of this vehicle.
c. In all cases where the nature of the repair, modifications, or
adjustment is beyond the scope or facilities of the unit, the respon-
sible ordnance service should be informed so that trained personnel
with suitable tools and equipment may be provided, or proper instruc-
tions issued.
d. .This manual includes operating and organizational mainte-
nance instructions from TM 10-1531, 1 October 1942. Together with
TM 9-1808A and TM 9-1808B this manual supersedes TM 10-1531,
1 October 1942.
TM 9-808
2
3/4 -TON 4x4 TRUCK (DODGE)
Section II
DESCRIPTION AND TABULATED DATA
Paragraph
Description ., 2
Differences among models 3
Data 4
2. DESCRIPTION.
a. The following models of vehicles are covered by this manual:
Type of Vehicle Model Type of Vehicle Model
Weapon carrier ^ WC-51 Command WC-56
Weapon carrier with Command with winch . . WC-57
winch WC-52 Telephone maintenance WC-59
Carryall WC-53 Emergency repair WC-60
Ambulance WC-54
PUBLICATIONS APPLYING TO THIS VEHICLE
OPERATORS MANUAL TM 9-
PARTS LIST SNL G-
MAINTENANCE MANUALS TM9-
RA PD 52784
Figure 1 —Publication Identlfieation Plate
b. All models are equipped with a liquid-cooled, 6-cylinder,
L-head gasoline engine, located at the front of the vehicle. Engine
power is transmitted from the four-speed transmission through a
short propeller shaft to the transfer case, and thence to both front
and rear axles. The vehicles may be driven with all four wheels or
with rear wheels only.
c. A manual identification plate is attached to the instrument
panel of each vehicle to designate the technical manual number and
parts list number pertaining to the vehicle (fig. 1).
d. A serial number plate is attached to the instrument panel ot
each vehicle. This plate gives pertinent vehicle information such as
model, serial number, weights, fuel and oil recommendations (fig. 2).
e. The steering gear of all models is mounted on the left side;
therefore, all models are known as "left-hand drive" vehicles.
Throughout this manual, the use of the terms "left" and "right"
indicate positions in relation to the location of the steering gear;
"left" means the steering gear side; "right" means the side opposite
steering gear.
TM 9-808
3
DESCRIPTION AND TABULATED DATA
3. DIFFERENCES AMONG MODELS.
a. Weapon Carrier; Models WC-51 and WC-52 (figs. 3 and 4).
The difference between models WC-51 and WC-52 is that the latter
is equipped with a power take-off and a drive shaft for the winch
mounted at the front of the vehicle. Both models can be identified
DODGE TRUCKS
DIVISION OF CHRYSLER CORPORATION
DETROIT, M ICH.
NOMENCLATURE
MODEL ■^^^^■IH SERIAL NS |
SUPPLY ARM OR SERVICE MAINTAINING TRUCK
GROSS WEIGHT _
MAX. TRAILED LOAD
IS. MAX.PAYLOAD
'lbs. DATE DELIVERY
RECOMMENDED OCTANE RATING GASOLINE 70MIN.
RECOMMENDED S.A.E. GRADE OIL SUMMER— 30
RECOMMENDED S. A. E. GRADE OIL W I N T E R — 1 O
RA PD 52710
Figure 2— Serial Number Plate
RA PD 52757
Figure 3-Weapon Carrier (Model WC-51 )-Left Front View
by the open driver's compartment and weapon carrier body with
tarpaulin mounted behind the driver's compartment. The electrical
system of both models is 6-volt with the battery located under the
hood.
b. Carryall; Model WC-53 (fig. 5). This model can be identified
by its closed body with side windows. The electrical system is 12 -volt
TM 9-808
3
3/4 -TON 4x4 TRUCK (DODGE)
RA PD 52707
Figure 4-Weapon Carrier (Model WC-52) with Wlneh-
Left Front View
RA PD 52708
Figure S-Carryall (Model WC-53)-Left Front View
TM 9-808
3
DESCRIPTION AND TABULATED DATA
RA PD 52706
figure 6-Atnbulanee (Model WC-54)-Left Front View
RA PD 52767
Figure 7-Command (Model WC-56}-Left Front View
TM 9-808
3
3/4 -TON 4x4 TRUCK (DODGE)
with battery located on right running board, and provision is made
for the installation of radio equipment.
c. Ambulance; Model WC-54 (fig. 6). This model can be iden-
tified by the large cross on each side of the body. It contains equip-
ment for the care of wounded personnel. The electrical system is
6-volt with battery located under the hood.
d. Command; Models WC-56 and WC-57 (figs. 7 and 8). The
difference between models WC-56 and WC-57 is that the latter is
equipped with a power take-off and a drive shaft for the winch
mounted at the front of the vehicle. Both models can be identified
by the open type body with folding top and side curtains. The elec-
RA PD 52760
Figure 8-Command (Model WC-57) with Winelt-Left Front View
trical system of both models is 12 -volt with battery located on the
right running board and provision is made for the installation of
radio equipment behind the front seat.
e. Telephone Maintenance; Model WC-59 (fig. ,9). This model
can be identified by its open cab and box-shaped body with exten-
sion ladder mounted on- the left side. The electrical system is 6-volt
with battery located under the hood.
f. Emergency Repair; Model WC-60 (fig. 10). This vehicle is
equipped with a body .-containing ordnance repair equipment. The
electrical system is 6-volt with battery located under the hood.
10
TM 9-808
3
DESCRIPTION AND TABULATED DATA
RA PD 52798
Figure 9— Telephone Maintenance (Model WC-59)—
Left Front View
RA PD 52907
Figure 1 0— Emergency Repair (Model WC-60)— Right Rear View
11
TM 9-808
4
3/4-TON 4x4 TRUCK (DODGE)
4. DATA.
a. Vehicle Specifications.
Engine (number of cylinders) 6
Transmission (number of speeds) 4 forward, 1 reverse
Transfer case (number of speeds) 1
Axle ratio (front and rear) 5.83 to 1
Tires:
Size 9.00 X 16 in., 8 ply
Rim size 16 x 6.50 CS
Electrical system voltage:
Weapon carrier, with and without winch 6 to 8 volts
Command, with and without winch 12 to 15 volts
Carryall 12 to 15 volts
Ambulance 6 to 8 volts
Telephone maintenance 6 to 8 volts
Emergency repair 6 to 8 volts
Winch, capacity 5,000 lb
Angle of approach and departure:
Approach Dapartur*
Weapon carrier, without winch 54 degrees 31 degrees
Weapon carrier, with winch 37 degrees 31 degrees
Carryall 54 degrees 28 degrees
Ambulance 53 degrees 24 degrees
Command, without winch 54 degrees 31 degrees
Command, with winch 37 degrees 31 degrees
Telephone maintenance 53 degrees 29 degrees
Emergency repair 53 degrees 32 degrees
Weights (road weight of fully equipped vehicle without
load or driver):
Weapon carrier, without winch 5,250 lb
Weapon carrier, with winch 5,550 lb
Command, without winch 5,375 lb
Command, with winch 5,675 lb
Carryall 5,750 lb
Ambulance 5,920 lb
Telephone maintenance 5,400 lb
Emergency repair 5,950 lb
Over-all width:
Weapon carrier, with and without winch 82^ in.
Command, with and without winch 78f^ in.
Carryall • 78f^ in.
Telephone maintenance 77^ in.
Emergency repair 81^ in.
Ambulance 77f^ in.
12
TM 9-808
4
DESCRIPTION AND TABULATED DATA
Tread, front and rear 64^4 in.
Over-all length:
Weapon carrier, without winch 166^ in.
Weapon carrier, with winch 176J4 '".
Command, without winch 166 in.
Command, with winch 175^ in.
Carryall 18554 in.
Ambulance 194J4 in.
Telephone maintenance 191/^2 in.
Emergency repair 186 in.
Over-all height:
Weapon carrier, with and without winch 81^ in.
Command, with and without winch 81^4 in.
Carryall 80^4 in.
Ambulance 90f^ in.
Telephone maintenance 80^4 in.
Emergency repair 89 in.
Road clearance, front and rear axle 10^%2 in.
Turning radius:
Weapon carrier and command, with and without winch . . 2 1 ft 2 in.
Carryall 24 ft 6 in.
Ambulance, telephone maintenance, and emergency
repair 26 ft 3 in.
b. Performance.
Brake horsepower (gross) 92 at 3,200 rpm
54.5 at 1,600 rpm
Engine compression pressure at cranking speed 98 to 118 lb
Engine oil pressure 30 to 50 lb above 30 mph
Maximum speed at 3,200 engine revolutions per minute
(all models) :
In fourth gear 55 mph
In third gear 33 mph
In second gear 18 mph
In first gear 9 mph
In reverse gear 7 mph
Maximum grade ascending ability (all models) of fully
loaded vehicle (1,500 lb allowance for pay load,
driver, and assistant driver):
In transmission low gear 60 pet (approx)
In transmission high gear 7 to 8 pet (approx)
In transmission high gear when towing 1,000-lb
load 6 to 7 pet (approx)
Maximum grade descending ability with vehicle fully
loaded (all models) 60 pet
13
TM 9-808
4
3/4 -TON 4x4 TRUCK (DODGE)
c. Capacities.
Fuel tank 30 gal
Crankcase (refill) 5 qt
Cooling system 17. qt
Transmission 2f^ qt
Transmission, with power take-off 3J4 Qt
Carburetor air cleaner 1 qt
Front and rear axle differentials 2^ qt for vehicles with serial
numbers up to 81674747 (ex-
cept serial numbers 81657582 •
through 81674101).
3 qt for vehicles with serial
numbers after 81657582 (ex-
cept serial numbers 81674101
through 81674747).
Transfer case 1^4 Q*
Winch worm housing 1 qt
14
TM
9-808
5
Section III
DRIVING CONTROLS AND OPERATION
Paragraph
Instruments and controls 5
Preparation of new vehicle for s«vice 6
Use of instruments and controls in vehicular operation 7
Towing the vehicle 8
Body equipment 9
5. INSTRUMENTS AND CONTROLS.
a. Ignition Switch (figs. 11 and 12). This switch has two posi-
tions, "ON" and "OFF." When turned clockwise ("ON"), the battery
is connected with the ignition circuit and the engine may be started.
With the switch "ON," the fuel gage registers the amount of fuel in
the tank, and the heater, defroster, and roof ventilator, are also oper-
ative (if so equipped).
ABCD E FGH
J K L M N O
_n,
^ \-\-i-ymrn
\ PQ R' S T U V W X Y
a.
I
Z AABB
I
A— COOLING SYSTEM
DRAIN CAUTION PLATE
B— TRANSMISSION AND TRANSFER
CASE SHIFT DIAGRAM PLATE
C— VOLTMETER SWITCH (COMMAND)
D— BEAM INDICATOR
E-VOLTMETER (COMMAND)
F— INSTRUMENT LIGHT
G- AMMETER
H— INSTRUMENT LIGHT
I— OIL PRESSURE GAGE
J — INSTRUMENT LIGHT
K-SPEEDOMETER
L— FUEL GAGE
M— INSTRUMENT LIGHT
N— THERMOMETER
O— PACKAGE COMPARTMENT
p_MAXIMUM PERMISSIBLE
ROAD SPEED CAUTION PLATE
Q— MANUAL IDENTIFICATION PLATE
R-VOLTMETER INSTRUCTION PLATE
(COMMAND)
S_MAIN LIGHTING AND BLACKOUT
SWITCH LOCK
T-MAIN LIGHTING AND
BLACKOUT SWITCH
U-IGNITION SWITCH
V— CHOKE CONTROL BUHON
W— SPEEDOMETER TRIP MILEAGE
SET STEM
X-THROTTLE CONTROL BUTTON
Y— INSTRUMENT LIGHT SWITCH
Z— BLACKOUT DRIVING LIGHT SWITCH
AA— SERIAL NUMBER PLATE
BB— WINCH CAUTION PLATE
RA PD 312544
Figure 1 1 —Instrument Panel (Open Bodies)
15
TM 9-808
5
3/4 -TON 4x4 TRUCK fDODGE)
BBCCGHIDJKLMNC F E ZPOA
DD EE Q W B
S T V R U X Y
A— COOLING SYSTEM
DRAIN CAUTION PLATE
B_TRANSMISSION AND TRANSFER
CASE SHIFT DIAGRAM PLATE
C— VOLTMETER SWITCH (CARRYALL)
D— BEAM INDICATOR
E— VOLTMETER (CARRYALL)
F— INSTRUMENT LIGHT
G— AMMETER
H— INSTRUMENT LIGHT
I — OIL PRESSURE GAGE
J — INSTRUMENT LIGHT
K-SPEEDOMETER
L— FUEL GAGE
M- INSTRUMENT LIGHT
N— THERMOMETER
O — PACKAGE COMPARTMENT
p_MAXIMUM PERMISSIBLE
ROAD SPEED CAUTION PLATE
Q-MANUAL IDENTIFICATION PLATE EE
R— VOLTMETER INSTRUCTION PLATE
(CARRYALL)
MAIN LIGHTING AND BLACKOUT
SWITCH LOCK
MAIN LIGHTING AND
BLACKOUT SWITCH
IGNITION SWITCH
CHOKE CONTROL BUTTON
SPEEDOMETER TRIP MILEAGE
SET STEM
THROTTLE CONTROL BUHON
INSTRUMENT LIGHT SWITCH
BLACKOUT DRIVING UGHT SWITCH
SERIAL NUMBER PLATE
ROOF VENTILATOR SWITCH
(AMBUlANCE)
DOME LIGHT SWITCH (AMBULANCE)
HEATER DEFROSTER BLOWER
SWITCH (AMBULANCE)
HEATER SWITCH (AMBULANCE)
RA PD 312545
S-
T—
U-
V-
w-
X-
Y-
z-
AA-
BB-
CC-
DD-
Ftgure 1 2— /nsfrumenf Panel (Closed Bodies)
b. Choke Control Button (figs. 11 and 12). This button controls
the fuel mixture for starting the engine when cold.
c. Throttle Control Button (figs. 11 and 12). This button con-
trols the opening and closing of the throttle, which in turn controls
engine speed.
d. Accelerator Pedal (figs. 13 and 14). This foot-operated pedal
is used to control engine speed while driving the vehicle.
e. Cranking Motor Pedal (figs. 13 and 14). This foot-operated
pedal actuates the starting motor for cranking the engine.
f. Clutch Pedal (figs. 13 and 14). When this foot-operated pedal
is pressed downward, the clutch is disengaged, and the transmission
gears may be shifted with the engine running without danger of
16
TM 9-808
5
DRIVING CONTROLS AND OPERATION
A -HORN BUnON
B -TRANSMISSION GEARSHIFT LEVER
C-COWL VENTILATOR HANDLE (RATCHET AND BRACE)
D -WINDSHIELD WIPER CONTROL KNOB
E- REAR VIEW MIRROR
F- CRANKING MOTOR PEDAL ROD BUTTON
G -WINDSHIELD CLAMP HANDLE
H -WINDSHIELD ADJUSTING ARM
I -WINDSHIELD ADJUSTING ARM LOCK NUT
J -CLUTCH PEDAL
K- BRAKE PEDAL
L-POWER TAKE-OFF CONTROL LEVER SHIFT LOCK
M-BEAM CONTROL SWITCH
N -POWER TAKE-OFF CONTROL LEVER
O-HAND BRAKE LEVER
P -ACCELERATOR PEDAL
Q -TRANSFER CASE HAND LEVER
R -MAP TABLE BOARD
S-FIRE EXTINGUISHER
RA PD 318322
Figure 1 3— front Compartment (Open Bodies)
17
TM 9-808
5
3/4 -TON 4x4 TRUCK (DODGE)
A -HORN BUTTON
B -TRANSMISSION GEARSHIFT LEVER
C-COWL VENTILATOR HANDLE (RATCHET AND BRACE)
D-V/INDSHIELD WIPER CONTROL KNOB
E- REAR VIEW MIRROR
F -CRANKING MOTOR PEDAL ROD BUTTON
G -WINDSHIELD PULL-TO HANDLE
H -WINDSHIELD ADJUSTING ARM
I -WINDSHIELD ADJUSTING ARM LOCK NUT
J -CLUTCH PEDAL
K -BRAKE PEDAL
M-BEAM CONTROL SWITCH
O-HAND BRAKE LEVER
P -ACCELERATOR PEDAL
Q -TRANSFER CASE HAND LEVER
R- MAP TABLE BOARD
S-FIRE EXTINGUISHER (CARRYALL)
T-DOOR WINDOW REGULATOR HANDLE
U-DOOR REMOTE CONTROL HANDLE
RA PD 318323
Figure 1 4— Front Compartmenf (Closed Bodies)
18
TM 9-808
5
DRIVING CONTROLS AND OPERATION
breaking gear teeth in the transmission. When foot pressure on the
pedal is relieved, it will return to the engaged position.
g. Transmission Gearshift Lever (figs. 13 and 14). This hand-
operated lever may be moved from neutral position to mesh the
gears in the transmission for first, second, third, fourth, or reverse
speeds.
h. Transfer Case Hand Lever (figs. 13 and 14). This lever may
be moved to either of two positions. In its forward position, power
is applied only to the rear axle. In its rear position (nearest the seat),
power is applied to both front and rear axles for four-wheel driving.
i. Hand Brake Lever (figs. 13 and 14). When this lever is pulled
back toward the seat, the hand brake is applied. Use the hand brake
lever only for the purpose of holding the vehicle while parked.
j. Brake Pedal (figs. 13 and 14). When this foot-operated pedal
is* pressed downward, the brakes at each wheel are applied to slow
down or stop the vehicle.
NOTE
RUN ENGINE TO CHARGE
BATTERY WHEN BATTERY
VOLTAGE WITH RADIO i
TRANSMITTER LOAD DROPS
TO RED LINE ON VOLTMETER,
OR 11.25 VOLTS
RA PD 52740
Figure 1 5— Voltmeter Instruction Plate
k. Instruments.
(1) Oil Pressure Gage (figs 11 and 12). This gage indicates the
pressure under which oil is pumped through the engine oiling system.
(2) Ammeter (figs. 11 and 12). This meter shows the amount of
electricity flowing into or out of the battery. When the electrical
units of the vehicle are using more electricity than the generator is
supplying, the pointer of the ammeter will be on the negative ( — )
side of zero. When less electricity is being consumed than the gener-
ator is supplying, the pointer will be on the. positive ( + ) side of zero.
(3) Voltmeter (figs. 11 and 12). Some vehicles having 12 -volt
electrical systems are equipped with a voltmeter which may be
switched in and out of the battery circuit to determine the voltage
of the battery. A plate (fig. 15) attached to the instrument panel
explains the use of the voltmeter. Leave the switch on only long
enough to take a reading and then switch it off.
THE ARMY LIBRARY
TM 9-808
5
3/4 -TON 4^x4 TRUCK (DODGE)
(4) Thermometer (figs. 11 and 12). The thermometer shows the
temperature of the cooling solution in the engine.
(5) Fuel Gage (figs. 11 and 12). This gage indicates the quantity
of fuel in the tank, when the ignition switch is turned on.
(6) Speedometer (figs. 11 and 12). The speedometer indicates
the speed of the vehicle in miles per hour. The needle is of the
luminous type, visible in the dark. The odometer at the top of the
speedometer face registers the total mileage covered by the vehicle.
The trip mileage odometer at the bottom of the speedometer face
may be returned to a zero reading by pushing in and turning the set
stem on the back of the speedometer.
LOCK
BUTTON
OUT
LOCK
BUTTON
OUT
DEPRESS
THE LOCK
BUTTON
LOCK
BUTTON
IN
/
THIRD POSITION
SECOND POSITION THIRD POSITION RA PD 312526
Figure 1 6— Main Lighfing and Blackout Switch Positions
1. Main Lighting and Blackout Switch (fig. 16). This switch
controls all vehicle lights except the dome lights in the Ambulance,
which operate independently of the main lighting and blackout
switch. The switch has four positions:
(1) Off Position. All lights except Ambulance dome lights are
inoperative. The Ambulance dome lights are controlled by a toggle
switch on the left side of the instrument panel.
(2) First Position. All blackout lights are operative. Service
lights are inoperative except Ambulance dome lights.
(3) Second Position. All service lights are operative. Blackout
lights are inoperative.
20
TM 9-808
5
DRIVING CONTROLS AND OPERATION
(4) Third Position. Service stop light is operative. All other
lights, except Ambulance dome lights are inoperative.
m. Instrument Light Switch (figs. 11 and 12). This switch is the
push-pull type. When pulled out, the instrument lights will light
provided the blackout switch is pulled out to the second position
(subpar. 1 above).
n. Headlights. The two headlights mounted on the front fenders
are controlled by the main lighting and blackout switch (subpar. 1
above) and beam control switch (figs. 13 and 14), which controls
the high and low beams of the headlights when they are turned on
by the blackout switch. Press the button with the foot to raise or
lower the headlight beams. The switch locks each time the button
is pressed. The headlight beam indicator (figs. 11 and 12), is illumi-
nated only when the high beam of the headlights is turned on.
o. Blackout Parking Lights. These lights (both head and tail)
contain specially shaped openings which enable the driver of a
vehicle to estimate the distance between his vehicle and another
vehicle during blackout conditions.
p. Blackout Driving Light. The blackout, driving light is located
on the left front fender. It contains a sealed beam unit which is con-
structed so that the beam of light is diffused, casting a fine spray
of limited illumination visible to the driver under blackout driving
conditions. The light is controlled by a switch (figs. 11 and 12) of
the push-pull type. When pulled out, the blackout driving light will
light provided the blackout switch is pulled out to the first position
(subpar. 1 above.
q. Tail and Stop Lights. These lights are controlled by the
blackout switch (subpar. 1 above).
r. Spotlight (Ambulance). The spotlight will operate only
when the blackout switch is pulled out to the second position (subpar.
1 above). The switch is mounted on the control handle.
s. Dome Light Switch.
(1) Ambulance. A toggle switch controls the dome lights in the
roof of the Ambulance (fig. 12). These lights operate independently
of the main lighting and blackout switch.
(2) Carryall. The dome light switch is incorporated in the
dome light. It may be turned on only .when the blackout switch is in
the second position (sUbpar. 1 above).
t. Trailer Wiring Connector (Weapon Carrier). This con-
nector is used for hooking up trailer lights with the vehicle lighting
system. The blackout switch controls trailer lights in the same
manner as other vehicle lights.
u. Fuel 'Pump Hand Primer. The fuel pump is equipped with
a hand primer which permits manual operation of the fuel pump to
force fuel to the carburetor in the event it runs dry.
V. Horn Button (figs. 13 and 14). This button operates the horn.
21
TM 9-808
5-6
3/4 -TON 4x4 TRUCK (DODGE)
w. Roof Ventilator Switch (Ambulance) (fig. 12). This toggle
switch controls the roof ventilator when the ignition switch is turned
on.
X. Heater Switches (Ambulance).
(1) Heater Defroster Blower Switch (fig. 12). This rheostat-
type switch is operated by rotating the knob of the switch. A slight
rotating motion of the knob puts the defroster motor in full speed
operation, and turning it farther reduces its speed.
(2) Heater Switch (fig. 12). This switch is operated by rotating
the knob of the switch. A slight rotating motion of the knob puts the
motor in fast speed operation. Rotating the switch farther decreases
motor operation to medium speed and finally to slow speed.
y. Windshield Wipers (figs. 13 and 14). The windshield wiper
motors are controlled by a push-pull type knob on the back of wiper
body.
CYLINDER BLOCK WATER JACKET
RA PD 52789
HOLD DOWN STRAPS— ONE UNDER
EACH FENDER— FOR SHIPPING
PURPOSES ONLY— REMOVE BEFORE
DRIVING THE VEHICLE
RA PD 52831
Figure 17— Cooling System
Drain Cocks
Figure 1 8— Hold-down Straps
6. PREPARATION OF NEW VEHICLE FOR SERVICE.
a. General. Before placing a n^w vehicle into service, it should
be completely inspected for evidence of damage or looseness of parts
resulting during the transportation of the vehicle. Particular consider-
ation should be given the following items during the inspection:
22
TM 9-808
6-7
DRIVING CONTROLS AND OPERATION
(1) Tighten Cooling System Drain Cocks (fig. 17). See that
the radiator drain cock and the cylinder block drain cock are securely
tightened.
(2) . Tighten Battery Connections. See that cables at battery,
cranking motor and ground at frame or engine are connected securely.
Check electrolyte level in battery and fill to proper level.
(3) Inspect Brake Master Cylinder. Remove filler plug and
inspect level of brake fluid. Level should be ^ inch below top of
filler opening in reservoir cover. If so equipped, remove rubber nipple
installed over vent opening for shipping purposes.
(4) Lubricate Vehicle. Lubricate the vehicle completely. Refer
to paragraph 24 for instructions.
(5) Inspect Wheels and Tires. Inflate or deflate tires to 40
pounds pressure. Tighten wheel stud nuts, front and rear axle drive
flange nuts and rim nuts securely.
(6) Remove Hold-down Straps (fig. 18). On rail shipped
vehicles, hold-down straps are fastened to the frame side members
under each fender. Make sure the straps are removed to avoid inter-
ference between the straps and other vehicle parts.
(7) Perform Before-operation Service (par. 19).
7. USE OF INSTRUMENTS AND CONTROLS IN VEHICULAR
OPERATION.
a. Starting the Engine. Before attempting to start the engine,
make sure the power take-off control lever for operation of winch on
vehicles so equipped is in neutral position with safety catch locked.
Then proceed as follows:
(1) Apply the hand brake.
(2) Put the transmission gearshift lever in neutral position.
(3) If the engine is cold, pull the choke button all the way out.
NOTE: // the engine is warm, see that the choke button is pushed
all the way in.
(4) Pull out the throttle control button about % of its total move-
ment or to a. point where the engine will run a little above idling
speed.
(5) Depress the clutch pedal to relieve the engine of the load of
turning the transmission gears.
(6) Turn on the ignition switch and push the cranking motor
pedal with the foot. To prevent damage to the starting mechanism,
release the cranking motor pedal immediately when the engine starts.
If the pedal does not release under its own spring mechanism stop the
engine immediately by turning off the ignition switch and pull the
pedal back by hand.
(7) If the battery, ignition, and fuel systems are in good condi-
tion, the engine should start immediately. If the engine does not start
within 10 to 15 seconds;, release the cranking motor pedal and wait
a few seconds to prevent overheating and possible damage to the
23
TM 9-808
7
3/4 -TON 4x4 TRUCK (DODGE)
cranking motor. Then push the cranking motor pedal again for 10 to
15 seconds. If the engine does not start after several attempts, report
the trouble to the proper officer.
(8) After the engine has started, release the clutch pedal. Then
push the throttle control button part way in to reduce Engine speed
and push the choke control button in to a point where the engine runs
smoothly. CAUTION: Push the choke control button all the way
in as soon as the engine will operate without stopping.
h. Starting the Engine after Running Out of Fuel. If the
vehicle has been run until the fuel tank is empty, fill the tank and
use the fuel pump priming lever to force fuel up to the bowl of the
carburetor (fig. 19) to avoid unnecessary use of the battery and
starting motor. Operate the priming lever 30 to 40 strokes, or until
I- FUEL PUMP HAND PRIMER
FUEL PUMP
RA PD 52846
Figure 1 9— Operating fuel Pump Hand Primer
the priming lever works freely and very little pressure is required to
move it. Free movement of the lever indicates that the fuel tubes,
filter, fuel pump, and carburetor bowl, are full of fuel. The engine
may then be started in the usual manner. NOTE: // the lever moves
freely without actuating the diaphragm, crank the engine one revo-
lution so that the fuel pump rocker arm will move off the high point
of the cam on the camshaft.
c. Driving the Vehicle (fig. 20). The best method of gearshifting
the vehicle is known as double-clutching, and the following instruc-
tions are based on this method. Although the vehicle is equipped
24
TM 9-808
7
DRIVING CONTROLS AND OPERATION
with front and rear axles for four-wheel driving, the position of the
transfer case hand lever, which controls engagement and disengage-
ment of the front axle, does not alter the procedure of shifting trans-
mission gears. Subparagraph e below contains instructions for driving
in four-wheel drive.
(1) Release the hand brake.
(2) Disengage the clutch (depress clutch pedal) and move the
transmission gear shifting lever to first or second speed forward posi-
tion. If the vehicle is standing on rough terrain or facing upward on
a grade, shift to first speed; if on a smooth hard level surface, shift
to second speed.
(3) Next, press the accelerator to speed up the engine a little and
at the sarhe time gradually relieve pressure on the clutch pedal.
(4) When the clutch is fully engaged," press the accelerator until
the vehicle attains the desired road speed.
DISENGAGE FRONT AXLE DRIVE WHEN
OPERATING ON HARD SURFACED ROADS
LOW DISENGAGED
6) ^ Q) n
REV. ENGAGED
TRANSMISSION FRONT AXLE DRIVE
RA PD 52713
figure 20— Gearshift Diagram Plate
(5) When the vehicle is in motion, shift into higher speeds as
follows:
(a) Disengage the clutch and release the accelerator pedal at the
same time.
(b) Move the gearshift lever to neutral and relieve pressure on
the clutch pedal to allow the clutch to engage. This synchronizes the
speed of transmission gears with the speed of the engine.
(c) Again disengage the clutch and move the gearshift lever to
the next higher speed position.
(d) Relieve pressure on the clutch pedal and press the acceler-
ator pedal to attain the desired road speed.-
(e) Repeat steps in steps (a) through (d) above for successive
shifts from first or second speed to higher speeds.
d. Reversing. Bring the vehicle to a complete stop before shift-
ing into reverse speed. Depress the clutch pedal, move the gearshift
lever to reverse position (fig. 20). Then release the clutch pedal and
press the accelerator pedal at the same time until the desired speed
is attained.
e. Driving in Four-wheel Drive. The purpose of four-wheel drive
is to permit maximum traction at all four wheels when driving on
25
TM 9-808
7
3/4 -TON 4x4 TRUCK (DODGE)
icy roads, through snow or mud, or over rough unimproved terrain.
On smooth, level, hard-surfaced roads and under ordinary conditions,
disengage the front axle drive and drive with the rear wheels only.
CAUTION: Never operate the vehicle at speeds in excess of 25 miles
per hour when the front axle is engaged.
(1) Engage Front Axle (fig. 20). Shift the hand lever to the
rear with the vehicle moving and engine under mild acceleration. The
speed of the vehicle must not exceed 25 miles per hour when the shift
is made. If resistance is felt midway in the shift, let up on the acceler-
ator pedal and complete the shift. The shift may also be made with
the vehicle standing still, but an easier shift can be accomplished with
vehicle in motion.
(2) Disengage Front Axle (fig. 20). Push the hand lever
forward.
— CAUTION-
MAX. PERMISSIBLE ROAD SPEEDS
TRANSMISSION
•
4TH 3RD 2ND 1ST REV.
•
55 33 18 9 7
DODGE TRUCKS
BUILT BY CHRYSLER CORPORATION
DETROIT, U.S.A.
RA PD 52712
Figure 2 1 —Speed Caution Plate
f . Driving Up or Down Steep Grades.
(1) When driving down a steep grade, shift into a lower trans-
mission gear. On exceptionally steep and long .downgrades, shift the
transmission to second speed so that the engine will help in slowing
the vehicle down and reduce the necessity for continuous or severe
application of the brakes.
(2) When driving up a long, steep grade, shift the transmission
to a lower gear when vehicle speed begins to decrease, to permit
driving the vehicle at the maximum possible governed speed witH
the least strain on engine and drive mechanism.
(3) To shift -to lower gears with the vehicle in motion on a steep
grade, use the double-clutch method, and start the shift to the lower
gear at the speed shown on the "MAX PERMISSIBLE ROAD
SPEEDS" caution plate (fig. 21) for the gear into which the shift
is to be made. To double-clutch, proceed as follows:
(a) Disengage the clutch and move the gearshift lever to neutral
position.
26
TM 9-808
7-8
DRIVING CONTROLS AND OPERATION
(b) Quickly engage the clutch and accelerate the engine to gov-
erned speed so that the transmission gears can be meshed in the next
lower gear.
(c^ Then again disengage the clutch, and shift immediately into
the next lower gear.
(4) When shifting to a lower gear with vehicle in motion, engage
the clutch before allowing the engine to slow down. If the engine is
allowed to slow down and the clutch is then engaged, excessive strain
will be' applied to the clutch, transmission, and drive line, and break-
age is very likely to occur.
g. Stopping the Vehicle. Relieve pressure on accelerator pedal
and apply the brakes. When the vehicle has been slowed down to
five or ten miles per hour, disengage the clutch and move the gear-
shift lever to neutral position. Then bring the vehicle to a complete
stop, release the clutch pedal and apply the hand brake.
hi Stopping the Engine. Allow the engine to slow down to idling
speed and turn off the ignition switch.
i. "Breaking-in" Speeds. New vehicles should be dri^n care-
fully during the breaking-in period. Vehicle speed should not exceed
25 miles per hour during the first 500 miles of operation. Also, care-
less operation in the lower gears may result in excessive engine speed
in spite of low vehicle speed. For example, the following vehicle
speeds in the lower gears are comparable to 25 miles per hour in
high gear:
3rd gear .• •■ • 15 mph
2nd gear 8 mph
1st gear 4 mph
During the next 1,500 miles of operation, the maximum speeds indi-
cated above should be increased for brief periods, until the breaking-
in process is completed. However, during this breaking-in, the vehicle
should be driven carefully when under full throttle, as maximum
power should not be required until vehicle has been driven 2,000
miles.
j. Maximum Permissible Road Speeds (fig. 21). The vehicle is
equipped with a governor which limits the maximum road speed of
the vehicle in the various gears- as shown on the plate attached to
the instrument panel of the vehicle. CAUTION: Do not permit the
vehicle to exceed maximum road speeds in any gear when driving
downhill, because the excessive engine speed developed under such
conditions might cause serious damage to the engine or power train.
To control the speed of the vehicle, use the foot brake intermittently
in order to prevent excessive engine speeds. The clutch must never be
disengaged when descending a hill in a low gear.
8. TOWING THE VEHICLE.
a. Tow Hooks. The two tow hooks bolted to the frame side
members at the front of the vehicle can be used to attach towing
chains or cables.
27
TM 9-808
8
3/4 -TON 4x4 TRUCK (DODGE)
b. Pintle Hook. The pintle hook (fig. 22), mounted on the frame
rear cross member, can be used to attach the tow bar of a trailer,
or to attach a towing chain or cable for towing another vehicle. To
open, release the trigger underneath the hook and pull the jaw open.
To close, engage the jaw with the trigger lock and push it to the
closed position.-
PRESS LATCH
TO RELEASE JAW
JAW CAN BE CLOSED AND LOCKED
BY BACKING OPEN JAW AGAINST
A TRAILER TOW-BAR
RA PD 312527
Figure 22-Pintle Hook
c. Towing Vehicle to Start Engine. Turn the engine over 3.
revolutions by hand. Attach a towing cable. Disengage the clutch and
shift the transmission of the towed vehicle to high gear. If shifted to
lower gears, the engine of the towed vehicle will turn over at a
greater speed and more power will be required to tow it. Shift the
transmission of the towing vehicle to low gear and begin towing.
When the towed vehicle is in motion (five to ten miles per hour),
slowly engage the clutch and turn on the ignition switch.
d. Towing Precautions.
(1) When steering the towing vehicle in a different direction,
make changes in direction in such a manner that the wheels of the
towed vehicle will follow in the tracks of the towing vehicle.
(2) When entering soft or muddy terrain, see that the front wheels
of both vehicles are in the straight ahead position, as it is more diffi-
cult to pull a towed vehicle with the front wheels at an angle.
(3) Use care to prevent front wheels of towed vehicle becoming
entangled with towing cable.
28
TM 9-808
9
DRIVING CONTROLS AND OPERATION
9. BODY EQUIPMENT.
a. Windshield.
(1). Open Cab Models (fig. 23). To open the windshield glass,
loosen the lock nuts, pull up on the adjusting arms, and push the
glass outward to the desired position. Then tighten the lock nuts.
To lower the windshield assembly, pull up on the clamp handles
which hold the windshield in an upright position. Push the windshield
assembly forward to the pad on the hood and fasten the catch. Jo
raise the windshield assembly, unhook the catches on the hood. Then
pull the windshield to an upright position and push the clamp
handles down to the locked position. Hook the catch on hood to the
catch rest.
RA PD 52747
Figure 23-Windshield (Open Bodies)
(2) Closed Cab Models (fig. 24). To open the windshield glass,
pull the handle in the center of the windshield at the lower edge and
turn it counterclockwise. Loosen the adjusting arms lock nuts, pull
up on the adjusting arms, and push the glass outward to the desired
position. Tighten the lock nuts. To close the windshield glass, loosen
the lock nuts and pull the windshield to the closed position with the
pull-to handle and turn it clockwise. Then tighten both lock nuts
evenly to prevent looseness and strain on the windshield glass at
the sides.
b. Lowering Folding Top (Command) (fig. 25).
(1) Loosen the lock nuts and set screws at the upper left and
right sides of the windshield. Loosen the large hand-operated knobs
in the top frame directly above the back of the front seat.
(2) Unsnap seven fasteners of rear curtain on each side. Do not
unshap the nine fasteners on the rear of the body. Unbuckle the two
29
TM 9-808
9
3/4 .TON 4x4 TRUCK (DODGE)
long straps between the top frame rear bow and the body and pass
the ends without buckle under the top fabric fastened to the rear of
body. Let the ends of the straps hang down over the rear of the body.
Lift the top off the windshield stanchions and allow it to drop back
toward the rear of the body.
(3) Fold the top frame down by pulling inward on each side at
the location of the large hand knobs. To prevent cutting or chafing
of fabric, allow the top decking to fall loosely over the rear of the
body so that the fabric will not catch between the bows of the frame
as it is folded back. CAUTION: Pull the rear curtain back as far as
possible to prevent breakage oi the rear glass by the tap frame as it
is folded down.
RA PD 52748
Figure 74-Windshield (Closed Bodies)
(4) Tie the top frame down at the center with the short strap
and fold the top decking neatly up over the top frame. Tuck the
loose ends under the frame and tie down with the long straps.
c. Raising Folding Top (Command) (fig. 25).
(1) Unbuckle the long straps and let the loose ends hang down
over rear of body. Unbuckle the short strap. Unfold the top fabric
and let it hang down over the rear of the body. Raise the top frame
and straighten out both sides at the location of the large hand-
operated knobs.
30
TM 9-808
9
DRIVING CONTROLS AND OPERATION
"0
e
E
E
u
e
a.
^~
D)
'C
"o
I
0)
I.
a
31
TM 9-808
9
3/4 -TON 4x4 TRUCK (DODGE)
(2) Let the top frame rest on the windshield and tighten the
large hand-operated knobs securely into position in the recesses in
the top frame sides.
(3) Engage the hole in the top frame with the knob of one wind-
shield stanchion, but do not force the frame all the way down on the
stanchion. Force the other side of the top frame over the knob of the
windshield stanchion. Spring the top frame as necessary to secure
alinement between the stanchion knob and hole in the top frame.
(4) See that both sides of the top frame are pushed down until
the stanchions are fully , entered into the holes in the top frame.
•Tighten the lock nuts and set screws securely at the stanchions to
prevent the top flying up when the vehicle is in motion. Place the
long straps in position over the rear bow of the top frame to relieve
strain on fabric and fasten the snap fasteners on each side of the top
at the rear.
THIRD FOLD FINAL FOLD ^^ pp ^„j,^
figure 76— folding Roof Tarpaulin (Weapon Carrier)
d. Side Curtains (Command). Four side curtains are supplied
with this model. The two front side curtains are fitted with a metal
frame with three hinge pins which fit into brackets on the sides of
the windshield. The two rear side curtains are fitted with a frame
and two hinge pins which fit into brackets on the body at the rear
of the front seat-back and in the top frame directly above. When
side curtains are installed, see that curtains are between the flaps
of the top and close all snap fasteners. To hold the side curtains in
the closed position, turn the lock handles just inside the body open-
32
TM 9-808
9
DRIVING CONTROLS AND OPERATION
ing. When the side curtains are not in use, fold them carefully and
place, them in the storage space in the tail gate compartment.
e. Removal of Tarpaulin (Weapon Carrier).
(1) Turn the fasteners on the front of the windshield and pull
the driver's compartment cover off the fasteners. Unbuckle the straps
on the roof tarpaulin and lift off the cover.
(2) Lift the. front seats and untie the roof tarpaulin ropes at the
two hooks on the front of the body. Untie the ropes at hooks on rear
and sides of the body. Open the snap fasteners on the center bow.
Remove the roof tarpaulin and fold as shown in figure 26.
(3) Untie the ropes for the front and rear end curtains at the
hooks on the sides of the body. Remove the rope laced through the
eyelets in the curtains and around the front and rear top bows.
(4) Remove the roof ridge pole. Lift the front and rear bows out
of the brackets on the body and remove the center bow.
f. Installation of Tarpaulin (Weapon Carrier).
(1) Install the Top Bows in the Brackets in the Body.
Install the bolts and nuts through the bracket for the center bow.
Then install the ridge pole through the brackets on the top bows and
fasten with bolts and wing nuts.
(2) Install the Front and Rear End Curtains. Place the
rope through the center eyelet in the end curtain. Adjust the two ends
of the rope so that even amounts protrude from each side of the
center eyelet. Place the end curtain on the top bow with the curtain
flap facing toward the outside. Hold it in position temporarily by
tying with cloth straps around the top bow. Lace the rope through
the eyelets of the curtain and tie the rope to the hooks on the sides of
the body.
(3) Install the Roof Tarpaulin. With the tarpaulin folded as
shown in figure 26, center it on the top bows at the juncture of the
ridge pole and the center top bow. Unfold down over bows. See
that the pads for the straps are on the outside, and the part of the
tarpaulin labeled front . is at the front of the vehicle. Adjust the
position of the tarpaulin so that the three pads for the straps along
each side of the tarpaulin are directly over the corners of the three
top bows. Lace the ropes through the eyelets in the bottom of the
front and rear curtains and tie the ropes on the hooks on the body.
Place the cloth strap around the center bow and close the snap
fastener. Attach the driver's compartment cover and fasten the cover
to the roof tarpaulin by buckling the four straps to the roof tarpaulin.
33
TM 9-808
10
3/4 -TON 4x4 TRUCK (DODGE)
Section IV
AUXILIARY EQUIPMENT CONTROLS AND
OPERATION
Paragraph
Winch controls 10
Fire extinguishers 11
10. WINCH CONTROLS.
a. General. The Weapon Carrier and Command 'are equipped
with a winch mounted on the front of the vehicle. Power for winch
operation is supplied by the engine of the vehicle. The winch can
be used as an auxiliary source of power to help lift or move a mired
vehicle. It can be used to move another vehicle, or the vehicle on
POWER TAKE-OFF CONTROL LpVER IN NEUTRAL POSITION
CLUTCH PEDAL
RELEASED
TO UNWIND.
WINCH CABLE
CONTROL LEVER
LOCK IN SHIFT.
POSITION
CLUTCH PEDAL
DEPRESSED
TO WIND UP
WINCH CABLE
-TRANSMISSION
GEARSHIFT
LEVER
CONTROL LEVER LOCK IN NEUTRAL POSITION
Figure 27— Winch Control Lever Positions
which it is mounted, by rigging the winch cable and snatch block
to suitable anchorage.
b. Winch Controls (fig. 27). The winch is controlled by a lever
in the driver's compartment and a clutch shifter fork handle mounted
on the winch. The lever "is locked in neutral position by a safety catch,
which must be lifted before the lever can be moved.
34
TM 9-808
10
AUXILIARY EQUIPMENT CONTROLS AND OPERATION
ENGAGED POSITION
DISENGAGED POSIT
RA PD 52745
Figure 28— Winch Clutch Shifter Fork Handle Positions
WINCH CAUTION PLATE
BRADEN MODEL MU2
POWER TAKE OFF cnnn.o^
FORWARD POSITION CAPACITY OF WINCH 5000 LBS.
ON FIRST LAYER OF ROPE, (j
I WIND VEHICLE AND Winch GUARANTEE
» NEUTRAL REQUIRE THAT WINCH SHALL BE
.UNWIND OPERATED AT ALL TIMES AS
p unwinu REQUIRED BY APPROPRIATE
REAR POSITION REGULATIONS.
RA PD 52746
Figure 29-Winch Caution Plate
c. To Hook On.
(1) Make sure the transmission gearshift lever is in neutral
position.
(2) Disengage the clutch shifter fork handle at the winch (fig.
28) and pull out the cable.
(3) If the cable is under a strain, depress the vehicle clutch
pedal and move the control lever to the rear (unwind) position.
Then run the engine at idling speed to relieve the strain on the cable.
35
TM 9-808
10
3/4 -TON 4x4 TRUCK (DODGE)
(4) Rig the cable to suitable anchorage. Always rig up the cable
so that it will be pulled straight into the winch drum.
d. To Pull.
(1) When using the winch, operate the engine at a reasonable
speed. High engine speeds are liable to damage the winch mecha-
nism or cause other serious trouble. Note winch caution plate (fig.
29) which is attached to the instrument panel of each winch-
equipped vehicle.
(2) Engage the clutch shifter fork handle (fig. 28).
(3) Depress the vehicle clutch pedal and shift the winch control
lever to forward position (fig. 27).
(4) Release the vehicle clutch pedal and accelerate the engine
to pull or lift the load.
ininnn
W'
RA PD 52770
Figure 30— Winding Winch Cab/e on Drum
(5) If the winch is being used to assist the vehicle on which it
is mounted, place the transmission gearshift levei in first speed (or
reverse) and utilize the driving wheels of the vehicle to assist in
pulling the vehicle. The transfer case control lever may be placed in
position for four-wheel drive or rear wheel drive depending on the
condition of the terrain.
e. To Reverse Winch Operation.
(1) With engine running at idling speed, depress the vehicle
clutch pedal and move the winch control lever to the rear (unwind)
position.
36
TM 9-808
10-11
AUXILIARY EQUIPMENT CONTROLS AND OPERATION
(2) Release the vehicle clutch pedal. Do not accelerate the engine
when reversing winch operation.
(3) Never try to lo\yer load by disengaging clutch shifter fork.
f. Winding Cable on Drum (fig. 30).
(1) To wind the cable on the drum, secure the end of it to a
suitable anchorage and allow the winch to pull the vehicle towards
the anchorage. This will help maintain tension on cable as it is being
wound on drum.
(2) Guide the cable as it winds on the drum so that the first
layer of coils are very close together to prevent the next laydf of
cable pressing down between the coils of the first layer.
(3) After the first layer is correctly wound on drum, the cable
win tend to follow the coils of the first layer, but start and end each
successive layer at the extreme edge of the drum.
(4) If the cable shows signs of rust or is excessively dirty, un-
wind cable and clean. Lubricate with engine oil applied with a cloth
as the cable is being rewound on drum.
PUSH AND PULL
PLUNGER TO
RELEASE FLUID FOR
FIRE FIGHTING
RA PD 52810
Figure 31— Operating Fire Cxtlngulsher
11. FIRE EXTINGUISHERS.
a. Location. The fire extinguisher is mounted on the right cowl
side panel on all except the Ambulance, where it is located to the
rear of the right front door. On later model Weapon Carriers, it is
located on the front of the seat riser. To remove the fire extinguisher,
37
TM 9-808
11
3/4 -TON 4x4 TRUCK (DODGE)
release the spring lock at the extinguisher handle and lift it out of
the bracket, or if equipped with a clamp type bracket, pull it out
of clamp.
b. Fire Classifications. The fire extinguisher is the vaporizing
liquid type. It may be used on any class of fire resulting from burn-
ing wood, textile, oil, grease, gasoline, flammable liquids, or elec-
trical short circuits. It may be used on burning electrical equipment
in the vehicle, such as generator, cranking motor, or wiring con-
nections.
c. Operation (fig. 31). To operate the extinguisher, turn the
handle and work it like a pump. To secure best results, direct the
discharge at the base of the flame. When used on burning liquids
in a container, direct the discharge against the inside of the container
just above the burning liquid.
d. Care. Keep the extinguisher clean. Wipe the exterior at the
top and around the handle to remove dirt and other matter which
might tend to obstruct operation of the extinguisher. After use, ex-
change the extinguisher immediately for one that is fully charged.
e. Test. Test by pumping some of the fluid in a clean glass con-
tainer. If the pump works satisfactorily, and the fluid in the glass
container is clean and free of foreign matter, pour the liquid back
into the extinguisher through the hole in the cap. Then, if the ex-
tinguisher is full of fluid (1 qt liquid capacity), it is in normal oper-
ating condition. If the pump dpes not operate satisfactorily, or the
extinguisher contains insufficient or dirty fluid, exchange the ex-
tinguisher for one that is in satisfactory operating condition.
38
TM 9-808
12-14
Section V
OPERATION UNDER UNUSUAL CONDITIONS
Paragraph
General 12
Unusual operation 13
Cold weather operation 14
Hot weather operation 15
Flood and submersion > 16
Decontamination 17
12. GENERAL.
a. Vehicle operation over dusty terrain, through deep mud or in
extreme temperatures imposes unusual demands on various parts of
the vehicle and the necessary precautions should be taken before and
during operation to avoid unnecessary failures.
13. UNUSUAL OPERATION.
a. Sand, Deep Mud, and Slippery Terrain.
(1) Preparation. Inspect and clean air cleaners and lubricate
chassis lubricant fittings more frequently than under normal driving
conditions.
(2) Driving in Sand or Soft Terrain. Drive slowly in loose,
dry sand or fresh, thick gravel. Even though greater vehicle speed
can be attained on certain types of sand and gravel surfaces, such
surfaces are unpredictable and great difficulty may be encountered
in steering the vehicle. When starting the vehicle in loose sand or
gravel, release pressure on the clutch pedal slowly so that the wheels
will not spin. Spinning the wheels causes them to work farther down
into the soft surface which may result in the vehicle becoming mired
to such an extent that it will have to be towed or winched out.
(3) Deep Mud and Slippery Terrain. When the vehicle be-
comes mired in soft terrain or deep mud, use good judgment if an
attempt is made to drive the vehicle out under its own power. If
the vehicle is pulling through soft mud with the front axle engaged,
and the driving wheels start spinning, do not race the engine or
attempt to "jump" the vehicle out of the mud by racing engine and
suddenly engaging the clutch. Racing the engine usually results in
digging the driving wheels deeper into the mud, and trying to
"jump" the vehicle will lead to destruction of some part of the
drive line, such as the clutch, transmission, propeller shafts, or axles.
When, the vehicle is hopelessly mired in deep mud, tow it out with
a winch or with another vehicle.
14. COLD WEATHER OPERATION,
a. General.
(1) Operation and maintenance of automotive vehicles at low
temperatures involve factors not found at normal operating tem-
39
TM 9-808
14
3/4 -TON 4x4 TRUCK (DODGE)
peratures, and operators must devote more time to protective main-
tenance. Failure to provide extra service will result in actual damage,
unnecessary and unwarranted expense, and failure to start.
(2) Temperatures have been divided into two ranges: above 0°F,
and below 0°F. Metals and lubricants undergo changes in their
physical properties below 0°F. In subzero temperatures accessory
equipment for supplying heat to engine, fuel, oil, and intake air, is
required.
b. Gasoline for Low Temperatures.
(1) Selection. Use the winter grade of gasoline procured under
U. S. Army Specification 2-103, grade C, latest revision.
(2) The formation of ice crystals from small quantities of water
in the fuel sometimes causes considerable trouble. To keep water out
of the fuel tank, observe the following precautions:
(3) Strain the gasoline through a filter paper or any other type
of strainer that will prevent the passage of water. CAUTION: Be
sure to provide a positive metallic contact between fuel container
and gasoline tank,^ unless both fuel tank and container are inde-
pendently grounded.
(4) In so far as possible, always keep the fuel tanks full. This will
reduce the free air space above the fuel from which moisture can be
condensed.
(5) Add one quart of denatured alcohol, grade 3, to fuel tank
at start of winter season and 1 pint per month thereafter. This will
reduce the hazard of ice formation in the fuel.
(6) Do not store fuel in old drums unless they are free from rust
and have been thoroughly cleaned. If time is not an urgent factor,
do not pump fuel from drum to vehicle until it has settled for 24
hours after filling or moving the drum. Keep portable fuel pumps
clean and protected from snow and frost.
(7) When a drum has been opened, be sure to cover the opening
or replace the bung to keep out snow, frost, or other foreign matter.
Store drums in a covered building or cover them with a tarpaulin.
c. Engine Lubrication.
(1) Engine lubrication at temperatures above 0°F is covered in
paragraph 24 and figure 32. The following instructions supplement
this information and apply only to instances where the temperature
falls below 0°F for long periods.
(2) Several methods of keeping engine oil sufficiently fluid for
proper lubrication at temperatures below 0°F are listed below. Give
preference to these methods in the order listed according to available
facilities.
(a) Keep the vehicle in heated enclosure when not in operation.
(b) \A/hen engine is stopped, drain crankcase oil while it is hot.
and store in a warm place until vehicle is to be operated again.
If warm storage is not available, heat the oil before reinstalling.
(Avoid overheating the oil; heat only to the point where the bare
40
TM 9-808
14
OPERATION UNDER UNUSUAL CONDITIONS
hand can be inserted without burning.) Tag the vehicle in a con-
spicuous place in the drive compartment to warn personnel that
crankcase is empty.
(c) Dilute the crankcase oil with gasoline as follows :
1. Fill engine crankcase to the "FULL" mark with the grade of
engine oil prescribed for use at temperatures from +32°F to 0°F.
Add iy2 quarts of gasoline to the crankcase.
2. Run the engine 5 to 10 minutes to mix the lubricant and
diluent thoroughly.
3. Stop the engine and note that the level of the diluted oil is
above the normal "FULL" mark on the oil gage. This level should
be marked on the gage for future reference.
4. The presence of a large percentage of light diluent will increase
oil consumption and, for that reason, the oil level should be checked
frequently. Use the grade of engine oil prescribed for use between
+32°F to 0°F to maintain the oil level to manufacturer's "FULL"
mark on the gage during operation.
5. If the vehicle is operated 4 hours or more at operating tem-
perature, redilution will be necessary if it is anticipated that the
vehicle will be left standing unprotected for 5 hours or more. This
can be accomplished by adding engine oil prescribed for use between
+ 32°F to 0°F to the manufacturer's "FULL" mark; then adding
gasoline to the dilution mark on the gage described in step 3 above.
d. Transmission, Transfer Case, and Differentials.
(1) Where the use of SAE 10 engine oil is prescribed for use at
temperatures +32°F to 0°F, it will be used undiluted for operation
below 0°F.
(2) SAE 80 universal gear lubricant, where prescribed, is suit-
able for use at temperatures as low as — 20°F. If consistent tem-
perature below 0°F is anticipated, drain the gear cases while warm
and refill with grade 75 universal gear lubricant which is suitable
for operation at all temperatures below +32°F. If grade 75 universal
gear lubticant is not available, SAE 80 universal gear lubricant,
diluted with the fuel used in the engine in the proportion of 1 part
fuel to 6 parts SAE 80 universal gear lubricant, shall be used.
Make-up oil will be diluted in the same proportion before it is
added to gear cases.
(3) After engine has been warmed up, engage clutch and main-
tain engine speed at fast idle for 5 minutes until gears can be en-
gaged. Put transmission in low (first) gear, and drive vehicle for
100 yards, being careful not to stall engine. This will heat gear lubri-
cants to the point where normal operation can be expected.
e. Chassis Lubricants.
(1) At temperatures below 0°F lubricate chassis points with
No. general purpose grease.
(2) Brake bands, particularly on new vehicles, have a tendency
to bind when they are very cold. Always have a blow torch handy
41
TM 9-808
14
3/4 -TON 4x4 TRUCK (DODGE)
to warm up these parts if they bind when you are attempting to
move the vehicle. Parking the vehicle with the brake released will
eliminate most of the binding. Precaution must be taken, under
these circumstances, to block the wheels or otherwise prevent move-
ment of the vehicle.
(3) Inspect the vehicle frequently. Shock resistance of metals,
or resistance against breaking, is greatly reduced at extremely low
temperatures. Operation of vehicles on hard, frozen ground causes
strain and jolting which will result in screws breaking or nuts
jarring loose. v
(4) Disconnect oil-lubricated speedometer cables at the drive end
when operating vehicles at temperatures of — 30°F and below. These
cables often fail to work properly at these- temperatures, and sorrfe-
times break due to the excessive drag caused by the high viscosity
of the oil with which they are lubricated. Grease-lubricated cables
should operate satisfactorily at all temperatures provided, they are
coated with No. general purpose grease and there is no excess
grease in the housing.
f. Antifreeze.
(1) Protect the cooling system with antifreeze compound for
opei-ation below +32°F. •
(2) Before adding antifreeze compound, be sure the cooling sys-
tem is clean and completely free from rust.
(3) Inspect all hoses and replace if deteriorated. Inspect hose
clamps, plugs, and petcocks, and tighten if necessary. Make sure
radiator does not leak, before adding antifreeze compound.
(4) After the cooling system is clean and tight, fill with water
to about % capacity. Then add antifreeze compound, in the quan-
tity shown below:
ANTIFREEZE TABLE
Lowest expected Quarts,
Temperature antifreeze compound
+ 10°F - 4f4
0°F 6
— 10°F 7
-20°F 8
-30°F 8^
— 40°F' 9%
-50°F 10^
(5) After adding antifreeze compound, fill with water to slightly
below the filler neck; then start and warm the engine to normal
operating temperature.
(6) The engine should then be stopped and the solution checked
with a hydrometer, adding antifreeze compound if required.
(7) Inspect the coolant weekly for strength and color. Rusty
solution must be drained, the cooling system thoroughly cleaned,
and new solution of the required strength added. CAUTION: Use
an accurate hydrometer. To test a hydrometer, use 1 part antifreeze
42
TM 9-808
14
OPERATION UNDER UNUSUAL CONDITIONS
compound to 2 parts water. This solution should produce a hydrom-
eter reading ot 0°F.
g. Other Lubrication Points.
(1) Drain steering gear housing if possible, or use suction gun to
remove as much lubricant as possible. Refill with grade 75 universal
gear lubricant, or, if not available, with SAE 80 universal gear lubri-
cant diluted with fuel used in the engine in the proportion of 1 part
fuel to 6 parts SAE 80 universal gear lubricant. Make-up oil will
be diluted in the same proportion before it is added to the housing.
(2) For oilcan points where engine oil is prescribed for above
0°F, use light preservative lubricating oil.
h. Protection of Electrical System.
(1) Generator and Starter. Inspect the brushes, commutators,
and bearings. See that the commutators are clean. The large surges
of current which occur when starting a cold motor require good con-
tact between brushes and commutators.
(2) Wiring. ■ Inspect and clean all connections, especially the
battery terminals. Take care that no short circuits are present, and
that there is no ice on spark plugs, wiring, or other electrical equip-
ment.
(3) Coil. Check coil for proper functioning.
(4) Distributor. Clean thoroughly, and replace points. Check
the ppints frequently. In cold weather the current is heavier, and the
points may pit and burn more than usual.
(5) Spark Plugs. Clean, test, and replace, if necessary. If it is
difficult to make the engine fire, reduce the gap 0.005 inches. This
will make sparking easier at the reduced voltages likely to prevail.
(6) Timing. Check carefully. Take care that the spark is not
unduly advanced or retarded.
(7) Batteries.
(a) The efficiency of batteries decreases sharply with decreasing
temperatures and becomes practically nil at — 40°F. Do not attempt
to start the engine with the battery when it has been exposed to
temperatures below — 30°F, until the battery has been warmed,
unless a warm slave battery is available.
(b) A fully charged battery will not freeze at temperatures likely
to be found even in arctic climates, while a fully discharged battery
will freeze and rupture at +5°F. See that the battery is always
fully charged with a hydrometer reading between 1.275 and 1.300.
(c) Do not add water to a battery when it has been exposed to
subzero temperatures unless the battery is to be charged immedi-
ately. If water is added and the battery not put on charge, the layer
of water will stay at the top and freeze before it has a chance to
mix with the acid. Keep vent holes in filler plugs open. Keep termi-
nals tight and clean. At regular intervals, apply a coating of No.
general purpose grease, or light, rust-preventive compound.
(8) Lights. Inspect lights carefully.
43
TM 9-808
14-15
3/4 -TON 4x4 TRUCK (DODGE)
i. General Conditions.
(1) Make sure that no heavy grease or dirt has been left on the
starter throwout mechanism. Heavy grease or dirt may keep the
gears from being meshed, or cause them to remain in mesh after
the engine starts and thus ruin the starter.
(2) Pull the choke control ajl the way out to secure the air-fuel
ratio required for cold weather starting. Make sure the butterfly
valve in the carburetor closes all the way and otherwise functions
properly.
(3) Remove or bypass oil filters at temperatures below — 30°F,
because the viscous oil will not flow freely through them.
(4) Remove and clean sediment bulb, strainer, etc., at frequent
intervals.
j. Starting and Operation.
(1) It is possible to start gasoline engines with batteries at tem-
peratures as low as — 30°F, if the engines are properly lubricated and
,in good mechanical condition.
(2) To insure that the engine will start on the first attempt,
proper preparation of the engine is very important. Should the
engine fire a few times and stop, water vapor which is a product of
combustion, may form frost in the combustion chamber and make
it impossible to start without heating the engine to above 32 °F.
Prolonged starting efforts wear down the battery.
(3) Pull the choke lever all the way out for starting, and keep
it partially pulled out until the engine has warmed up. Since only
the lightest components of the gasoline vaporize in a cold engine,
a very rich mixture is necessary. Depress the clutch pedal to ease
the starting load.
(4) After the engine is started, idle it at 800 to 1,000 revolutions
per minute until it has warmed up enough to run smoothly. Do not
place the vehicle in operation under its own power until its operating
temperature of 160°F has been reached. Maintain this temperature
by covering or partially covering the radiator.
(5) Cover engine with tarpaulin, tent, or portable shed. Place
oil stoves, fire pots, or four or five ordinary kerosene lanterns, under
the covering about three hours prior to starting time.
(6) Keep vehicles in sheltered areas shielded from wind. Cold
winds increase starting difficulties.
k. Stopping. Increase engine speed before turning off ignition.
Then turn off ignition cand release throttle at the same time. As the
engine coasts to a stop, it will blow out all the residual products of
combustion, including water vapor, and leave only air and gasoline
vapor in the engine.
15. HOT WEATHER OPERATION.
a. Lubrication Attention. Lubricate the vehicle for hot weather
operation as instructed in paragraph 24. Do not use engine oil heavier
than that recopimended on the Lubrication Guide.
44
TM 9-808
15-16
OPERATION UNDER UNUSUAL CONDITIONS
b. Cooling System. Use the correct radiator cap to prevent the
loss of cooling solution. Keep the fan belt tension properly adjusted.
Keep the radiator core clean. Remove insects or other foreign ma-
terial lodged between the fins of the core. To do this, direct a stream
of water under pressure through the openings in the core from the
engine side of the core.
c. Manifold Heat Control. Change the position of the manifold
heat control to the summer setting (par. 56).
d. Ignition System. During wet or damp weather, dry the dis-
tributor cap, spark plugs, and wires with a clean rag if hard starting
is experienced.
e. Fuel and Exhaust Systems. A heat shield is used over the
fuel pump to prevent heat reaching the fuel pump. See that the heat
shield is kept in place to prevent engine stopping as a result of
vapor lock. A clogged or damaged muffler or tail pipe will cause
back pressure and overheating of the engine. If the muffler or tail
pipe is damaged during operation, report the condition.
16. FLOOD AND SUBMERSION.
a. General. When a vehicle has been driven through deep water
heavily laden with dirt and abrasives or completely submerged,
certain precautions must be taken to avoid serious damage to the
engine, clutch, transmission, transfer case, axles, universal joints,
winch, steering gear, battery, fuel tank, brakes, wheel bearings, etc.
If it is known that water, dirt, abrasives, or salt water have con-
taminated the various units of the vehicle, notify the proper
authority at once. Each unit which has been submerged must be
completely dismantled, cleaned, and lubricated. If units of the vehicle
have been subjected to salt water, certain units will be damaged
beyond repair.
b. Emergency Procedure. If emergency requirements make
complete dismantling and cleansing of units impossible, each unit
subjected to water should be inspected, cleansed, and lubricated to
defer as much damage as possible. CAUTION: Emergency cleansing
cannot be considered as assurance that further damage will not result,
and if the damage is great, notify the proper officer at once that
complete dismantling and cleansing of affected units is necessary to
avoid serious damage.
(1) Inspect Battery. Remove filler plugs. Check electrolyte for
level and appearance. Normal level after immersion indicates little
or no water has entered battery. Clean electrolyte solution, even
though slightly high, indicates no absorption of excess dirt or dam-
aging foreign material. If solution is dirty, replace battery. Test
gravity. If the battery is discharged, recharge or replace.
(2) Lubricate Vehicle Completely (par. 24).
(3) Fuel Filters. Clean fuel filters on dash and in fuel pump
(pars. 75 and 76). If fuel tank has been submerged, dr^in and refill,
run engine, and' clean fuel filters again.
45
TM 9-808
16-17
3/4 -TON 4x4 TRUCK (DODGE)
(4) Air Cleaners. Clean and reoil carburetor air cleaner (par.
72), breather pipe air cleaner (par. 65), and ventilator outlet pipe
air cleaner (par. 66).
(5) Wheel Bearings. Remove all wheel bearings, clean and re-
pack with lubricant and reassemble. Replace the oil seals in the wheel
hubs, if they are contaminated with dirt, to avoid damage to seal
surfaces and lubricant leakage (pars. 144 and 150).
(6) Clutch. If the clutch has been submerged, notify higher
authority that complete dismantling and cleansing is required. Do.
not attempt to flush the clutch.
(7) Brake Master Cylinder. If the brake master cylinder has
been submerged, notify higher authority, as it will be necessary to
drain and flush the brake system completely with alcohol, at least
twice, and then refill with fresh brake fluid.
(8) Starting Motor Generator, Distributor, and Car-
buretor. If these units have been submerged, notify higher authority.
(9) Engine. If it is known that water or dirt has entered engine,
drain engine oil, fill crankcase with five quarts of engine oil SAE 10,
and run engine for several minutes at just above idling speed, with
clutch released. Before draining engine oil and refilling with correct
grade of fresh engine oil, remove valve cover plates and, if necessary,
clean chamber with dry-cleaning solvent. If this inspection reveals
a dirty condition, notify higher authority, as it will be necessary to
remove the oil pan and clean the pan and strainer.
(10) Oil Filter. If water or dirt has entered engine, replace oil
filter after flushing engine (step (9) above).
(11) Drive Line Units. If the transmission, transfer case or
winch (if so equipped) has been submerged, drain lubricant and
refill, using engine oil, SAE 10. Drain front and rear axles completely,
and refill with y^ gallon of engine oil, SAE 10. Next, with front and
rear axle on jacks, drive all four wheels at a speed of approximately
15 miles per hour for 5 minutes to flush the drive line units. Also
run the winch to flush it. Then drain all units thoroughly and refill
with correct grade of lubricant (par. 24).
17. DECONTAMINATION.
a. Refer to Armored Force Field Manual FM 17-59, covering
decontamination of Armored Force Vehicles.
46
TM 9-808
18
Section VI
FIRST ECHELON PREVENTIVE MAINTENANCE
SERVICES
Paragropt^
Purpose 18
Before-operation service . 19
During-operation service 20
At-halt service , 21
After-operation and weekly service 22
18. PURPOSE.
a. To insure mechanical efficiency it is necessary that the vehicle
be systematically inspected at intervals each day it is operated and
weekly, so defects may be discovered and correcte4 before they
result in serious damage or failure. Certain scheduled maintenance
services will be performed at these designated intervals. The services
set forth in this section are those performed by driver or crew
Before-operation, During-operation, At-halt and After-operation and
Weekly.
b. Driver Preventive Maintehance Services are listed on the back
of "Driver's Trip Ticket and Preventive Maintenance Service Record"
W. D. Form No. 48 tq cover vehicles of all types arid models. Items
peculiar to specific vehicles but not listed on W. D. Form No. 48 are
covered in manual procedures under the items with which they are
related.' Certain items listed on the form that do not pertain to the
vehicle involved are eliminated from the procedures as written into
the manual. Every organization must thoroughly school each driver
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 expressed in this manual to provide specific procedures
for accomplishment of the. inspections and services. These services
are arranged to facilitate inspection and conserve the time of the
driver and are not necessarily in the same numerical order as shown
on W. D. Form No. 48. The item numbers, however, are identical
with those 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
see whether 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 beyond
safe or serviceable limits. The term "good condition" is explained
further 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.
47
TM 9-808
18-19
3/4 -TON 4x4 TRUCK (DODGE)
(2) The inspection of a unit to see that it is "correctly assembled"
is usually an external visual inspection to see whether it is in its
normal assembled position in the vehicle.
(3) The inspection of a unit to determine if it is "secure" is
usually an external visual examination, a wrench, hand-feel, or a
pry- bar check for looseness. Such an inspection should include any
brackets, lock washers, lock nuts, locking wires, or cotter pins, used
in assembly.
(4) "Excessively worn" will be understood to mean worn close-to
or beyond serviceable limits, and likely to result in a failure if not
replaced before the next scheduled inspection.
e. Any defects or unsatisfactory operating characteristics beyond
the scope of first echelon to correct must be reported at the earliest
opportunity to the designated individual in authority.
19. BEFORE-OPERATION SERVICE.
a. This inspection schedule is designed primarily as a check to
see that the vehicle has not been damaged, tampered with, or sabo-
taged, since the After-operation Service was performed. Various com-
bat conditions may have rendered the vehicle unsafe for operation and
it is the duty of the driver to determine whether or not the vehicle
is in condition to carry out any mission to which it is assigned. This
operation will not be entirely omitted, even in extreme tactical
situations.
b. Procedures. Before-operation Service consists of inspecting
items listed below according to the procedure described, and cor-
recting or reporting any deficiencies. Upon completion of the service,
results should be reported promptly to the designated individual in
authority. '
(1) Item 1, Tampering and Damage. Look for any injury to
vehicle, its accessories or equipment, caused by tampering or sabo-
tage, collision, falling debris, or shell fire, since parking. Look within
engine compartment for evidence of these conditions, and for loosened
or damaged engine accessories or drive belt, loose fuel, oil or coolant
lines, or disconnected control linkage.
(2) Item 2, Fire Extinguisher. See that extinguisher is securely
mounted and not damaged, and look for evidence of opened oper-
ating valve or leakage.
(3) Item 3, Fuel, Engine Oil, and Coolant Supply. Check
supply of fuel, oil and coolant and add as necessary to bring to
proper levels. NOTE: Any appreciable drop in levels since After-
operation Service should be investigated and cause corrected or re-
ported. During freezing weather when antifreeze solution is in use,
if any appreciable addition of water is needed, antifreeze value
should be tested by second echelon and added if necessary. Be sure
spare fuel, oil and water cans are full and securely mounted.
(4) Item 4, Accessories and Drives. Examine units, such .as
carburetor, generator, cranking motor, fan, and air cleaners for
48
TM 9-808
19
FIRST ECHELON PREVENTIVE MAINTENANCE SERVICES
looseness, damage or leaks. Be sure drive belt is in good condition
and has approximately Yz inch finger pressure deflection.
(5) Item 6, Leaks (General). Look on ground and under vehicle
and within engine compartment for leaks, particularly at fuel tanks
and lines, crankcase and oil filters, radiator, water pump, water
lines and connections, brake fluid lines, shock absorbers, and all gear
cases. Trace any leaks found to their source, and correct or report
them.
(6) Item 7, Engine Warm-up. Start engine, noting any tendency
toward hard starting. Observe action of cranking motor, particularly
if it has adequate cranking speed, and engages, and disengages
without unusual noise when in operation. Set hand throttle so engine
runs at fast idle, and during warm-up proceed with following Before-
operation Services. NOTE: // oil pressure is not evident in 30
seconds, stop engine and investigate.
(7) Item 8, Choke. When starting engine, check operation of
choke. As engine warms up, reset choke as required for engine to run
smoothly and to prevent overchoking and oil dilution.
(8) Item 9, Instruments.
(a) Oil Gage. Pressure above 30 miles per hour should be 30 to
50 pounds; at idle speed, at least 15 pounds.
(b) Ammeter. Ammeter should show a high positive ( + ) charge
immediately after starting engine at fast idle. High charge readings
may continue if battery is low or electrical load heavy.
(c) Engine Temperature Gage. Reading should increase gradu-
ally after starting, to normal operating range, 160°F to 185°F.
Maximum safe operating temperature 200°F.
(d) Fuel Gage. Ordinarily, tank will be filled after operation and
gage should register "full."
(9) Item 10, Horn and Windshield Wipers. If tactical situation
permits, test horn for proper operation and . tone. Test wiper oper-
ation and observe if blades contact glass evenly and arms, travel
through full stroke. Inspect for damage.
(10) Item 11, Glass and Rear-vision Mirror. Clean all glass
and inspect for damage. Aim rear-vision mirror and tighten if loose.
(11) Item 12, Lamps (Lights) and Reflectors. Clean all lamps
and warning reflectors. Examine them for looseness or damage. If
tactical situation permits, check operation of all lights.
(12) Item 13, Wheel and Flange Nuts. See that all wheel side
ring, mounting, and axle flange nuts are present and secure.
(13) Item 14, Tires. Pressure 40 pounds (maximum) cool. In-
spect tires for damage, and remove any objects lodged in carcass.
(14) Item 15, Springs and Suspensions. Inspect springs and
shock absorbers to see that they are secure and not damaged. Examine
shocks for leaks.
(15) Item 16, Steering Linkage. Inspect gear case for lubricant
leaks and all linkage connections for looseness or damage.
49
TM 9-808
19-20
3/4 -TON 4x4 TRUCK (DODGE)
(16) Item 17, Fenders and Bumpers. Inspect these units for
looseness or damage.
(17) Item 18, Towing Connections. Inspect all towing devices
for looseness or damage. Examine pintle to be sure it operates freely
and locks securely. -
(18) Item 19, Body Load and f aRps. Inspect cab, body, and
tarpaulins, for looseness and damage. See that any cargo is secure
, and properly distributed ; that doors, windows, and windshield, oper-
ate properly and latch securely, and that stretchers or other special
ambulance equipment is properly stowed.
(19) Item 20, Decontaminator. Be sure unit is present, fully
charged, and secure.
(20) Item 21, Tools and Equipment. Be sure all items are
present, serviceable, and properly mounted or stowed.
(21) Item 22, Engine Operation. Before vehicle is put in motion,
be sure oil gage registers 30 to 50 pounds at normal operating speed.
Accelerate and decelerate and listen for any unusual vibration or
noise. Note any unsatisfactory operating characteristics or excessive
exhaust smoke.
(22) Item 23, Driver's Permit and Form 26. Driver must have
his operator's permit on his person. Check to see that Standard
Accident Report Form No. 26, operator's manual. Lubrication
Guide and W. D. Form No. 478 are present in vehicle, legible, and
properly stowed.
(23) Item 25, During-operation Check. The During-operation
Services and observations start immediately the vehicle is • put in
motion as follows. ^
20. DURING-OPERATION SERVICE.
a. While, vehicle is in motion, listen for any unusual sounds that
may indicate trouble. Be on the alert to detect any odor of over-
heated components or units such as generator, brakes or clutch, fuel
vapor from a leak in fuel system, exhaust, gas, smoke, or other signs
of trouble. Any time the brakes are used, gears shifted, or vehicle
turned, consider this a test and notice any unsatisfactory or unusual
performance. Watch the instruments constantly.
b. Procedures. During-operation Services consist of observing
items listed below according to the procedures following each item,
and investigating any indications of serious trouble. Notice minor
deficiencies to be corrected or reported at earliest opportunity,
usually next scheduled halt.
(1) Item 27, Foot and Hand Brakes. Foot brakes should stop
vehicle smoothly on about 54 of the total pedal travel. Pedal should
have Vie i"ch free travel before meeting resistance, and return to off
position immediately foot pressure is released. Hand brake should
lock and hold vehicle on a reasonable incline, leaving J/4 to % of
ratchet travel in reserve.
50
TM 9-808
20-21
FIRST ECHELON PREVENTIVE MAINTENANCE SERVICES
(2) Item 28, Clutch. Clutch should release fully to allow easy
gear shifting, must not grab during engagement, or slip \yhen fully
engaged under load. Pedal should have 1^ inch free travel before
meeting resistance and must release fully without striking bottom
of floor plate.
(3) Item 29, Transmission. Gears should shift easily and not
creep out of mesh during operation.
(4) Item 30, Transfer. Transfer unit should shift easily and
not creep out of mesh during operation.
(5) Item 31, Engine and Controls. Be on the alert for defi-
ciencies in engine performance such as lack of usual power, misfiring
or ^stalling, unusual noise or vibration, indications of overheating or
excessive exhaust smoke. Observe if engine responds to all controls
and if controls appear to be in proper adjustment, and not exces-
sively loose or binding. NOTE: // radio interference is reported
during operation, the driver will cooperate with the radio operator
injocating its sources (par. 42).
(6) Item 32, Instruments. Observe readings of all instruments
frequently during operation to be sure units to which they apply are
functioning satisfactorily.
(a) Oil Pressure Gage. Reading should show 30 to 50 pounds
above 30 miles per hour.
(b) Ammeter. During operation with all lamps and accessories
turned off, ammeter should indicate a positive ( + ) charge above
20 miles per hour, or with fully charged battery it may register zero.
Investigate or report excessive negative ( — ) readings.
(c) Engine Temperature Gage. Reading should increase gradu-
ally during warm-up to normal operating range, 160°F to 185°F.
Maximum safe temperature. 200°F.
(d) Speedometer. Pointer should indicate actual vehicle speed
and odometer should register total accumulated mileage.
(7) Item 33, Steering Gear. Note any indication of looseness or
binding, pull to one side, wandering, shimmy, wheel tramp, or unusual
noise.
(8) Item 34, Running Gear. Be on alert for any unusual operat-
ing characteristics or noise from wheels, axles, or suspension units,
that might indicate looseness or damage, or under-inflated tires.
(9) Item 35, Body. Note any noise or abnormal condition that
might indicate shifting, loose top tarpaulin or curtains, loose or dam-
aged doors, hardware, load, or mounted body attachments.
21. AT-HALT SERVICE.
a. At-halt Services may be regarded as minimum maintenance
procedures and should be performed under all tactical conditions
even though more extensive maintenance services must be slighted
or omitted altogether.
b. Procedures. At-halt Services consist of investigating any de-
ficiencies noted during operation, inspecting items listed below ac-
51
TM 9-80V
21
3/4 -TON 4x4 TRUCK (DODGE)
cording to the procedures following the items, and correcting any
deficiencies found. Deficiencies not corrected should be reported
promptly to the designated individual in authority.
(1) Item 38, Fuel, Oil, and Water Supply. See that fuel, engine
oil, and coolant supply, is adequate to operate the vehicle to the
next stop. Install all caps securely. If engine is hot, fill radiator
slowly while engine is running at a fast idle.
(2) Item 39, Temperatures: Hubs, Brake Drums, Transfer,
Transmission, and Axles. Place hand cautiously on each brake
drum and wheel hub to see if it is abnormally hot. Inspect transfer
case, transmission and axle housings for excessive lubricant leakage.
(3) Item 40, Axle and Transfer Vents. Inspect vents for dam-
age or clogging.
(4) Item 41, Propeller Shafts. Inspect all drive shafts and
universal joints for any foreign matter wound around shafts or joints.
(5) Item 42, Springs and Suspensions. Inspect for broken or
shifted spring leaves or damaged spring parts.
(6) Item 43, Steering Linkage. Examine all steering control
mechanism and connections for looseness or damage. Investigate any
unusual condition noted during operation.
(7) Item 44, Wheel and Flange Nuts. See that all wheel side
ring mounting, and axle flange nuts are present and secure.
(8) Item 45, Tires. Inspect all tires for under-inflation or dam-
age. Remove objects lodged in carcasses. See that spare is inflated
and secure in carrier.
(9) Item 46, Leaks (General). Look under vehicle and within
engine compartment for indications of leakage of fuel, oil, or coolant.
Trace any found to their source and correct or report them,
(10) Item 47, Accessories and Belts. Examine all accessible
units for looseness or damage. Be sure fan belt is adjusted to Yi inch
finger pressure deflection. If radio -interference was reported, examine
the wiring, and noise suppression units in engine compartment for
loose connections or mountings. Give special attention to resistor-
suppressors at spark plugs and distributor.
■ (11) Item 48, Air Cleaners. If operating under extremely dusty
or sandy condition, inspect air cleaner and breather cap to see that
they are in condition to deliver properly. Service as necessary.
(12) Item 49, Fenders and Bumper. Inspect front and rear
bumpers and fenders for looseness or damage.
(13). Item 50, Towing Connections. Inspect all connections for
looseness or damage. Be sure locking devices are secure.
(14) Item 51, Body, Load, and Tarpaulins. Inspect all items
for damage, or indications of looseness or shifting.
(15) Item 52, Glass. Clean all windshield, door, window, mirror,
light, and warning reflector glass and inspect for damage.
52
TM 9-808
22
FIRST ECHELON PREVENTIVE MAINTENANCE SERVICES
22. AFTER-OPERATION AND WEEKLY SERVICE.
a. After-operation Servicing is particularly important because
at this time the driver inspects his vehicle to detect any deficiencies
that may have developed and corrects those he is permitted to
handle. He should report promptly to the designated individual in
authority the results of his inspection. If this schedule is performed
thoroughly, the vehicle should be ready to roll again on a moment's
notice. The Before-operation Service, with a few exceptions, is then
necessary only to ascertain whether the vehicle is in the same condi-
tion in which it was left upon completion of the After-operation
Service. The After-operation Service should never be entirely omitted
even in extreme tactical situations, but may be reduced to the bare
fundamental services outlined for the At-halt Service if necessary.
, b. Procedures. When performing the After-operation Service
the driver must remember and consider any irregularities noticed
during the day in the Before-operation, During-operation, and At-halt
Services. The After-operation Service consists of inspecting and
servicing the following items. Those items of the After-operation
Service that are marked by an asterisk (*) require additional weekly
services, the procedures for which are indicated in step (b) of each
applicable item.
(1) Item 55, Engine Operation. Accelerate and decelerate
engine and note any tendency to miss or back-fire. Listen for any
unusual noise or vibration that may indicate worn or inadequately
lubricated parts, loose mountings, incorrect fuel mixture or faulty
ignition. Note any unusual exhaust smoke. Investigate and correct
or report any deficiencies noted during operation.
(2) Item 56, Instruments. Check all instruments to be sure
they register and indicate correct engine performance. Inspect them
for looseness or damage. Stop engine.
(3) Item 54, Fuel, Oil, and Water Supply. Fill fuel tank and
check fuel gage for fuel indication. Check crankcase oil and coolant
supply and add as necessary to bring to correct level. In freezing
weather if any appreciable amount of coolant is necessary, have
antifreeze value checked and add sufficient to protect cooling system
against freezing. Do not add coolant while engine is too hot. Fill all
spare fuel, oil, and water cans, if supply has been used.
(4) Item 57, Horn and Windshield Wipers. Inspect to see if
these items are loose or damaged. If tactical conditions permit, test
horn for proper operation and tone.
(5) Item 58, Glass and Rear Vision Mirror. Clean all glass
and inspect for looseness or damage.
(6) Item 59, Lamps (Lights) and Reflectors. Inspect for
looseness or damage. If tactical situation- permits, test all lamps and
switches for proper operation. Clean lenses.
(7) Item 60, Fire Extinguisher. Inspect for looseness or dam-
age and full charge. If extinguisher has been in use or valves opened,
report for refill or exchange.
53
TM 9-808
22
3/4 -TON 4x4 TRUCK (DODGE)
(8) Item 61, Decontaminator. Inspect for looseness or damage
and full charge; if used, report for refill or exchange.
(9) Item 62, *Battery and Voltmeter.
(a) Inspect battery to see that it is, clean, secure, and not leaking
or damaged. See that filler caps are fingertight.
(b) Weekly. Clean top of battery. If terminal connections or
posts are corroded, clean and apply fresh, thin coating of grease
and tighten. Check level of solution and add water if required. Dur-
ing freezing weather, do not 'add water until just before operation.
Battery and carrier should be secure, and battery not bulging or
leaking. Tighten any loose mountings cautiously so as not to damage
the battery case.
(10) Item 63, Accessories and Belts. Inspect units such as
carburetor and air cleaner, generator, starting motor, fan, water
pump, distributor, regulator unit, and oil filter, for looseness, damage,
or leakage. Check condition and adjustment of fan belt. Should have
J4 inch finger pressure deflection. Investigate and correct or report
any deficiencies noted during operation.
(11) IffEM 64, Electrical Wiring. Inspect all ignition and acces-
sible low voltage wiring for looseness or damage; wipe off grease or
moisture. Be sure all wiring is supported, so as not to chafe against
other vehicle parts. Examine resistor- suppressors at spark plugs and
distributor to see if they are scorched or damaged.
(12) Item 65, *Air Cleaner and Breather Cap.
(a) Inspect for looseness or damage. Examine oil in reservoirs
for correct level and excessive dirt. When operating in sandy or dusty
conditions, clean and service engine air cleaner, crankcase ventilator
breather cap, and ventilator outlet filter element as often as necessary.
(b) Weekly. Remove engine air cleaner and crankcase breather
reservoirs and elements, wash in dry-cleaniW solvent, refill oil-bath
type • reservoirs with clean oil and install securely. On element type
ventilators, wash in dry-cleaning solvent, dry, dip in clean engine
oil, and install. Be sure all gaskets seal properly and that joints and
connections are secure.
(13) Item 66, *Fuel Filter.
(a) Inspect for looseness, damage, and fuel leaks.
(b) Weekly. Remove drain plug and drain off all accumulated
dirt and water. If draining shows excessive dirt or water, remove
bowl and clean filter element in dry-cleaning solvent. Do not dis-
assemble element. Replace all unserviceable gaskets. NOTE: // ex-
cessive water is present, report to higher echelon for cleaning of fuel
tank.
(14) Item 67, Engine Controls. Examine all engine operating
control linkage for looseness, damage, excessive wear, and adequate
lubrication.
(15) Item 68, *Tires.
(a) Examine all tires, including spares, for damage and excessive
wear. Remove all embedded foreign matter, such as nails, glass, or
54
TM 9-808
22
FIRST ECHELON PREVENTIVE MAINTENANCE SERVICES
stones from carcasses. Check for low pressures and proper position
of valve stem and presence of valve caps. Inflate to 40 pounds
pressure as needed (cool).
(b) Weekly. Replace badly worn or otherwise unserviceable tires.
Serviceable tires which show abnormal wear should be relocated to
other wheels to even wear. Apparent mechanical deficiencies causing
such wear should be reported for attention by higher echelon.
(16) Item 69, Springs and Suspensions. Inspect for looseness
or damage, abnormal spring sag, shifted • spring leaves, and shock
absorber leakage. Investigate any noise or unusual condition noted
during operation.
(17) Item 70, Steering Linkage. Inspect for looseness, damage,
and proper lubrication. Investigate any unusual operating condition
noted during operation.
(18) Item 71, Propeller Shafts. Inspect all drive shafts and
universal joints for looseness or. damage and excessive oil leaks. Re-
move any foreign material wound around shafts or joints.
(19) Item 73, *Axle and Transfer Vents.
(a) See that all axle housing and transfer case vents are present,
in good condition and clean. Inspect for indications of excessive
lubricant leakage from vents.
(b) Weekly. Remove accessible vents, clean out passages and
install securely.
(20) Item 73, Leaks (General). Look in engine compartment
and under vehicle for indications of fuel, engine oil, coolant, shock
absorber or brake fluid, or gear oil leaks.
(21) Item 74, Gear Oil Levels. Check gear oil levels in differ-
entials, transfer case, transmission and steering gear housing, and
report if low. Correct levels are from lower edge of filler hole (hot)
to Yz inch below (cold).
(22) Item 76, Fenders and Bumpers. Inspect front and rear
fenders and bumpers for looseness or damage.
(23) Item 77, Towing Connections. Inspect towing hooks, pintle
hook and lock pins and chdins for looseness, excessive wear or damage.
(24) Item 78, Body, Load, and Tarps. Inspect cab and body
carefully for damage or loose parts. Examine top tarpaulin and side
or end curtains for worn spots or other damage, and see that they
are secure. See that any cargo is secure and properly distributed.
Inspect doors or windows and their hardware to see if they are in
good condition, and securely mounted, and that they operate
properly.
(25) Item 79, *Winch.
(a) Examine winch assembly for looseness or damage and ex-
cessive oil leaks at worm gear housing. See that winch drive shaft
shear pin is secure. Be sure sliding clutch operates freely and locks
securely.
(b) Weekly. If vehicle has been operated in deep water, sample
lubricant for contam'ination. If water is present, report condition.
55
TM 9-808
22
y4-TON 4x4 TRUCK (DODGE)
Pull the vehicle up a steep bank with the winch. Release engine
clutch; if vehicle starts to back down, the brake needs adjusting.
If winch cable is dry or wound unevenly, unwind entire length, clean
with thin oil or kerosene, rewind evenly on winch drum, applying a
thin coat of engine or gear oil while winding, and secure cable chain
and hook securely to front tow hooks. NOTE: Clean, used oil is
satisfactory.
(26) Item 82, *Tightening.
(a) Tighten any mounting or external assembly nuts or screws
where inspection of vehicle has indicated the necessity.
(b) Weekly. Tighten wheel side ring, mounting and axle flange
nuts and cap screws; spring U-bolts, shackles and rebound clips;
universal joint companion flanges; engine mountings, transfer case
mountings; steering arms, towing connections, or any other mount-
ing or assembly nuts or screws that inspection or experience indicates
are necessary on a weekly or mileage basis.
(27) Item 83, *Lubricate as Needed.
(a) Lubricate all items such as shackles, hinges, latches, control
linkage frictional joints, or any point where inspection has indicated
oilcan or hand greasing is needed.
(b) Weekly. Lubricate all points of the vehicle indicated on the
Lubrication Guide, figure 71, as needing lubrication on a weekly or
a mileage basis.
(28) Item 84, *Clean Engine and Vehicle.
(a) Clean dirt and grease or oil drippings from inside cab and
body, and from engine compartment and exterior of engine. Wipe
off excess dirt and grease from entire vehicle.
(b) Weekly. Wash vehicle when possible or- wipe off thoroughly.
Inspect paint or camouflage pattern for rust or for bright spots which
might cause light reflections. See that vehicle markings are legible
unless covered for tactical reasons. CAUTION: // vehicle is driven
into water for washing, care must be taken to see. that water or dirt
does not get into wheel bearings, gear cases or brakes, or on electrical
units or wiring.
(29) Item 85, *Tools and Equipment.
(a) Check vehicle stowage and tool lists to see that all items are
present. Inspect items to see that they are in good condition and
properly mounted or stowed (pars. 25 and 26).
(b) Weekly. Clean all tools and equipment of rust or dirt, and
apply preservative where necessary, when possible. See that tools
with cutting edges are sharp and properly protected and that all
items are securely mounted or stowed.
56
TM 9-808
23-24
Section VII
LUBRICATION
Paragraph
Introduction 23
Lubrication Guide 24
23, INTRODUCTION.
a. Lubrication is an essential part of preventive maintenance,
determining to a great extent the serviceability of parts and
assemblies.
24. LUBRICATION GUIDE.
a. Lubrication instructions for this materiel are consolidated in
a Lubrication Guide (fig. 32). These specify the points to be lubri-
cated, the periods of lubrication, and the lubricant to be used. Iri
addition to the items on the Guide, other small moving parts, such
as hinges and latches, must be lubricated at frequent intervals.
b. Supplies. In the field it may not be possible to supply a com-
plete assortment of lubricants called for by the Lubrication Guide
to meet the recommendations. It will be necessary to make the best
use of those available, subject to inspection by the officer concerned,
in consultation with responsible ordnance personnel.
c. Lubrication Notes. The following notes apply to the Lubrica-
tion Guide (fig. 32). Figures 33 through 38 illustrate in detail various
points to be lubricated. All note references in the Guide itself (fig.
32) are to the subparagraph below having the corresponding number:
(1) Fittings. Clean before applying lubricant. Lubricate until
new lubricant is forced from the bearing, unless otherwise specified.
CAUTION: Lubricate chassis points after washing truck.
(2) Intervals. Intervals indicated are for normal service. For
extreme conditions of speed, heat, water, sand, mud, snow, rough
roads, dust, etc., reduce interval by one-third or one-half, or more,
if conditions warrant.
(3) Cleaning. Dry-cleaning solvent or Diesel fuel oil will be used
to clean or wash all parts. Use of gasoline for this purpose is pro-
hibited. All parts will be thoroughly dry before relubrication.
(4) Air Cleaners. Daily, check level and refill oil reservoir of
engine air cleaner to bead level with used crankcase oil or OIL,
engine, SAE 30 above +32°F and SAE from -|-32°F to 0°F. From
0°F to — 40°F use FLUID, shock-absorber, light. Below — 40°F
remove oil and operate dry. Every 1,000 miles, daily under extreme
dust conditions, remove and wash all parts. Every 1,000 miles, wash
crankcase breather pipe air cleaner and ventilator outlet pipe air
cleaner (located on right rear side of engine) and saturate filter
element with used crankcase oil or OIL, engine, SAE 30 above +32°F
and SAE 10 from +32°F to 0°F. Drain off excess oil before installing.
From 0°F to — 40°F use FLUID, shock-absorber, light. Below
— 40°F wash element and replace dry.
57
TM 9-808
24
3/4 -TON 4x4 TRUCK (DODGE)
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LUBRICATION
TM 9-808
24
CO
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Bifer Coie Drain
in and refill) (Note 7)
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Slip Joint (Note 10)
Transfer Cosa Fill and Level
(Chack level) (Note 7)
Universal Joint (Note 10)
Rear Axle Di«. Fill and Level
(Chack level) (Note 7)
r >lxle OHIerenilal Drain
inandrefill)(Note7)
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59
TM 9-808
24
3/4 -TON 4x4 TRUCK (DODGE)
FITTINGS
8 FITTINGS (2 EACH SHACKLE).
PRESSURE GUN.
LUBRICATE FROM UNDER VEHICLE.
SPRING SHACKLES
I - -, I
U n al
4 FITTINGS (1 EACH SPRING)
PRESSURE GUN.
LUBRICATE FROM UNDER VEHICLE.
SPRING BOLTS
FITTINGS
-FITTING
2 FITTINGS (1 EACH END).
PRESSURE GUN.
LUBRICATE FROM UNDER VEHICLE.
TIE ROD ENDS
FITTING
3 FITTINGS (1 EACH SHAFT).
5 FITTINGS IF EQUIPPED V/ITH
WINCH (1 EACH END OF
WINCH DRIVE SHAFT).
PRESSURE GUN.
LUBRICATE FROM UNDER VEHICLE.
PROPELLER SHAFT SPLINE YOKE
2 FITTINGS (1 EACH END).
PRESSURE GUN.
LUBRICATE FROM UNDER VEHICLE.
STEERING DRAG LINK
2 FITTINGS (1 EACH PEDAL).
PRESSURE GUN.
LUBRICATE FROM UNDER VEHICLE.
CLUTCH AND BRAKE PEDALS
RA PD 58345
Figure 33— Lubrication Fittings
60
TM 9-808
24
LUBRICATION
(5) Crankcase. Drain only when engine is hot. To aid in com-
plete draining, the front end of the truck should be slightly higher
than the rear. Refill to "FULL" mark on gage. Run engine a few
minutes and recheck oil level. CAUTION: Level should be at "run-
ning level," or center mark between "FULL" and "J4 FULL" marks
on gage. Be sure pressure gage indicates oil is circulating.
(6) Oil Filter. Every 1^000 miles, drain sediment. Every 6,000
miles or more often if filter becomes clogged, drain filter, clean inside
and renew element. Run engine a few minutes, check crankcase level
and add OIL, engine, to "FULL" mark on gage (SAE 30 above
+ 32°F to 0°F, below 0°F, refer to OFSB 6-11).
(7) Gear Cases. Weekly, check level with truck on level ground
and, if necessary, add lubricant to J4 inch below plug level when
cold or to plug level when hot. Winch gear case and steering gear
case will be filled to plug level at all times. Drain and refill at
intervals indicated on Guide. Drain only after operation. Keep vents
clean.
(8) Shock Absorbers. To fill, disconnect linkage at lower end.
Clean surface around fill plug. Remove plug and fill to level with
FLUID, shock-absorber, light. Pump arm up and down to expel
air. Repeat this procedure until no more fluid can be added. Install
plug and connect linkage.
(9) Universal Joints (Front Wheels). With truck on level
ground, remove plug at bottom of ball end of axle housing and
lubricate through fitting at top of steering knuckle until lubricant
comes out of bottom hole. Replace bottom plug. Every six months,
disassemble, clean and repack each joint with one pound of lubri-
cant before reassembling.
(10) Universal Joints and Slip Joints. Apply GREASE,
general purpose. No. 1 above +32°F and No. below -f 32°F, to
universal joints until it overflows at ends of cross and to slip joint
until lubricant is forced from end of slip joint. If lubricant does not
overflow at ends of all crosses, apply "C" clamp if available and
tighten on bearings where lubricant appeared; then relubricate. This
will cause lubricant to flow into all bearings.
(11) Brake Master Cylinder. Every 1,000 miles, inspect level
of brake fluid in reservoir. Add sufficient FLUID, brake, hydraulic,
to bring level 54 inch from top of opening in reservoir. Report at
once any excessive loss or leakage.
(12) Distributor. Every 6,000 miles, wipe distributor breaker
cam lightly with GREASE, general purpose. No. 1 above -}-.32°F
and No. below +32'^F and lubricate breaker arm pivot and wick
under rotor with one to two drops of OIL, engine, SAE 30 above
+ 32°F, SAE 10 +32°F to 0°F; and OIL, lubricating, preservative,
special, below 0"F.
(13) Wheel Bearings. Remove bearing cone assemblies from
hub and wash spindle and inside of hub. Inspect bearing races and
replace if necessary. Wet the spindle and inside of hub and hub cap
with GREASE, general purpose. No. 2, to a maximum thickness of
61
TM 9-808
24
3/4 -TON 4x4 TRUCK (DODGE)
FiniNG
2 FiniNGS (1 EACH SIDE).
PRESSURE GUN.
LUBRICATE FROM FRONT OF VEHICLE.
WINCH DRUM BEARINGS
SLIDING SURFACE OF JAW CLUTCH
AND LINKAGE.
OIL CAN.
LUBRICATE FROM FRONT OF VEHICLE.
WINCH CLUTCH
OIL CUP.
OIL CAN.
LUBRICATE FROM UNDER
LEFT SIDE OF HOOD.
CRANKING MOTOR
1 HHING.
PRESSURE GUN.
LUBRICATE FROM ABOVE FRONT
OF VEHICLE .
WINCH SHAFT
1 FiniNG.
PRESSURE GUN.
LUBRICATE FROM UNDER
LEFT SIDE OF HOOD-
WATER PUMP
PINS AND CONNECTIONS.
OIL CAN.
LUBRICATE FROM REAR OF VEHICLE.
PINTLE HOOK RA PD 318325
figure 34— Lubrication fiffings
62
TM 9-808
24
LUBRICATION
FITTING
6 FITTINGS (1 EACH JOINT CROSS), 8
FiniNGS IF EQUIPPED WITH WINCH.
PRESSURE GUN.
LUBRICATE FROM UNDER VEHICLE. THE
FRONT JOINT FITTING ON THE TRANS-
MISSION TO TRANSFER CASE SHAFT
IS LUBRICATED THROUGH COVERED
OPENING IN FLOOR OF FRONT COM-
PARTMENT, EXCEPT AMBULANCE.
UNIVERSAL JOINTS
1 FITTING.
PRESSURE GUN.
LUBRICATE THROUGH COVERED OPEN-
ING IN FRONT COMPARTMENT FLOOR.
LOOSEN COVER SCREWS AND SLIDE
COVER FROM OPENING.
SCREW DRIVER.
RETURN COVER AND TIGHTEN
(EXCEPT AMBULANCE) .
.OIL CUP
OIL CUP AND WICK.
OIL CAN.
LUBRICATE FROM UNDER LEFT SIDE OF
HOOD.
REMOVE CAP AND ROTOR AND APPLY
2 OR 3 DROPS OF ENGINE OIL TO
WICK BENEATH ROTOR. SEE THAT NO
OIL IS ON OR NEAR BREAKER POINTS.
CLEAN VENT HOLE IN CAP.
DISTRIBUTOR
OIL CUPS
2 OIL CUPS (1 ON EACH END).
OIL CAN.
LUBRICATE FROM UNDER LEFT SIDE OF
HOOD.
GENERATOR (12 VOLT)
RA PD 58347
Figure 35— Lubrication Fittings
63
TM 9-808
24
OIL WICK
3/4 -TON 4x4 TRUCK (DODGE)
FILLER AND LEVEL PLUG
TRANSFER CASE SHIFT, HAND BRAKE
CONTROL, FOOT PEDAL LINKAGE AND cm , cR HOLE (REMOVE PLUG!
CLUTCHRELEASEFORKBUSHINGWICK. FRENCH, OPEN END 5/,-IN
OIL CAN.
LUBRICATE FROM UNDER VEHICLE.
OIL CLEVIS PINS, ROD CONNECTIONS I^qq^
AND WICK IN CLUTCH RELEASE FORK instaLL PLUG
FLANGE AT LEFT SIDE OF CLUTCH
HOUSING.
LINKAGE STEERING GEAR
PUMP GUN.
LUBRICATE FROM UNDER LEFT SIDE OF
FILLER HOLE (REMOVE PLUG).
WRENCH, OPEN END s/j-IN.
PUMP GUN.
LUBRICATE FROM UNDER VEHICLE.
REMOVE AND CLEAN VENT.
WRENCH, OPEN END Vs-IN.
DRAIN AND FLUSH, REMOVE DRAIN
PLUG.
WRENCH, OPEN END y,6-IN.
INSTALL PLUGS AND VENT.
FRONT AND REAR AXLES
REMOVE HOB and BEARINGS.
WRENCHES, WHEEL BEARING ADJUST-
ING NUT AND OPEN END Va. Vm AND
3/8-IN.
CLEAN AND REPACK.
LUBRICATE FROM SIDES OF VEHICLE.
ASSEMBLE AND ADJUST.
WHEEL BEARINGS
RA PD 58348
Figure 36— Lubrication Fittings
64
TM 9-808
24
LUBRICATION
FILLER AND LEVEL PLUG
•RAIN PLUG
FILLER HOLE (REMOVE PLUG).
WRENCH, OPEN END s/g-IN.
PUMP GUN.
LUBRICATE FROM UNDER VEHICLE.
DRAIN AND FLUSH, REMOVE DRAIN
PLUG.
WRENCH, OPEN END s/j-IN.
INSTALL PLUGS.
TRANSMISSION
VENT
DRAIN PLUG
FILLER HOLE IN REAR OF CASE (RE-
MOVE PLUG).
WRENCH, OPEN END Vs-IN.
PUMP GUN.
LUBRICATE FROM UNDER VEHICLE.
REMOVE AND CLEAN VENT.
PLIERS.
DRAIN AND FLUSH, REMOVE DRAIN
PLUG.
WRENCH, DRIVE END %-\H.
INSTALL PLUGS AND VENT.
TRANSFER CASE
FILLER AND
VENT PLUG
LEVEL PLUG
4 PLUGS (2 EACH JOINT), UNSCREW
PLUGS AND SCREW ANGLE FITTING
IN TOP HOLE IF TOP HOLE IS NOT
EQUIPPED WITH FITTING.
SCREW DRIVER AND WRENCH, OPEN
END J^«-IN.
PRESSURE GUN.
LUBRICATE FROM UNDER VEHICLE.
INSTALL PLUGS.
FRONT AXLE UNIVERSAL
LEVEL PLUG
FILLER AND LEVEL HOLES (REMOVE
PLUGS).
WRENCHES, OPEN END, ?<« AND ^-IN.
PUMP GUN.
LUBRICATE FROM FRONT OF VEHICLE.
CLEAN VENT HOLE IN FILLER PLUG.
TO DRAIN AND FLUSH, REMOVE DRAIN
PLUG.
WRENCH, OPEN END M6-IN.
INSTALL PLUGS.
WINCH HOUSING
RA PD 58349
Figure 37— Lubrication Fittings
65
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V4-TON 4x4 TRUCK (DODGE)
1/16 ^^'^^ O'^ly to retard rust. Wash bearing cones and grease seals.
Inspect and replace if necessary. Lubricate bearings with GREASE,
general purpose, No. 2, with a packer or by hand, kneading lubri-
cant into all spaces in the bearing. Use extreme care to protect bear-
ings from dirt and immediately reassemble and replace wheel. The
lubricant in the bearings is sufficient to provide lubrication until the
next service period. Do not fill hub or hub cap. Any excess might
result in leakage into the brake drum.
(14) Winch Cable. After each use, clean and oil with used crank-
case oil or OIL, engine, SAE 30 above +32°F and SAE 10 from
-|-32°F to 0°F and OIL, lubricating, preservative, special, below
0°F. Weekly, if cable has not been used, coat outer coils with used
ENGINE OIL LEVEL INDICATOR
RA PD 312529
figure 38— Oil Level Indicator
crankcase oil or OIL, engine, SAE 30 above +32°F and SAE 10
from +32°F to 0°F and OIL, lubricating, preservative, special,
below 0°F. Monthly, unwind entire cable, clean and oil.
(15) Clutch Pilot Bearing. When clutch is disassembled for
any other purpose, clean and repack with^GREASE, general purpose.
No. 2.
(16) Oilcan Points. Every 1,000 miles lubricate transfer case
shift, hand brake control, foot pedal linkage, winch control linkage,
pintle hook, hood ■ and windshield hinges and locks, and ambulance
rear folding step joints with OIL, engine, SAE 30 above +32°F;
SAE 10 +32°F to 0°F and OIL, lubricating, preservative, special,
66
TM 9-808
24
LUBRICATION
below 0°F. CAUTION. Do not oil throttle control linkage. Also coat
door latches, hinges, wedges, checks and striker plates with GREASE,
general purpose, No. 1 above +32°F and No. below +32°F.
(17) Rubber Bushings. Every 1,000 miles, apply FLUID, brake,
hydraulic, to shock absorber link bushings. CAUTION: Do not use
oil.
(18) Points Requiring No Lubrication Service. These are the
clutch release bearing, generator bearings (6-volt), and fan.
(19) Cold Weather. For lubrication and service below 0°F, refer
to OFSB 6-11.
d. Reports and Records. If lubrication instructions are closely
followed, proper lubricants used, and satisfactory results are not
obtained, a report will be made to the ordnance officer responsible
for the maintenance of the materiel. A complete record of lubrication
servicing will be kept.
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25
V4-TON 4x4 TRUCK (DODGE)
Section Vni
TOOLS AND EQUIPMENT STOWAGE ON THE
VEHICLE
Paragraph
Vehicle tools and equipment 25
25. VEHICLE TOOLS AND EQUIPMENT.
a. Vehicle Tools. The tools and equipment supplied with all
vehicles are listed and illustrated in figure 40. Space for carrying
tools and equipment is provided in each vehicle as follows:
(1) Weapon Carrier, Telephone Maintenance, and Emer-
gency Repair: In space provided under front seats.
BLACKOUT
PARKING LAMP
taillight lamp unit
(blackout)
NO. 22 GAGE
WIRE
TIRE VALVE
CORES
STOP LIGHT
LAMP UNIT
TAILUGHT AND
STOP LIGHT
LAMP UNIT (BLACKOUT)
(SERVICE)
TIRE VALVE
CAPS—*
SPARK PLUG
AND GASKET
COTTER PINS
WINCH UNIVERSAL
DRIVE JOINT
SHEAR PINS
FRICTION TAPE
RA PD 312547
Figure 39— Spare Parts Kit
(2) Carryall: In the tool box built under the driver's seat.
Store tire chains in the space provided to the rear of the right wheel
housing.
(3) Ambulance: In the locker boxes along the right and left sides
in the interior of the body.
(4) Command: In the rear deck compartment.
b. Spare Parts Kit. Each vehicle is equipped with a kit, contain-
ing spare parts as illustrated in figure 39. The kit is located in the
spare parts box, under the map board.
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25
TOOLS AND EQUIPMENT STOWAGE ON THE VEHICLE
A— BAG, TOOL
B— WRENCH, WHEEL SOCKET
C— HANDLE, WHEEL WRENCH
D— JACK
E — CHAINS, TIRE
F— BLOCK, SNATCH
(WINCH EQUIPPED VEHICLES)
G— CRANK, STARTING
H — GAGE, TIRE PRESSURE
|_WRENCH, ADJUSTABLE
J— PLIERS
K— ADAPTER, GREASE GUN
L— GUN, GREASE
M— PUMP, TIRE
N— SCREWDRIVER, CROSS RECESS,
SMALL
O-SCREWDRIVER, CROSS RECESS,
LARGE
P— SCREWDRIVER, PLAIN
Q— HAMMER
R— WRENCH, SPARK PLUG
S- WRENCH, OPEN END, %7 IN.
AND Vs IN.
T- WRENCH, OPEN END, '/i6 IN.
AND /2 IN.
U— WRENCH, OPEN END, '/i* IN.
AND Va IN.
V— WRENCH, OPEN END, "/32 IN.
AND "/,« IN.
W— WRENCH, OPEN END, =/, IN.
AND % IN.
X-CAN, OIL
Y— WRENCH, WHEEL BEARING
ADJUSTING NUT
Z- HANDLE, JACK
RA PD 312546
Figure 40— Vehicle Tools and Equipment
c. Care of Tools and Equipment. Tools subjected to water and
dirt will rust if not cleaned and wiped dry. After using tools and
equipment, clean and dry them thoroughly and store in the spaces
provided on vehicles.
d. Pioneer Equipment. The following pioneer equipment is on
the vehicle:
AX, 41-A-1277 MATTOCK, 41-M-720,
CONTAINER, 5 gal,
42-D-1280
with handle
SHOVEL, 41-S-3170
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V4-TON 4x4 TRUCK (DODGE)
PART TWO-VEHICLE MAtNTENANCE INSTRUCTIONS
Section IX
RECORD OF MODIFICATIONS
Paragraph
MWO and major unit replacement record 26
26. MWO AND MAJOR UNIT REPLACEMENT RECORD.
a. Description. Every vehicle is supplied with a copy of AGO
Form No. 478 which provides a means of keeping a record of each
MWO 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 and
that it remain with the vehicle until the vehicle is removed from
service.
b. Instructions for Use. Personnel performing modifications or
major unit assembly replacement must record clearly on the form
a description of the work completed and must initial the form in
the columns provided. When each modification is completed, record
the date, hours and/or mileage, and MWO number. When major
unit assemblies, such as engines, transmissions, transfer cases, are
replaced, record the date, hours and/or mileage and nomenclature
of the unit assembly. Minor repairs and minor parts and accessory
replacements need not be recorded.
c. Early Modifications. 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 modifications
applied prior to the date of AGO Form No. 478.
70
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27-28
Section X
NEW VEHICLE RUN-IN TEST
Paragraph
Introduction 27
Run-in test procedures 28
27. INTRODUCTION.
a. General. When a new or reconditioned vehicle is first received
at the using organization, it is necessary for second echelon personnel
to determine whether or not the vehicle will operate satisfactorily
when placed in service. For this purpose, inspect all accessories, sub-
assemblies, assemblies, tools, and equipment, to see that they are in
place and correctly adjusted. In addition, they will perform a run-in
test of at least 50 miles as directed in AR 850-15, paragraph 25,
table III, according to procedures in paragraph 28 below.
b. Correction of Deficiencies. Deficiencies disclosed during the
course of the run-in test will be treated as follows :
(1) Correct any deficiencies within the scope of the maintenance
echelon of the using organization before the vehicle is placed in
service.
(2) Refer deficiencies beyond the scope of the maintenance
echelon of the using organization to a higher echelon for correction.
(3) Bring deficiencies of serious nature to the attention of the
supplying organization.
28. RUN-IN TEST PROCEDURES,
a. Preliminary Service.
(1) Fire Extinguisher. See that the portable extinguisher is
present and in good condition. Test it momentarily for proper opera-
tion, and mount it securely.
(2) Fuel, Oil, and Water. Fill fuel tank. Check crankcase oil
and coolant supply, add oil and coolant as necessary to bring to
correct levels. Allow room for expansion in fuel tank and radiator.
During freezing weather, test value of antifreeze and add as neces-
sary to protect cooling system against freezing. CAUTION: // there
is a tag attached to Slier cap or steering wheel concerning engine oil
in crankcase, follow instructions on tag before driving the vehicle.
(3) Fuel Filter. Inspect fuel filter for leaks, damage, and secure
mountings and connections. Drain filter sediment bowl. If any
appreciable amount of .water or dirt is present, remove bowl, and
clean bowl and element in dry-cleaning solvent. Also drain accurru-
lated water or dirt from bottom of fuel tank. Drain only until fuel
runs clean.
(4) Battery. Make hydrometer and voltage test of battery, and
add clean water to bring electrolyte 54 inch above plates.
(5) Air Cleaner and Breather Cap. Examine carburetor air
cleaner, crankcase filler breather cap, and ventilator outlet filter
71
TM 9-808
28
3/4 -TON 4x4 TRUCK (DODGE)
unit, to see if they are in good condition and secure. Clean elements
and reservoirs. Fill oil bsrth cleaners to proper level with fresh oil.
Dip ventilator outlet element in clean oil. Reinstall all units securely.
Be sure all gaskets are in good condition and that ducts and air
horn connections are tight.
(6) Accessories and Belts. See that accessories such as car-
buretor, generator, regulator, cranking motor, distributor, fan, water
pump, and oil filter are securely mounted. Make sure fan and gen-
erator drive belt is in good condition, and adjusted to have Yi inch
finger pressure deflection.
(7) Electrical Wiring. Examine all accessible wiring and con-
duits to see if they are in good condition, securely connected, and
properly supported.
(8) Tires. See that all tires, including spare, are properly inflated
to 40 pounds, cool; that stems are in correct position; all valve caps
present and fingertight. Inspect for damage, and remove objects'
lodged in treads and carcasses.
(9) Wheel and Flange Nuts. See that all wheel mounting and
axle flange nuts are present and secure.
(10) Fenders and Bumper. Examine fenders and front bumper
for looseness and damage.
(11) Towing Connections. Inspect tow hooks and pintle hook
for looseness or damage. See that pintle hook operates properly and
latches securely.
(12) Body and Tarpaulins. Inspect body for damage and loose
mountings. See that all attachments arid items of special equipment
are in good condition, and examine tarpaulins and curtains where
used for damage and loose fastenings. Be sure doors fit, close, and
latch properly. Inspect glass for damage. See that any window lift
mechanism and all hardware is in good operating condition and
secure. Examine seats, safety straps, floorboards and skid strips,
and stowage compartments for good condition, correct assembly,
and secure mounting.
(13) Winch. Inspect winch for damage, secure mounting, and
oil leaks. Test winch clutch mechanism for proper operation. Test
drag brake to see if it holds drum for spinning and as cable is
unwound; inspect it for wear, damage, and adequate lubrication.
Test winch automatic brake by placing vehicle at top of steep
incline and attaching cable to another vehicle at bottom. While
drawing towed vehicle uphill, release engine clutch; if towed vehicle
backs downhill, brake needs adjustment. Start lowering vehicle
downhill with winch; throw out engine clutch; if towed vehicle
does not stop or drifts more than one or two inches, brake needs
adjustment (par. 189). After test, rewind cable evenly and tightly
on drum and as winding, clean cable thoroughly and apply a film
of engine oil.
(14) Lubricate. Perform a complete lubrication of the vehicle,
covering all intervals, according to the instructions on the Lubri-
cation Guide (par. 24), except gear cases, wheel bearings, and other
72
TM 9-808
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NEW VEHICLE RUN-IN TEST
units lubricated in items (1) to (13). Check all gear case oil levels,
and add as necessary to bring to correct level. Change only if con-
dition of oil indicates the necessity, or if gear oil is not of proper
grade for existing atmospheric temperature. Perform items (15) to
(18) during lubrication.
(15) Springs and Suspensions. Inspect front and rear springs
and shocks to see that they are in good condition, correctly as-
sembled, secure, and that bushings and shackle pins are not exces-
sively loose, or damaged.
(16) Steering Linkage. See that all steering arms, rods and
connections are in good condition and secure; and that gear case is
securely mounted and not leaking excessively.
(17) Propeller Shafts. Inspect all shafts and universal joints
to see if they are in good condition, correctly assembled, alined, secure,
and not leaking excessively.
(18) Axle and Transfer Vents. See that axle housing and
transfer case vents are present, in good condition, and not clogged.
(19) Choke. Examine choke to be sure it opens and closes fully
in response to operation of choke button.
(20) Engine Warm-up. Start engine and note if cranking motor
action is satisfactory, and engine has any tendency toward hard
starting. Set hand throttle to run engine at fast idle during warm-up.
During warm-up, reset choke button so engine will run smoothly,
and to prevent overchoking and oil dilution.
(21) Instruments.
(a) Oil Pressure Gage. Immediately after engine starts, observe
if oil pressure is satisfactory. (Nprmal operating pressure, hot, at
running speeds is 40 to 50 pounds, at idle speed 15 pounds.) Stop
engine if pressure is not indicated in 30 seconds.
(b) Ammeter. Ammeter should show slight positive ( + ) charge.
High charge may be indicated until generator restores to battery,
current used in starting.
(c) Temperature Gage. Engine temperature should rise gradu-
ally during warm-up period, to normal range, 160°F to 185°F.
(d) Fuel Gage. Fuel gage should register "FULL" if tank has
been filled.
(22) Engine Controls. Observe if engine responds properly to
controls and if controls operate without excessive looseness or binding.
(23) Horn and Windshield Wipers. See that these items are in
good condition and secure. If tactical situation perrnits, test horn
for proper operation and tone. See if wiper arms will operate through
their full range and that blade contacts glass evenly and firmly.
(24) Glass and Rear-view Mirror. Clean all body glass and
rear-view mirror and inspect for looseness and damage. Adjust mirror
for correct vision.
(25) Lamps (Lights) and Reflectors. Clean lenses and inspect
all units for looseness and damage. If tactical situation permits,
73
TM 9-808
28
3/4-TON 4x4 TRUCK (DODGE)
open and close all light switches to see if lamps respond properly.
(26) Leaks (General). Look under vehicle, and within engine
compartment, for indications of fuel, oil, coolant, and brake fluid
leaks. Trace any leaks found to source and correct or report them
to designated authority.
(27) Tools and Equipment. Check tools shown in figures 39 and
40, to be sure all items are present, and see that they are serviceable
and properly mounted or stowed.
b. Run-in Test. Perform the following procedures (1) to (10)
inclusive during the road test of the vehicle. On vehicles which have
been driven 50 miles or more in the course of delivery from the
supplying to the using organization, reduce the length of the road
test to the least mileage necessary to make observations listed-below.
CAUTION: Continuous operation of the vehicle at speeds approach-
ing the maximums indicated on the caution plate should be avoided
during the. test.
(1) Dash InSI-ruments and Gages. Do not move vehicle until
engine temperature reaches 135°F. Maximum safe operating tem-
perature is 190°F. Observe readings of ammeter, oil, temperature,
and fuel gages to be sure they are indicating the proper function of
the units to which they apply. Also see that speedometer registers
the vehicle speed and that odometer registers accumulating mileage.
(2) Brakes: Foot and Hand. Test service brakes to see if they
stop vehicle effectively, without side pull, chatter, or squealing, and
observe if pedal free travel is ^ig inch before meeting resistance and
pedal to under side of floor plate clearance is 54 inch. Parking brake
should hold vehicle on a reasonable incline, with J^ t° Vs lever
ratchet travel in reserve. CAUTION: Avoid long application of
brakes until shoes become evenly seated to drums.
(3) Clutch. Observe if clutch operates smoothly, without grab,
chatter, or squeal on engagement, or slippage under load, when fully
engaged. See that pedal has 1% inch free travel before meeting
resistance. CAUTION: Do not ride clutch pedal unnecessarily, and
do not engage or disengage new clutch severely, until driven and
driving disks have become properly worn in.
(4) Transmission and Transfer. Gearshift mechanism should
operate easily and smoothly, and gears should operate without
unusual noise, and not slip out of mesh. Test front axle declutching,
and power take-off mechanism (on vehicles so equipped) for proper
operation.
(5) Steering. Observe steering action for binding or looseness,
and note any excessive pull to one side, wander, shimmy, or wheel
tramp. See that column, bracket, and wheel are secure.
(6) Engine. Be on the alert for any abnormal engine operating
characteristics or unusual nois^,Usuch as lack of pulling power or
acceleration, backfiring, misfiring, <stalling,'~§verheating, or excessive
exhaust smoke. Observe if engine responds, properly to all controls.
(7) Unusual Noise. Be on |he alert throughout road test for any
unusual noise from body and attachments,' running gear, suspen-
74
TM 9-808
28
NEW VEHICLE RUN-IN TEST
sions, or wheels, that might indicate looseness, damage, wear, inade-
quate lubrication, or underinflated tires.
(8) Halt Vehicle at 10-mile Intervals for Services (9) and
(10) Below.
(9) Temperatures. Cautiously hand-feel each brake drum and
wheel hub for abnormal temperatures. Examine transmission, trans-
fer case, and differential housings, for indications of overheating and
excessive lubricant leaks at seals, gaskets, or vents. NOTE: Transfer
case temperatures are normally higher than other gear cases.
(10) Leaks. With engine running, and fuel, engine oil, and cooling
systems under pressure, look within engine compartment and under
vehicle for indications of leaks.
c. Upon completion of run-in test, correct or report any defi-
ciencies noted. Report general condition of vehicle to designated
individual in authority.
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29
3/4 -TON 4x4 TRUCK (DODGE)
Section XI
SECOND ECHELON PREVENTIVE MAINTENANCE
Paragraph
Second echelon preventive maintenance services 29
29. SECOND ECHELON PREVENTIVE MAINTENANCE
SERVICES.
a. Regular scheduled maintenance inspections and services are a
preventive maintenance function of the using arms, and are the
responsibility of commanders of operating organizations.
(1) Frequency. The frequency of the preventive maintenance
services outlined herein is considered a minimum requirement for
normal operation of vehicles. Under unusual operating conditions,
such as extreme temperatures, dusty or sandy terrain, it may be
necessary to perform certain maintenance services more frequently.
(2) First Echelon Participation. The drivers should accom-
pany their vehicles and assist the mechanics while periodic second
echelon preventive maintenance services are performed. Ordinarily,
the driver should present the vehicle for a scheduled preventive
maintenance service in a reasonably clean condition: that is, it
should be dry and not caked with mud or grease to such an extent
that inspection and servicing will be seriously hampered. However,
the vehicle should not be washed or wiped thoroughly clean, since
certain types of defects, such as cracks, leaks, and loose, or shifted
parts or assemblies are more evident if the surfaces are slightly
soiled or dusty.
(3) If instructions other than those which are contained in the
general procedures in step (4) or the specific procedures in step (5)
which follow, are required for the correct performance of a preven-
tive maintenance service, or for correction of a deficiency, other
sections of this manual pertaining to the item involved, or a desig-
nated individual in authority, should be consulted.
(4) General Procedures. These general procedures are basic
instructions which are to be followed when performing the services
on the items listed in the specific procedures. NOTE: The second
echelon personnel must be thoroughly trained in these procedures
so that they will apply them automatically.
(a) When new or overhauled subassemblies are installed to cor-
rect deficiencies, care should be taken to see that they are clean,
correctly installed, properly lubricated, and adjusted.
(b) When installing new lubricant retainer seals, a coating of
the lubricant should be wiped over the sealing surface of the lip of
the seal. When the new seal is a leather seal, it should be soaked
in SAE 10 engine oil (warm if practicable) for at least 30 minutes.
Then the leather lip should be worked carefully by hand before
installing the seal. The lip must not be scratched or marred.
76
TM 9-808
29
SECOND ECHELON PREVENTIVE MAINTENANCE
(c) The general inspection of each item applies also to any sup-
porting member or connection, and usually includes a check to see
whether or not the item is in good condition, correctly assembled,
secure, or excessively worn.- The mechanic must be thoroughly
trained in the following explanations of these terms:
1. The inspection for "good condition" is usually an external
visual inspection to determine if the unit is damaged beyond safe
or serviceable limits. The term "good condition" is explained further
by the following terms: not bent or twisted, not chafed or burned,
not broken or cracked," not bare or frayed, not dented or collapsed,
not torn or cut.
2. The inspection of a unit to see that it is "correctly assembled"
is usually an external visual inspection to see whether or not it is in
its normal assembled position in the vehicle.
3. The inspection of a unit to determine if it is "secure" is usually
an external visual examination, a wrench, hand-feel or a pry-bar
check for looseness. Such an inspection should include any brackets,
lock washers, lock nuts, locking wires, or cotter pins used in assembly.
4. "Excessively worn" will be understood to mean worn close to,
or beyond, serviceable limits, and likely to result in a failure if not
replaced before the next scheduled inspection.
(d) Special Services. These are indicated by repeating the item
numbers in the columns which show the interval at which the serv-
ices are to be performed, and show that the parts, or assemblies,
are to receive certain mandatory services. For example, an item
number in one or both columns opposite a tighten procedure, means
that the actual tightening of the object must be performed. The
special services include:
1. Adjust. Make all necessary adjustments in accordance with
the pettinent section of this manual, special bulletins, or other cur-
rent directives.
2. Clean. Clean units of the vehicle with dry-cleaning solvent to
remove excess lubricant, dirt, and other .foreign material. After the
parts are cleaned, rinse them in clean fluid and dry them thoroughly.
Take care to keep the parts clean until reassembled and be certain
to keep cleaning fluid away from rubber or other material that it
would damage. Clean the protective grease coating from new parts
since this material is usually not a good lubricant.
3. Special lubrication. This applies either to lubrication oper-
ations that do not appear on the vehicle Lubrication Guide, or to
items that do appear on such guides, but which should be performed
in connection with the maintenance operations, if parts have been dis-
assembled for inspection or service.
4. Serve. This usually consists of performing special operations,
such as replenishing battery water, draining and refilling units with
oil, and changing or cleaning the oil and fuel filter or cartridge:
5. Tighten. All tightening operations should be performed with
sufficient wrench torque (force on the wrench handle) to tighten the
unit according to good mechanical practice. Use a torque-indicating
77
TM 9-808
29
3/4 -TON 4x4 TRUCK (DODGE)
Figure 41— Top View of Chassis
78
TM 9-808
29
SECOND ECHELON PREVENTIVE MAINTENANCE
A— FRONT BUMPER
B— GENERATOR
C— SHOCK ABSORBER— LEFT FRONT
D— BRAKE WHEEL CYLINDER— LEFT
FRONT
E— BREATHER PIPE AIR CLEANER
F— WHEEL, TIRE, HUB AND BRAKE
' DRUM— LEFT FRONT
G— DISTRIBUTOR
H— IGNITION CQIL
I— OIL FILTER
J- CRANKING MOTOR
K— STEERING GEAR COLUMN JACKET
L— HAND BRAKE BAND
M— STEERING WHEEL
N— SHOCK ABSORBER— LEFT REAR
O— BRAKE WHEEL CYLINDER— LEFT
REAR
P— WHEEL, TIRE, HUB AND BRAKE
DRUM— LEFT REAR
Q— FUEL TANK
R— TRAILER WIRING CONNECTOR
S— TAIL AND SIGNAL LAMP— LEFT
T— REAR BUMPER— LEFT
U— WINCH CABLE AND DRUM
V— WATER PUMP
W— ENGINE
X— FUEL PUMP
Y— CARBURETOR AND GOVERNOR
Z— BRAKE WHEEL CYLINDER— RIGHT
FRONT
AA— FRONT AXLE HOUSING
BB— SHOCK ABSORBER- RIGHT FRONT
CO— WHEEL, TIRE, HUB AND BRAKE
DRUM— RIGHT FRONT
DD— CARBURETOR AIR CLEANER
EE— HORN
FF— CLUTCH HOUSING
GG— TRANSMISSION GEARSHIFT LEVER
HOUSING OR COVER
HH— SHOCK ABSORBER— RIGHT REAR
II— BRAKE WHEEL CYLINDER— RIGHT
REAR
JJ— REAR AXLE HOUSING
KK— WHEEL, TIRE, HUB AND BRAKE
DRUM— RIGHT REAR
LL— FUEL GAGE (TANK UNIT)
MM— TAIL AND SIGNAL LAMP— RIGHT
NN— REAR BUMPER— RIGHT
RA PO 318324.B
Legend for figure 41— Top View of Chassis
wrench where specified. Do not overtighten, as this may strip threads
or cause distortion. Tightening will always be understood to include
the correct installation of lock washers, lock nuts, and cotter pins,
provided to secure the tightening.
(e) When conditions make it difficult to perform the complete
preventive maintenance procedures at one time, they can sometimes
be handled in sections, planning, to complete all operations within
the week if possible. All available time at halts, and in bivouac areas,
must be utilized if necessary to assure that maintenance operations
are completed. When limited by the tactical situation, items with
special services in the columns, should be given first consideration.
({) The numbers of the preventive maintenance procedures that
follow are identical with those outlined on W.D. AGO Form No.
461, which is the Preventive Maintenance Service Work Sheet for
Wheeled and Half-track Vehicles. Certain items on the work sheet,
that do not apply to this vehicle, are not included in the procedures
in this manual. In general, the numerical sequence of items on the
work sheet is followed in the manual procedures, but in some in-
stances there is deviation for conservation of the mechanic's time
and effort.
(5) Specific Procedures. The procedures for performing each
item in the 1,000-mile (monthly) and 6,000-mile (six-month) main-
tenance procedures are described in the following chart. Each page
y9
TM 9-808
29
3/4 -TON 4x4 TRUCK (DODGE)
RA PD 52786
Figure 42— Bottom View of Chassis
80
TM 9-808
29
SECOND ECHELON PREVENTIVE MAINTENANCE
A— FRONT SPRING SHACKLE
B— FRONT SPRING
C— ENGINE DUST PAN— RIGHT
D— BRAKE SUPPORT AND ADJUSTING
PINS
E— STEERING TIE ROD
F— FRONT AXLE DIFFERENTIAL AND
CARRIER
G— FRONT SPRING REAR BOLT
H— EXHAUST PIPE
I— CLUTCH HOUSING PAN
J— TRANSMISSION
K— FRONT PROPELLER SHAFT AND
UNIVERSAL JOINTS
L— MUFFLER
M— TRANSFER CASE
N— MUFFLER TAIL PIPE
O— REAR SPRING FRONT BOLT
P— BRAKE SUPPORT AND ADJUSTING
PINS
Q— HOUSING COVER
R— REAR SPRING
S— REAR SPRING SHACKLE
T— PINTLE HOOK
U— WINCH V^^ORM HOUSING
V— FRONT SPRING SHACKLE
W— WINCH DR'IVESHAFT AND
UNIVERSAL JOINTS
X— FRONT SPRING •
Y— BRAKE SUPPORT AND ADJUSTING
PINS
Z— ENGINE DUST PAN— LEFT
AA— STEERING DRAG LINK
BB— BRAKE MASTER CYLINDER
CC— FRONT SPRING REAR BOLT
DD— ENGINE OIL PAN
EE— POWER TAKE-OFF
FF— HAND BRAKE DRUM
GG— INTERMEDIATE PROPELLER SHAFT
AND UNIVERSAL JOINTS
HH— FRAME
II— REAR SPRING FRONT BOLT
JJ— REAR PROPELLER SHAFT AND
UNIVERSAL JOINTS
KK— REAR AXLE DIFFERENTIAL AND
CARRIER
LL— BRAKE SUPPORT AND ADJUSTING
PINS
MM— REAR SPRING
NN— REAR SPRING SHACKLE
RA PD 52786B
Legend tor Figure 42— Bottom View of Chassis
of the chart has two columns at its left edge corresponding to the
6,000-mile and the 1,000-mile maintenance respectively. Very often
it will be found that a particular procedure does not apply to both
scheduled maintenances. In order to determine -which procedure to
follow, look down the column corresponding to the maintenance due,
and wherever an item number appears perform the operations indi-
cated opposite number.
MAINTENANCE
6D00
1000
Mile
Mile
1
1
3
3
ROAD TEST
NOTE: When the tactical situation does not permit a
full road test, perform those items which require little,
or no, movement of the vehicle: When a road test is
possible, it should be for preferably 5 miles and not
over 10 miles.
Before-operation Service. Perform the Before-oper-
ation Service as described in paragraph 19.
Dash Instruments and Gages.
Oil Pressure Gage. Oil pressure should be 30 to 50
pounds above 30 miles per hour; and at least 15 pounds
at normal idling speed. Stop engine if oil pressure is
too low.
81
TM 9-808
29
MAINTENANCE
soon
Mile
1000
Mile
3/4 -TON 4x4 TRUCK (D6dGE)
Ammeter. Ammeter should show a positive ( + )
charge immediately after starting engine. With battery
fully charged, ammeter may show zero or only slight
charge. Stop engine and investigate discharge ( — )
readings with lights and accessories turned off.
Engine Temperature Gage. Reading should increase
gradually after starting to normal operating tempera-
ture, 160°F to 185°F. Maximum safe temperature is
200°F.
Speedometer. See that speedometer and odometer are
functioning.
Fuel Gage. Gage should register approximate amount
of fuel in tank.
Horns, Mirrors, and Windshield Wipers. If tactical
situation permits, test horn for proper operation and
tone. See that rear vision mirror and wipers are in good
condition and secure. Test operation of wiper motors
and see that wiper blades contact glass evenly and
operate through their full range.
Brakes. Operate brakes at various speeds during road
test.
Foot Braks. Test brakes for effectiveness, pull to
one side, unusual noise, or chatter. Pedal should have
^16 inch free travel before meeting resistance, and
should return to off position when released without
striking rear engine support.
Hand Brake. Stop vehicle on reasonable incline;
apply hand brake and observe if it latches and holds
vehicle effectively; that lever has y^ to V3 travel in
reserve.
Clutch. Pedal free travel should be 1% inch before
meeting resistance. Clutch should stop transmission en-
tirely when vehicle is standing. Note any unusual noise
when pedal is depressed which may indicate unsatisfac-
tory release bearing. With transmission in gear, note any
tendency to chatter or grab when clutch is engaged or
to slip when fully engaged under load.
Transmission and Transfer Case. Transmission lever
should move into each gear range position easily. Test
transfer case shift lever to see that front axle engages.
Note any noise or vibration that may indicate loose
mountings, excessively worn or inadequately lubricated
parts.
Steering. With vehicle in motion, observe whether there
is any indication of looseness or binding or any tend-
ency to wander, shimmy, or pull to one side.
82
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29
SECOND ECHELON PREVENTIVE MAINTENANCE
MAINTENANCE
6000
Mill
1000
Mile
10
13
10
13
14
14
16
16
17
18
17
18
Engine. Observe engine operating characteristics as
follows:
Idle. Engine, should idle smoothly without stalling.
Unusual Noises. Accelerate and decelerate, and listen
for knocks and rattles while the engine is under both
light and heavy loads.
Acceleration and Power. Note if engine has normal
pulling power and acceleration or any tendency to stall
while shifting. A slight ping during fast acceleration is
normal.
Governed Speed. With the vehicle in low gear,
observe the speedometer reading to see if the vehicle
reaches, but does not exceed, 9 miles per hour with no
load. Engine must not surge at full throttle.
Unusual Noises. Be on alert during road test for any
noise that might indicate loose or damaged attachments
mounted on vehicle, loose cab or body mountings, floor
plates, doors, windshield, or hardware.
Temperatures. Place hand cautiously on .all brake
drums and wheel hubs to see if they are abnormally hot.
Inspect axle, housings, transmission, and transfer case,
for indications of overheating. NOTE: Transfer case
will run considerably hotter than the other units.
Leaks. Look in engine compartment, and under vehicle
for indications of engine oil, coolant, or fuel leaks.
MAINTENANCE OPERATIONS
Raise Vehicle— Block Safely
Gear Oil Level and Leaks. Check lubricant levels in
front and rear axles, transmission, and transfer case.
Proper level is from lower edge of filler hole (hot) to
^ inch below (cold). Note condition of lubricant. If an
oil change is due in any of these units or condition of
lubricant indicates ah oil change is necessary, drain
and refill units. Notice any indications of excessive lubri-
cant leaks at oil seals or gaskets. NOTE: Slight seepage
at seals is not considered as leakage.
Unusual Noises. Trace and correct any unusual noises
noted during road test.
Cylinder Heads and Gaskets. Look for cracks or indi-
cations of oil, coolant, or compression leaks around
83
TM 9-808
29
MAINTENANCE
GOOD
Mile
1000
Mile
19.
19
22
22
22
20
20
21
23
23
3/4 -TON 4x4 TRUCK (DODGE)
studs, nuts, and gaskets. CAUTION: Cylinder heads
should not be tightened unless there is definite evidence
of leaks. If tightening is necessary, use torque-indicating
wrench, and tighten head nuts in the proper sequence
and to 52.5 to 57.5 foot pounds tension (par. 58).
Valve Mechanism. Adjust valve stem clearance only if
noisy. Intake and exhaust clearance, 0.010 inch "go",
0.012 inch "no go" (hot).
Adjust. Set valve stem clearances to above specifica-
tions. Install covers securely with new gaskets.
Battery. Clean top of battery. Inspect case for cracks
and leaks. Inspect cables, terminals, bolts, straps, and
hold-downs, for good condition. . Test specific gravity
and voltage (par. 88) and record on W.D. AGO Form
No. 461. Specific gravity readings below 1.225 indicate
battery should be recharged or replaced. For extremely
hot weather (95 °F and above) see paragraph 88. Add
distilled or clean water to bring battery solution 54 inch
above top of plates.
Perform high-rate discharge test according to instruc-
tions for "condition" test which accompany test in-
strument and record voltage on W.D.; AGO Form No.
461. Cell variation should not be more than 30 percent.
NOTE: Specific gravity must be above 1.225 to make
this test.
Spark Plugs. Without removal, wipe off plugs and
examine insulation for damage or indications of com-
pression leaks.
Blow dirt from spark plug depressions in cylinder
head and remove all plugs. Look for broken insulators,
excessive carbon or oxide deposits, . and for burned
electrodes. Clean plugs thoroughly. If plug cleaner is
not available, install new or reconditioned plugs.
NOTE: Do not install plugs until item 21 has been
performed. Set plug gaps to 0.025 inch by bending only
grounded electrodes.
Compression Test. Test compression with all spark
plugs removed. Compression pressure at cranking speed
is normally 98 to 118 pounds. There should not be more
than 20 pounds variation between cylinders. Record
compression pressures on back of work sheet, Form No.
461.
Crankcase. With engine idling, examine exterior of
engine for oil leaks. Stop engine and check to see if oil
is at proper level. If an oil change is due, or condition of
84
TM 9-808
29
SECOND ECHELON PREVENTIVE MAINTENANCE
MAINTENANCE
6000
Mile
24
25
25
26
26
27
1000
Mile
24
25
26
27
27
oil indicates the necessity, drain crankcase and refill to
correct level. NOTE: Do not again start engine until
item 24 has been performed.
Oil Filter and Lines. Inspect filter and external engine
oil lines to see if they are in good condition, secure, and
not leaking. Remove filter body drain plug and drain
off contents. Remove filter cartridge . and check condi-
tion. If cartridge change is due, or condition indicates
the necessity, replace with new cartridge being sure
gaskets are in place and tighten cover and drain plug
securely.
Radiator (Core, Shell, Mountings, Hose, Cap and
Casket, Antifreeze Record, Overflow Pipe). Inspect
all parts of cooling system to see that they are in good
condition, secure, and not leaking. Examine condition
of coolant to see whether it is contaminated and system
should be cleaned. If cleaning is necessary, proceed only
according to current directives covering proper pro-
cedure and recommended cleaner, neutralizer, and
inhibitor materials. Clean all insects, dirt, or grease
deposits, from core air passages and inspect for bent
cooling fins. CAUTION: Use only a suitably shaped
piece of wood or blunt instrument to straighten fins. If
antifreeze is in use, test its protective value and record
in space provided on back of work sheet Form No. 461.
Tighten. Tighten all loose radiator mountings, water
connections, hose clamps and radio noise suppression
bond straps (particularly points where toothed lock
washers are used), for bonding.
Water Pump and Fan. Inspect pump to see if it is in
good condition, secure, and not leaking. Inspect fan to
see if it is in good condition, and that blades and hub.
are secure.
Tighten. Tighten water pump, fan and mounting
nuts.
Generator, Starter, and Switch. Inspect generator,
starter, and switch, to see if they are in good condition,
securely mounted, and if wiring connections are clean
and secure. See that radio noise suppression condenser
on cranking motor is securely mounted and connected.
' Remove generator and starter inspection covers and
examine commutators and brushes for excessive wear.
See that brushes are free in holders and connection wires
are secure and not chafing.
Clean. Blow out commutator end of generator and
starter with compressed air. If brushes or commutators
85
TM 9-808
29
MAINTENANCE
6000
Mile
27
29
1000
Mile
29
31
31
31
32
33
32
33
33
34
34
3/4 -TON 4x4 TRUCK (DODGE)
are worn excessively, replace unit.
Tighten. Tighten starter mounting bolts securely.
Drive Belt and Pulleys. Examine fan belt for good
condition. Inspect all drive pulleys and hubs to see if
they are in good condition and securely mounted.
Adjust. Adjust fan belt for ^ inch finger pressure
deflections (par. 82).
Distributor. Observe if distributor body and external
attachment are in good condition and secure. Examine
other parts as follows:
Cap, Rotor, and Points. Remove cap and clean.
Look for cracks and carbon streaks in cap and rotor,
corrosion of terminals and connections. See that points
are well alined and adjusted to 0.020 inch, when wide
open.
If inside of distributor is dirty, remove assembly,
clean in dry-cleaning solvent, dry thoroughly with com-
pressed air and lubricate according to Lubrication
Guide. If breaker points are pitted, burned or worn to
an unserviceable degree, replace. When cleaning points
use contact point dresser (never use emery) and blow
out filings with compressed air.
Shaft. Test shaft by hand-feel for excessive wear in
shaft for bushings.
Centrifugal Advance. Install rotor on shaft and
turn clockwise as far as it will go and note if it will
return to its original position when released without hang
up or binding.
Adjust. Set breaker point gaps to 0.020 inch, when
wide open.
Coil and Wiring. Inspect coil, ignition wiring including
shielding or conduits to see if they are in good condition,
clean, securely connected, and properly mounted. In-
spect all low voltage wiring in engine compartment in
like manner.
Manifolds and Caskets. Inspect for looseness, damage,
or exhaust leaks at gaskets. Examine for evidence of
cracks or sand holes usually indicated by carbon streaks.
Make sure spark plugs and distributors to coil wire
resistor-suppressors are firmly attached to wires, and
not scorched or cracked, and that coil ground strap
connections are secure.
Tighten. Tighten all manifold assembly and mount-
ing nuts securely.
Air Gleaner. Inspect carburetor air cleaner to see if it
is in good condition, securely mounted and connected,
86
TM 9-808
29
SECOND ECHELON PREVENTIVE MAINTENANCE
MAINTENANCE
EOOO
Mill
35
36
37
100D
Mile
35
36
37
38
38
39
40
41
38
39
40
41
and not leaking. Remove reservoir and element, wash in
dry-cleaning solvent, dry, fill reservoir to proper level
with clean engine oil and reassemble. Be sure gaskets
are in place and all joints and air horn connections
tight.
Breather Cap and Ventilator. Inspect crankcase
breather cap and ventilator outlet to see if they are in
good condition, secure, and not leaking. Remove oil
reservoir and element, or filter type elements, wash
clean in dry-cleaning solvent, refill reservoir with fresh
engine oil and reassemble securely. If not oil bath type,
dip elements in clean engine o.il, drain off excess and
reinstall securely. If engine is equipped with a positive
type ventilator, remove metering valve and tube as-
sembly. Disassemble and clean all parts with dry-
cleaning solvent to remove carbon and gum deposits
and assemble to engine.
Carburetor and Governor. See if they are in good con-
dition, correctly assembled, and securely installed; that
carburetor does not leak; that control linkage, including
choke and throttle shaft, is not excessively worn; if
choke valve- opens fully when the control is in its
released position; if throttle valve opens fully when the
accelerator is fully depressed; and if the governor is
secure and properly sealed.
Fuel Filter and Lines. Examine filter to see if it is in
good condition,* securely mounted and connected, and
not leaking.
Clean. Remove sediment bowl and element. Wash
clean in dry-cleaning solvent and reassemble securely
with gasket in place. CAUTION: // element cannot
be cleaned without disassembly by loosening, separat-
ing, and washing disk, replace unit. Do not scrape ele-
ment to clean.
Fuel Pump (pressure). Inspect pump to see if it is
in good condition, securely mounted and not leaking.
Remove sediment bowl and screen and wash in dry-
cleaning solvent. Be sure gasket is in place and service-
able when bowl is reinstalled.
Attach a test gage to pressure side of fuel pump and
after starting engine in item 39 see that pressure is 3
pounds minimum to 5J4 pounds maximum at idle speed.
Cranking Motor. Start the engine, observing if general
action of cranking motor is satisfactory, has adequate
cranking speed; and if the engine starts readily.
Leaks. Recheck all points for leaks, with engine run-
ning. Trace any found to source and correct or report
them.
Ignition Timing. With engine running and a neon
timing light connected, observe if ignition timing is
87
TM 9-808
29
MAINTENANCE
UOI
Mlh
41
42
42
till
Mlh
42
42
43
43
43
47
47
3/4 -TON 4x4 TRUCK (DODGE)
correct. Also note whether automatic controls advance
the timing as engine is accelerated gradually.
Adjust ignition timing according to instructions (par. 99).
Engine Idle and Vacuum Test. Inspect as follows:
Adjust. See paragraph 70. Adjust engine to its normal
idle speed and then adjust the idle-mixture until vacuum
gage indicates a steady maximum reading.
Vacuum Test. See paragraph 70. With the engine
running at normal idling speed, vacuum gage should
read not less than 17 inches at sea level with a reduc-
tion of approximately 3^ inchies for each 5,000 feet
altitude and pointer should be steady. At full throttle,
vacuum reading should be at least 16 inches at sea
level.
Regulator Unit. Inspect generator regulator to see if
it is in good condition, securely mounted, and connected.
Be sure radio noise suppression filter is securely
mounted and connected.
Test. Connect a low-voltage-circuit tester and observe
if voltage regulator, current regulator, circuit breaker
and control generator output properly. Follow instruc-
tions in paragraph 36. Replace if test shows faulty
operation.
Tires and Rims. Inspect as follows:
Valve Stems and Caps. Observe if all valve stems
and caps are in good condition and in correct position.
Condition. Examine all tires for cuts, bruises, breaks,
and blisters. Remove embedded glass, nails, and stones.
Look for irregular tread wear, watching for any sign
of flat spots, cupping, feather edges, and one-sided wear.
Remove tires worn thin at center of tread (or other un-
serviceable tires) and exchange for new or retreaded
tires. Any mechanical deficiencies causing such condi-
tions should be determined and corrected or reported.
Wheel positions of tires with irregular wear should be
relocated to even up wear (par. 162).
Direction. Directional tires and non-directional tires
should not be installed on same vehicle. Directional
tires on rear wheels should be mounted so that the "V"
of chevron will point down when viewed from the front.
Directional tires on all front wheels will ordinarily be
mounted so that "V" of chevrons will point up when
viewed from front of vehicle.
Matching. With tires properly inflated, inspect them
to see if they are matched according to over-all circum-
ference and type of tread.
88
TM 9-808
29
SECOND ECHELON PREVENTIVE MAINTENANCE
MAINTENANCE
60110
Mile
1000
Mile
47
47
48
49
49
Spare Tire Carriers. See whether spare tire carriers
are in good condition and secure.
Rims. All rims and side lock rings and flanges should
be in good condition and secure.
Tighten. Tighten all wheel side ring, mounting and
flange nuts securely.
Serve. With all tires properly inflated to 40 pounds
(cold), check over-all circumference, including spares.
Select tires to be mounted on driving axles, so that
difference in over-all circumference does not'exceed the
^-inch limits specified in current directives and bulle-
tins. NOTE: Spares must be matched properly and
mounted for use on one of the road wheels at intervals
not exceeding 90 days. A convenient time to do this is
during these maintenance services. CAUTION: After
performing the tire-matching service do not reinstall
until wheel bearing services are completed.
Rear Brakes. Inspect and service as follows: Remove
rear wheels.
NOTE: On 6,000-mile maintenance several wheel bear-
ings and brake items up to 52 are group services and
overlap. Perform in best order for economy of time
and orderly reassembly.
Drums and Supports. Clean dirt and grease from
drums and supports (dust shields) keeping dry-cleaning
solvent away from linings. Examine drums and supports
to see if they are in good condition, securely mounted,
and if drums are excessively worn or scored.
Wheel Cylinders. Inspect cylinders to see if they
are in good condition, securely mounted, connected, and
if leaking. See if rubber end covers are deteriorated.
Tighten. Tighten front brake support cap screws and
all hubs to drum screws securely.
Rear Brake Shoes. Examine linings through inspection
holes to determine if satisfactory for another 1,000 miles
of operation. If vehicle has been operated in deep water,
mud, or loose sand, remove one of the brake drums and
examine lining for damage. If damaged, remove all
drums and service brakes as necessary.
Adjust. Adjust shoes if necessary (par. 151). Remove
rear wheels, hubs, and drums and inspect linings to see
if they are in good condition. Also see if sho'es are in
good condition. Thickness of lining at most worn point
should be enough for at least 1,000 miles of service
before rivet heads are likely to contact drums.
Clean. Remove all dirt from linings with wire brush,
cloth, or compressed air. If there is evidence of grease
orTjrake fluid, reline brakes.
89
TM 9-808
29
MAINTENANCE
1010
Mlh
ino
Mile
52
52
52
52
52
52
53
53
54
54
54
54
55
55
3/4-TON 4x4 TRUCK (DODGE)
Adjust. After subsequent related items to 60 inclusive
are completed, adjust shoes (par. 151).
Rear Wheels. Inspect and service as follows :
Wheels. Inspect wheels to see if they are in good
condition and secure.
Bearings and Seals. Check for looseness of wheel
bearing, adjustment. Revolve wheels and listen for evi-
dence of dry or damaged bearings. Inspect around
flanges and brake supports for lubricant leaks.
Drive Flanges and Nuts. Note if they are in good
condition and if nuts are tightened securely.
Clean. Disassemble rear wheel bearings and oil seals.
Clean thoroughly in dry-cleaning solvent and examine
bearing cups and cones to see if they are in good condi-
tion; if machined surfaces they contact are in good
condition and if there is any excessive wear.
Lubrication. When all of the related items are per-
formed to the point where wheel bearings are to be
reinstalled, lubricate bearings according to Lubrication
Guide (par. 24).
Adjust. After lubricating wheel bearings, reassemble
hub-and-drum assemblies into place and adjust wheel
bearings correctly according to paragraph 147.
Front Brakes. Inspect front brake hose to see if it is in
good condition, correctly assembled, and secure.
Remove front wheels, hubs and drums and inspect
and service as follows:
Drums and Supports. Clean and inspect in same man-
ner as in item 48.
Wheel Cylinders. Inspect in same manner as in
item 48.
Front Brake Shoes. Inspect in same manner as in item
49.
Adjust. Adjust if necessary (par. 151). Inspect shoes,
linings, anchors, and springs, in same manner as in item
49 at 6,000-mile service.
Clean. Clean in same manner as in item 49.
Adjust. Adjust in same manner as in item 49 after
subsequent related items to 60 inclusive are completed
(par. 151).
Steering Knuckles (Joints, Bearings, Seals). Inspect
to see if knuckle housings are in good condition. Look
particularly for cracks around steering arms. See if
outside knuckle felt seals and seal flanges are in good
90
M*rNTEN«NCE
(000
Mlh
1000
Mill
55
55
55
56
56
.57
57
57
58
58
58
60
60
TM 9-808
29
SECOND ECHELON PREVENTIVE MAINTENANCE
condition and secure. Remove lower lubrication level
plug and examine sample of lubricant to see if it appears
to be contaminated.
Clean. Remove constant velocity universal joint as-
sembly. Wash thoroughly in dry-cleaning solvent, and
without disassembly of universal joint, inspect parts to
see if they are in good condition and not excessively
worn. Pay particular attention to universal joint balls
and races, axle splines, flanges, and pivot bearings or
bushings.
Lubrication. Pack new lubricant well into constant
velocity universal joint until it fills all space between
balls and races. Reassemble steering knuckle, taking
care to replace any unserviceable lubricant retainer
seals, boots, or gaskets.
Adjust. Adjust knuckle bearing to 25 to 27^4 foot-
pounds. Install shims under upper bearing retainer plate
or steering arm to insure correct alinement of parts
(par. 143).
Front Springs. See if they are in good condition, cor-
rectly assembled, and secure. Spring leaves should not
be shifted out of their correct position; this may be
an indication of a sheared center bolt. Note if deflec-
tion of both springs is approximately the same. Test
hangers and bolts for excessive wear by means of a
pry bar.
Tighten. Tighten all spring U-bolts securely and uni-
formly.
Steering. See if all parts of steering mechanism are in
good condition, correctly and securely assembled and
mounted, if steering gear case is leaking lubricant and
if lubricant is at proper level. Pay particular attention
to pitman arm to see if it is securely mounted and not
bent out of its normal shape. Also observe if steering
system is in good adjustment.
Tighten. Tighten steering arm shaft nut securely.
Loosen steering column bracket and tighten steering
gear case assembly mounting bolts. Tighten steering
column bracket.
Front Shock Absorbers and Links. See if bodies are
in good condition, secure to frame, and not leaking; if
links are secure and not damaged. If rubber bushings
are hard or cracked, apply brake fluid to exposed sur-
faces.
Serve. Fill shock absorber bodies with specified fluid
(par. 176).
Front Wheels. Inspect front wheels, bearings, seals,
91
TM 9-808
29
MAINTENANCE
6000
Mils
1000
Mile
60
60
61
61
62
62
62
63
63
64
64
64
65
65
3/4 -TON 4x4 TRUCK (DODGE)
drive flanges, and nuts in same manner as in item 52
for similar rear wheel items.
Clean. Disassemble, clean, and inspect the front
wheel bearings and oil seals in the same manner as
described in item 52.
Lubrication. Apply in same manner as described in
item 52.
Adjust. Adjust wheel bearings in same manner as
described in item 52 (par. 142), and adjust brake shoes
as described in item 49 (par. 151).
Front Axle. If front axle appears to be out of line,
measure distance from front spring eyebolt to center
of axle spring pad on each side. Distance should be
equal. Inspect axle housing to see if it is in good condi-
tion and not leaking. Examine pinion shaft for excessive
end play and seal for leaks.
Clean. Clean axle housing vent thoroughly.
Front Propeller Shaft. See if universal joints are in
good condition, correctly and securely assembled and
mounted; if the universal joints are properly alined
with each other and are not excessively worn; that the
slip joint is free, not excessively worn, and well lubri-
cated; and that the seals on slip joint do not leak.
NOTE: Slight seepage at seals is not considered as
leakage.
Tighten. Tighten all universal joint assembly and
companion flange bolts securely.
Engine (Mountings, Ground Strap, Side Pans).
These items should be in good condition and securely
mounted and connected. Be sure to examine both front
and rear engine mountings; and to see that rubber is
not separating from its metal backing. If mounting
bolts are loose, tighten them properly, taking care not
to overtighten (par. 67). Remove oil or grease from
rubber mountings. Apply a film of brake fluid if rubber
is hard or cracking.
Hand Brake. Examine to see if ratchet, pawl, and link-
age are in good condition, secure and not excessively
worn; that drum is not scored or pily; and that lining
is not oil soaked or worn too thin.
Adjust. Set clearance between brake drum and lining
to 0.010 inch to 0.012 inch (par. 157).
Clutch Pedal. Check pedal free travel. Should be IJ/^
inch before meeting resistance. Examine to see if pedal
is securely mounted to shaft, if clutch operating link-
age is in good condition, secure and not excessively
92
MAINTENANCE
(000
Mile
1000
Mll<
65
66
66
67
67
67
67
71
71
72
72
72
73
73
75
75
77
77
78
78
78
79
79
TM 9-808
29
SECOND ECHELON PREVENTIVE MAINTENANCE
worn at friction joints. See if return spring has proper
tension to bring pedal to correct released position, and
that stop is set to allow J4 inch between pedal, and
bottom of floor plate.
Adjust. Adjust clutch pedal free travel to IJ/^ inches
(par. 130).
Brake Pedal. Pedal should not bind on support shaft.
Be sure return spring has tension to bring pedal to
correct released position. Set .pedal-stop screw so that
pedal does not strike engine support when released.
There should be %6 i"ch free travel before pedal starts
to apply master cylinder push rod (par. 151).
Brake Master Cylinder. Cylinder should be in good
condition and secure. Filler plug vent must be open and
boot properly installed. Inspect for fluid leaks. See that
stop light switch is securely mounted and connected.
Serve. Wipe dirt from around filler plug, remove
plug and fill master cylinder reservoir to correct level
with specified fluid. Clean out filler plug vent hole.
Install plug securely, using new gasket if needed.
Transmission. Note if transmission case is in good
condition, securely mounted, and inspect for lubricant
leaks at seals and gaskets. NOTK: Slight seepage at
seals is not considered as leakage.
Transfer Case. See if case is in good condition, securely
mounted, that shift control linkage and mechanism is
securely connected and not damaged. Look for evidence
of lubrication leaks at seals and gaskets. NOTE: Slight
seepage at seals is not considered as leakage. Clean vent
passage if clogged.
Tighten. Draw up all external assembly and mount-
ing nuts securely.
Rear Propeller Shaft. Inspect in same manner as in
item 62.
Tighten. Draw up all universal joint and companion
flange bolts securely.
Rear Axle. Inspect in the same manner as in item 61
for front axle.
Clean. Clean axk housing vent thoroughly.
Rear Springs. Inspect and tighten in same manner as
in item 56.
Rear Shock Absorbers and Links. Inspect in same
manner as in item 58.
Serve. Service and make operating check in same
manner as in item 58.
Cab and Body Mountings. Examine all mountings to
see if they are in good condition and properly com-
pressed (par. 185).
93
TM 9-808
29
MAINTENANCE
fin
Mile
80
not
Mill
80
81
81
82
82
82
83
83
84
84
85
85
86
86
87
87
3/4 -TON 4x4 TRUCK (DODGE)
Tighten. Tighten cab and body mounting bolts
securely (par. 185), taking care to loosen the steering
column clamp before alining or tightening cab. Be sure
to tighten steering column clamp.
Frame. Inspect frame, brackets, side rails, and cross
members to see if they are in good condition, secure and
correctly alined. If the frame appears to be out of line,
report to higher echelon.
Wiring, Conduit, and Grommets. Observe these items
underneath the vehicle, to see if they are in good condi-
tion, properly supported, connected, and secure.
Fuel Tank, Fittings, and Lines. Inspect fuel tank to
see if it is in good condition and securely mounted. Ex-
amine cap for defective gasket. See that filler neck is in
good condition and that cap fits securely.
Remove fuel tank drain plug and drain off accumu-
lated water and dirt in bottom of tank. Drain only until
fuel runs clear. Use necessary precautions against fire.
Brake ' Lines. Examine all line's, fittings, and brake
hose under vehicle to see if they are in good condition,
securely connected, so that they do not leak, and sup-
ported so lines or hose will not chafe against other ve-
hicle parts.
Exhaust Pipes and Muffler. Examine exhaust pipe to
see if it is securely attached to exhaust manifold, that
gasket or packing does not show evidence of leakage,
and that the other end is clamped securely to muffler.
Inspect muffler to see if it is in good condition and
securely mounted. Check tail pipe to see if it is securely
clamped to muffler, properly supported, and unob-
structed at its outer end.
Vehicle Lubrication. Lubricate all points of vehicle in
accordance with Lubrication Guide (par. 24) and cur-
rent lubrication bulletins or directives, using only clean
lubricants and omitting items that have had lubrication
during this service. Replace damaged or missing fittings,
vents, or plugs.
LOWER VEHICLE TO GROUND
Toe-in and Turning Stops. With front wheels in
straightahead position, check toe-in which should be
to 5^ inch. Vie preferred (par. 141). Turn wheels fully
in both directions and see if turn is limited by stops.
In this position note if tires clear all parts of vehicle.
If tires touch any part of the vehicle, report for check
of turning angle by higher echelon.
Winch. On winch-equipped vehicles (Weapons Carrier
and Command), inspect winch, drive, and controls to
94
TM 9-808
29
SECOND ECHELON PREVENTIVE MAINTENANCE
MAINTENANCE
8000
Mile
1000
Mile
87
91
91
91
92
93
94
92
93
94
95
96
95
96
see if they are in good condition, correctly assembled,
and secure. See if clutch moves freely and locks se-
curely. Test safety brake. Pull the vehicle up a steep
bank with the winch. Release engine clutch; if vehicle
does not stop or drifts more than one or two inches,
brake needs adjusting. Test drag brake to see that it
holds drum from spinning when cable is unwound. In-
spect winch drive shaft in same manner as in item 62.
Note if cable is wound evenly and tightly, and properly
secured. Add or drain worm gear housing oil as neces-
sary to bring to correct level. If an oil change is due, or
condition of lubricant warrants, drain gear case and
refill to proper level.
Clean and Serve. Unwind cable and inspect for
excessive wear, damage, and rust. Clean entire length
of cable. As cable is rewound evenly, apply a film of
engine oil. Fasten cable securely to front tow hooks.
Lamps (Lights). Operate all switches and note if
lamps respond. See if foot switch controls head lamp
beams properly and if beams are aimed so as not to
blind oncoming traffic. Examine all lights to see if they
are in good condition and securely mounted and
whether lenses are dirty or reflectors discolored.
Adjust. Adjust head lamp beams.
Safety Reflectors. See if they are all present, in good
condition, clean, and secure.
Front Bumper Tow Hooks, Brush Guards, and Grille,
See if they are in good condition, secure, and that radi-
ator grille is not obstructed.
Hood and Fasteners. Inspect engine hood and fasteners
to see if they are in good condition and that fasteners
operate properly and hold hood securely. Also be sure
all radio suppression units not covered in the foregoing
procedures are in good condition and securely mounted
and connected (figs. 112 to 120).
Front Fenders and Running Boards. Examine fenders
and running boards to see if they are in good condition
and securely mounted.
Cab or Passenger Body. Inspect doors, hardware,
windshield and glass, top and frame, side curtains,
seats, safety straps and grab rails, floor boards, venti-
lators, map compartment and tables, to see if they are
in good condition and secure; that the hardware and
ventilators operate properly and are adequately lubri-
cated ; and if the doors engage their bumpers and strikers
and latch properly in the closed position. See that the
doors are properly alined with their openings. NOTE:
95
TM 9-808
29
MAINTENANCE
EOOO
Mile
1000
Mill
97
97
97
98
98
99
99
100
100
101
101
103
103
104
104
131
131
3/4 -TON 4x4 TRUCK (DODGE)
Glass need not be replaced as unserviceable even though
cracked or if laminated layers have separated, unless
condition constitutes a -safety hazard or obstructs vision,
of driver or crew.
Heater, Fan, and Defroster. On vehicles equipped with
any or all of these items, inspect them to see if they are
in good condition, securely mounted and connected, and
if they function satisfactorily. Examine heaters for
leaks. See that vent fan (Ambulance) opening is not
obstructed.
Special Lubrication. Apply a few drops of light oil
to fan motor bearings.
Circuit Breaker, Observe if in good condition, clean,
dry, and securely connected and mounted.
Rear Fenders. See that they are in good condition and
securely mounted.
Body (Panels, Rear Doors, Tailgate and Chains,
Floor, Skid Strips, Bows, Top Tarpaulins, Curtains,
Troop Seats, Stowage Compartments, Stretchers).
Inspect all applicable items on each type of vehicle, to
see that they are in good condition, correctly and se-
curely assembled and mounted, and adequately lubri-
cated. . Any hinges and latches must be free but not
excessively worn.
' Pintle Hook. Examine pintle to see if it is in good
condition and securely rnounted to frame. Test pintle
and latch to see if they operate properly; are adequately
lubricated, and if lock pin is present and securely
attached by chain. Pay particular attention for broken
spring or worn draw bar.
Paint and Markings. Examine paint of entire vehicle
to see if it is in good condition, paying particular atten-
tion to any bright spots in finish or camouflage pattern,
that might cause glare or reflection. Inspect vehicle
markings and identification, unless covered for tactical
reasons, for legibility. Include identification plates and
their mountings if furnished.
Radio Bonding (Suppressors, Filters, Condensers,
and Shielding). See that all radio suppression units not
covered in the foregoing procedures are in good condir
tion and securely mounted and connected (figs. 112 to
120).
TOOLS AND EQUIPMENT
Tools (Vehicle and Pioneer). Inspect standard ve-
hicle and pioneer tools -to see if they are all present in
good condition, clean, and properly stowed or securely
96
TM 9-«08
29
SECOND ECHELON PREVENTIVE MAINTENANCE
MAINTENANCE
6000
Mils
132
133
134
135
136
1C00
Mile
132
133
134
135
136
137
137
139
139
141
141
142
142
mounted (pars. 25 and 26). Also examine tools which
have cutting edges to see that they are sharp. Any tools
mounted on outside of vehicle which have bright or
polished surfaces, should be painted or otherwise treated
to prevent rust, glare, or reflection.
Fire Extinguisher. See if it is in good condition, se-
curely mounted, and fully charged. The charge may be
determined on gas-type extinguishers by weighing with
a scale and on liquid-type by shaking. Also be sure
nozzles are free from corrosion.
Decontaminator. See if it is in good condition, securely
mounted and fully charged. Make the latter check by
removing filler plug. NOTE: This solution must be
replaced every three months, as it deteriorates.
First Aid Kit (if specified). See if it is in good condi-
tion, and that all of its items are present and properly
packed. Report any deficiencies immediately.
Publications and Form No. 26. The vehicle and equip-
ment manuals. Lubrication Guide, and Standard Form
No. 26 (Accident Report Form) should be present,
legible, and properly stowed.
Traction Devices (Chains). Examine tire chains to be
sure they are in good condition, clean (if not in use),
not excessively worn, protected against rust, and prop-
erly mounted or stowed.
Tow (Chains, Cables, Rope, Snatch Blocks). See if
the provided towing devices are in good condition, clean,
and properly stowed. Tow chains or cables should be
properly protected "against rust when not in use. If
snatch blocks are furnished, check to see that they oper-
ate freely.
Fuel and Water Cans and Brackets. Observe if they
are in good condition, secure; if the caps fit tightly
and are secured to the can with a chain; and if cans
are leaking.
IVlodifications (MWO's Completed). Inspect vehicle
to determine that all MWO's have been completed and
entered on W.D., A.G.O. Form No. 478. Enter any modi-
fications on Major Unit Assembly Replacements made
during this service.
Final Road Test. Make a final road test, rechecking
items 2 to 15 inclusive, and also be sure to recheck the
transmission, transfer case, and all driving axles to see
that the lubricant is at the correct level and not leaking.
Confine this road test to the minimum distance neces-
sary to make satisfactory observations. NOTE: Correct
or report all deficiencies found during final road test.
97
TM 9-808
30-31
3/4 -TON 4x4 TRUCK (DODGE)
Section XII
ORGANIZATION TOOLS AND EQUIPMENT
Paragraph
Standard tools and equipment 30
Special tools 31
30. STANDARD TOOLS AND EQUIPMENT.
a. All standard tools and equipment available to second echelon
are listed in SNL N-19. These tools and equipment have been utilized
in describing maintenance operations on the materiel covered by this
manual.
31. SPECIAL TOOLS.
Fedaral Stock
Tool Number
DRIFT, front axle shaft, inner oil seal,
and bushing, installing 41-D-1535-25
DRIFT, front wheel, inner bearing oil
seal, installing 41-D-1535-50
FIXTURE, engine lifting
PULLER, rear spring front hanger bolt 41-P-2951-70
WRENCH, governor adjusting 41-W-3734
98
TM 9-808
32-33
Section XIII
TROUBLE SHOOTING
Paragraph
Introduction 32
Engine 33
Fuel system 34
Exhaust system 35
Cooling system .- 36
Starting system 37
Ignition system 38
Battery and generating system 39
Lighting system 40
Instruments, gages, horn, heater, and roof ventilator 41
Radio interference suppression 42
Clutch 43
Transmission 44
Transfer case 45
Propeller shafts 46
Front and rear axles 47
Foot brakes - 48
Hand brake 49
Wheels and tires 50
Steering 51
Springs and shock absorbers 52
Winch 53
32. INTRODUCTION.
a. This section contains trouble shooting information and tests
which can be made to help determine the causes of some of the
troubles that may develop in vehicles used under average climatic
conditions (above 32 °F). Each symptom of trouble given under
the individual unit or system is followed by a list of possible causes
of the trouble. The tests necessary to determine which one of the
possible causes is responsible for the trouble are explained after each
possible cause.
33. ENGINE.
a. Engine Will Not Turn.
(1) Starter Inoperative. See paragraph 37.
(2) Incorrect Oil Viscosity. Drain and refill with proper grade
of oil (par. 24).
(3) Seizure. Attempt to turn engine with hand crank. If engine
will not turn, seizure is indicated ; notify higher authority.
b. Engine Turns but Will Not Start.
(1) Combustion Chambers Flooded with Fuel. If the choke
99
TM 9-808
33
3/4 .TON 4x4 TRUCK (DODGE)
has been used excessively when cranking engine, fuel may flood the
combustion chambers and cause hard starting. Push choke button
all the way in, pull throttle button all the way out and crank engine
to clear out excessive fuel in cylinders. If flooding continues and
engine will not start, check fuel system (par. 34).
(2) Fuel Does Not Reach Carburetor (fig. 43). Disconnect
fuel tube at carburetor and operate hand priming lever on fuel pump.
This should cause fuel to flow from the open tube. (If the lever oper-
ates freely without actuating the diaphragm, turn the crankshaft
one revolution by hand as fuel pump rocker arm may be on the
high point of cam on camshaft.) If free flow of fuel is not evident,
fuel is not reaching carburetor. See paragraph 34.
FUEL PUMP
HAND PRIMER
RA PD 52737
Figure 43— fuel Delivery Test
(3) Improper Ignition. Remove wire from spark plug, hold end
of wire about ]^ inch from cylinder head and crank engine. If spark
does not jump ^-inch gap, ignition is inadequate (par. 38).
(4) Slow Cranking Speed. See paragraph 37.
c. Engine Misfires at High Speed.
(1) Improper Ignition. Inspect distributor breaker points for
evidence of burning and measure gap; clean and adjust or replace
points. Test breaker arm spring tension and adjust with spring scale
(par. 101). Inspect for loose wiring connections in distributor and
between coil, distributor, and spark plugs. With distributor rotor
100
TM 9-808
33
TROUBLE SHOOTING
removed, check for play in distributor drive shaft bushings; if exces-
sive, replace distributor. Clean and inspect spark plugs for wide
gaps; inspect for broken porcelains (par. 100). Test ignition coil and
condenser (par. 35).
(2) Valves Sticking; Valve Springs Weak or Broken. If
ignition system is functioning properly (step (1) above) and engine
still misfires, notify higher authority.
d. Engine Misfires on Acceleration.
(1) Improper Ignition. Clean and inspect spark plugs for wide
gaps; inspect for damaged porcelains (par. 100). Test ignition coil
(par. 35). Inspect for loose wiring connections in distributor and
FUEL PUMP TO CARBURETOR TUBE
PRESSURE GAGE-
RA PD 52896
Figure 44— Fuel Pump Pressure Test
between coil, distributor, and spark plugs. Inspect distributor breaker
points and measure gap (par. 101).
(2) Insufficient Fuel Delivery. Clean fuel filter (par. 74).
Test fuel pump (par. 34 a (3)). If engine continues to misfire on
acceleration, carburetor may be at fault; notify higher authority.
e. Engine Does Not Idle Properly.
(1) Carburetor Improperly Adjusted. Adjust throttle stop
screw and idle adjustment screw with vacuum gage (par. 70).
(2) Air Leaking Into Intake Manifold. Apply a small amount
of oil at carburetor and intake manifold flanges; if oil is sucked in,
air is leaking into manifold. Tighten flange nuts or replace gaskets.
101
TM 9-808
33
3/4 -TON 4x4 TRUCK (DODGE)
Remove windshield wiper tube and hold finger over manifold con-
nection; if idling improves, air is leaking through windshield wiper
connections or tube is broken.
(3) Improper Ignition. Check ignition timing (par. 99). Clean
and space spark plugs; inspect for broken porcelains (par. 100).
(4) Intake Manifold Overheated. Check setting of heat con-
trol valve (par. 56).
(5) Compression Low. Test (par. 55). If low, notify higher
authority.
f. Engine Does Not Develop Full Power.
(1) Improper Fuel Mixture. Inspect air cleaner for restriction
of air due to accumulation of dirt in oil reservoir (par. 69). Clean fuel
filter (par. 74).
(2) Low Fuel Pump Pressure. See paragraph 34 a (3).
(3) Intake Manifold Overheated. Check setting of heat con-
trol valve (par. 56).
(4) Ignition Timing Late. Check with timing light and adjust
(par. 99).
(5) Restricted Exhaust. Inspect tail pipe for damage; muffler
for clogging and repair or replace (pars. 77, 78, and 79).
(6) Compression Low. Test (par. 55). If low, notify higher
authority.
(7) Valves Sticking; Valve Springs Broken. If causes listed
in steps (1) through (5) above are not evident, notify higher
authority.
g. Spark Knock or Ping. (A sharp metallic knock occurring on
acceleration or when operating under heavy load.)
(1) Ignition Timing Too Early for Grade of Fuel Used.
Check with timing light and adjust (par. 99).
(2) Carbon Accumulaton in Combustion Chambers. Remove
cylinder head and clean carbon (par. 58).
(3) Engine Overheating. See paragraph 36.
(4) Distributor Automatic Advance Functioning Im-
properly. If the causes listed in steps (1) through (3) above are not
evident, notify higher authority.
h. Valve Noise.
(1) Valve Tappets Improperly Adjusted. Check adjustment
(par. 57).
(2) Valve Spring Cocked or Broken. Aline or replace (par. 57).
(3) Valve Stems or Tappets Worn. Notify higher authority.
i. Piston Slap. Piston slap is a clear metallic knock when engine
is under load at low speed but may not be heard at higher speed or
at idling speed. Noise noticeable when engine is cold; will diminish
as engine temperature increases.
j. Piston Noise Due to Scored or Worn Pistons or Cylinders.
Scored or worn cylinders will cause a noise similar to piston slap
after engine has reached operating temperature and vehicle is acceler-
102
TM 9-808
33
TROUBLE SHOOTING
ated under load. The noise can be heard through the oil breather
pipe after removing breather pipe air cleaner.
k. Piston Pin Noise. Piston pin noise is a metallic knock, usually
occurring when idling with engine hot. The noise will come and go
as the piston pin turns or shifts in piston. Notify higher authority.
1. Bearing Noise.
(1) Loose Bearing. A loose bearing is usually heard when
accelerating at about % maximum engine speed. The noise is usually
heard momentarily in a series of rapid, distinct knocks. It is difficult
to distinguish by sound between main and connecting rod bearing
noise. Notify higher authority.
(2?) BuRNED-ouT Connecting Rod Bearing. A burned-out con-
necting rod bearing will be heard as a sharp, distinct knock at most
engine speeds, especially noticeable on quick acceleration. The bear-
ing responsible for the knock can usually be determined by shorting
the ignition at the spark plugs. Notify higher authority.
(3) Burned-out Main Bearing. A burned-out main bearing
will cause a knock at moderate speeds, especially under acceleration.
If the front or intermediate main bearing is responsible, the noise
usually can be shorted out; if in the rear main bearing, the knock
will have a duller sound, due to the additional area of that bearing.
Notify higher authority.
m. Other Engine Noises. Other noises that are frequently con-
fused with bearing or piston noise are listed below.
(1) Fan Belt Partially Broken or Glazed. A partially broken
fan belt will cause a rhythmic metallic noise. A glazed fan belt will
cause an intermittent squeal. Replace belt (par. 82).
(2) Spark Plug Loose in Cylinder Head. A loose spark plug
will cause a sharp metallic knock at piston speed frequently con-
fused with other internal engine troubles.
(3) Flywheel Rubbing Clutch Housing Pan. If the clutch
housing pan is damaged or bent, the flywheel may rub against the
pan causing a scraping sound. The sound may be intermittent when
driving over rough terrain.
n. Low or No Oil Pressure.
(1) Engine Oil Level Below Oil Pump Strainer. Fill crank-
case with oil to proper level (par. 24).
(2) Oil Leakage. Inspect for leakage at oil tubes and connections
at filter, gage, and cylinder bloc^. Tighten connections or replace
tube. If external leakage is not apparent, remove oil pan and tighten
oil pump suction and outlet pipe connections.
(3) Oil Pressure Relief Valve Plunger Not Seating. Re-
move and clean (par. 61).
(4) Oil Pump Gears Worn or Drive Shaft Broken; Exces-
sive Clearance in Engine Bearings. If causes listed in subpara-
graphs (1) through (3) above are not evident, notify higher authority.
103
TM 9-808
33-34
3/4 -TON 4x4 TRUCK (DODGE)
o. Excessive Oil Consumption.
(1) Oil Supply Above Recommended Level. Keep oil level at
"running level" on oil level indicator (par. 24).
(2) External Oil Leakage. Inspect for leakage at external oil
tubes and connections, chain case cover and oil pan. Tighten con-
nections and attaching cap screws. .
(3) Excessive Clearance in Engine Bearings, Pistons and
Cylinder Walls; Leakage Due to Worn Oil Seals. If causes
listed in steps (1) and (2) above are not evident, notify higher
authority.
34. FUEL SYSTEM.
a. Fuel in Tank Does Not Reach Carburetor.
(1) Pressure Fuel Cap Not Functioning. Replace cap.
(2) Fuel Filter Clogged with Dirt. Clean filter (par. 74).
(3) Fuel Pump Inoperative (fig. 44). Connect low pressure gage
between the fuel tube and the carburetor and start the engine. If
3 to 5 54 pounds pressure is shown on the gage, the fuel pump is oper-
ating satisfactorily. If the pressure shown by the gage is less than
3 pounds, inspect the fuel tubes and filter between pump and tank
for leaks or obstruction. If fuel tubes and filter are clear and tight,
replace fuel pump (par. 73).
b. Fuel Does Not Enter Cylinders.
(1) Choke Does Not Close. Remove air cleaner. Pull out choke
button and note whether choke closes. If not, connect or adjust link-
age (par. 70).
(2) Carburetor Fuel Passages Clogged or Float Valve
Stuck. If fuel reaches carburetor (subpar. a above) and choke closes
properly (step (1) above), replace the carburetor or notify higher
authority.
c. Fuel Flooding Cylinders.
(1) Fuel Tank Cap Vent Clogged. Replace cap.
(2) Choke Does Not Open Fully. Remove air cleaner. Push
choke button in as far as possible and note whether choke opens.
If not, connect or adjust linkage (par. 70).'
(3) Carburetor Float Valve Not Seating. If causes listed
under steps (1) and (2) above are not evident, replace the carburetor
or notify higher authority.
d. Excessive Fuel Consumption.
(1) Air Cleaner Restricted. Service (par. 69).
(2) Ignition Timing Late. Test with timing light (par. 99).
(3) Choke Does Not Open Fully. See subparagraph c (1)
above.
(4) Carburetor Improperly Adjusted. Adjust (par. 70).
(5) Brakes Dragging. Check brake adjustment (par. 150).
104
TM 9-808
34-36
TROUBLE SHOOTING
(6) Lubricant too Heavy in Transmission, Front and Rear
Axles. Use proper grade (par. 24).
(7) Low Engine Operating Temperature. See paragraph 14.
Inspect cooling system thermostat (par. 84).
(8) Fuel Pump Pressure too High. Test pump (par. 34 a (3)).
(9) Carburetor Float Level too High; Low Engine Com-
pression. If the causes listed in steps (1) through (8) above are not
evident, notify higher authority.
e. Governor Not Functioning Properly.
(1) Maximum Engine Speed Incorrect. Adjust governor ^par.
70 b).
(2) Engine Surges at Maximum Speed. Adjust governor (par.
70 b).
(3) Governor Lags in Controlling Maximum Speed. Adjust
governor (par. 70 b).
35. EXHAUST SYSTEM.
a. Exhaust Fumes Entering Body, or Noisy Exhaust.
(1) Tail Pipe Loose or Out of Muffler. Tighten or replace
(par. 77).
(2) Muffler Damaged. Replace (par. 78).
(3) Manifold Gaskets Leaking. Replace (par. 59).
b. Exhaust System Restricted. Restricted exhaust is indicated
by continuous blow or "hiss" from the tail pipe rather than normal
intermittent exhaust noise.
(1) Tail Pipe Kinked or Plugged with Dirt. Repair or re-
place pipe (par. 77).
(2) Muffler Clogged. Replace muffler (par. 78).
36. COOLING SYSTEM.
a. Overheating. .■
(1) Insufficient Cooling Solution. Replenish solution.
(2) Fan Belt Loose or Broken. Adjust or replace belt.
(3) Hose Connections Collapsed or Obstructed. Replace
hose.-
(4) Dirt or Other Foreign Matter Lodged Between
Radiator Fins. Blow out with compressed air or flush from engine
side with water from hose.
(5) Thermostat Damaged, Blocking Circulation. Replace
thermostat (par. 84).
(6) Water Pump Inoperative or Circulation Obstructed in
Cylinder Block or Radiator Core. If causes listed under steps
(1) through (5) above are not evident, notify higher authority.
105
TM 9-808
36-37
3/4 -TON 4x4 TRUCK (DODGE)
b. Engine Runs too Cold.
(1) Thermostat Does Not Close. Replace thermostat (par. 84).
(2) Thermostat Opens at too Low Temperature. Test
thermostat (par. 84).
(3) Thermostat Gasket Left Out. Install gasket (par. 84).
(4) Low Atmospheric Temperatures. Use partial cover over
radiator (par. 14).
c. Loss of Coolant.
(1) Hose Connection Leaks. Tighten clamps or replace hose.
(2) Drain Cocks Leak. Tighten or replace.
(3) Cylinder Head Gasket Leaks. Replace gasket (par. 58).
(4) Radiator Cap Inoperative. Replace cap.
(5) Water Pump or Radiator Core Leaks. Replace pump
(par. 85) or radiator (par. 86).
37. STARTING SYSTEM.
a. Cranking Motor Will Not Crank Engine.
(1) Battery Discharged. Test (par. 88).
(2) Loose or Corroded Connections. Clean and tighten battery
cable connections at battery and ground .(engine or chassis). Examine
cables for damaged terminal connections.
(3) Engine Seizure. See paragraph 33 a (3).
(4) Switch or Cranking Motor Inoperative. Disconnect bat-
tery positive cable. Disconnect cable at cranking motor switch. Re-
move switch and hold battery cable tightly against cranking motor
terminal post. Then touch the other end of the battery cable to
battery post. If cranking motor runs, replace switch; if cranking motor
does not run, replace cranking motor.
b. Slow Cranking Speed.
(1) Engine Oil Too Heavy. In cold weather heavy oil will
retard cranking speed and cause voltage drop, especially when engine
is cold. Use correct grade of oil (par. 24).
(2) Loose or Corroded Connections. Clean and tighten battery
cable connections at battery and ground (engine or chassis). Examine
cables for damaged terminal connections.
(3) Cranking Motor Switch Contacts Burned or Dirty.
Disconnect battery cable; remove switch and examine contacts. If
burned or dirty, replace switch or clean contacts.
(4) Internal Friction or Voltage Drop in Cranking Motor.
If the causes listed in steps (1) through (3) above are not evident,
replace cranking motor or notify higher authority.
c. Cranking Motor Operates and Engages Flywheel but Will
Not Turn Engine.
(1) Seizure. See paragraph 33 a (3).
(2) Battery Run Down. Test (par. 88).
106
TM 9-808
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TROUBLE SHOOTING
(3) Cranking Motor Clutch or Spring Broken or Stuck.
If the causes listed in steps (1) and (2) above are not evident, replace
cranking motor or notify higher authority.
38. IGNITION SYSTEM,
a. Improper Ignition.
(1) Moisture on Ignition Units. Wipe distributor cap termi-
nals, cables, spark plugs, and coil thoroughly dry with cloth or cloth
saturated with carbon tetrachloride.
(2) Distributor Faulty. Remove distributor cap and rotor;
inspect for cracks or carbon runners. Clean contact points and adjust
or replace if excessively burned. Examine condenser lead wire for
breakage or loose connection. Crank engine and note whether dis-
tributor shaft turns; if not, shaft may be broken; replace distributor
or notify higher authority.
(3) Ignition High-tension Circuit Inoperative. Remove
cable from a spark plug. With the ignition switch turned on and the
engine being cranked, hold the loose end of the spark plug cable
about J4 inch from the cylinder head. If current jumps from the cable
to the cylinder head, the ignition circuit is complete through cable
tested. Test other cables in the same manner. Test spark plugs in
spark plug tester.
(4) Ignition Primary Circuit Inoperative (fig. 45). If the
headlights burn fairly bright, there will be ample current in the igni-
tion primary circuit at least as far as the ammeter. If the headlights
do not bum, but the cranking motor will crank the engine, test for
current through wire from cranking motor switch to ammeter. Then
test primary circuit from ammeter to coil and distributor. Remove
the distributor cap and rotor and turn the engine until the distribu-
tor breaker points are definitely closed. Turn on the ignition switch
and push the breaker points apart with finger. If there is a slight arc
of x:urrent as the points open, the primary circuit is complete and
will function if the points make and break properly when the engine
is crajnked. If no current is indicated by making and breaking contact
of th^ breaker points when the ignition switch is on, turn the engine
until the breaker points are open and connect the negative lead from
a voltmeter to any part of the chassis that will provide a definite
ground, and make the following tests:
(a) Test the wire and connections between the ammeter and the
ignition switch by holding the positive lead from the voltmeter
against the left post of the ignition switch. If approximate battery
voltage is shown on the voltmeter, the circuit is complete to the
switch.
(b) Test the switch by moving the voltmeter positive lead to the
right post of the switch. If about the same voltage is shown, current
is passing through the switch.
(c) Test primary wires and connections from ignition switch
through radio filter to the coil by moving the voltmeter positive lead
to the lower left post of the coil. If battery voltage is again shown,
current is reaching that post.
107
TM 9-808
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3/4-TON 4x4 TRUCK (DODGE)
(d) Test primary circuit from coil to distributor breaker points
by moving the voltmeter positive lead to the lower right post of the
coil, to each side of the distributor filter (if so equipped) and finally
to the distributor breaker arm. If battery voltage is shown at any of
these points of test and not at the next point, the trouble will be
located between these two points. If very little or no voltage is shown
at any point between the coil and breaker arm, disconnect the con-
denser lead wire from the distributor body and connect the volt-
meter positive lead to the breaker arm. A normal battery voltage
reading then would show a shorted condenser. No voltage reading
at any of the points between the coil and breaker arm (with the
breaker points open and the condenser lead disconnected), would
indicate a broken primary circuit in the coil.
CONNECT THE BLACK (NEGATIVE) LEAD TO A DEFINITE CHASSIS GROUND.
CONNECT THE RED (POSITIVE) LEAD TO OUTLET TERMINAL OF CIRCUIT
OR PART OF CIRCUIT TO BE CHECKED
RA PD 52936
Figure 45— Cheeking Ignition Primary Circuit
39. BATTERY AND GENERATING SYSTEM.
a. General Information. All tests described below to determine
causes of trouble in the battery and generating system are based on
the use of the low voltage circuit tester (17-T-5575). This tester con-
tains a voltmeter, ammeter, and switches, for making the various
tests described.
(1) Tester Connections (fig. 46). A diagram of the connections
for the low voltage circuit tester is shown on a plate attached to the
cover of the tester. Make all connections shown except those for the
field rheostat. Use this hookup only when making test described in
108
TM 9-808
39
TROUBLE SHOOTING
FIELD RHEOSTAT
HOOKUP
SEE TEST 4 ON
TESTER PLATE
GRD.
REGULATOR
■TESTER
GENERATOR
CRANKING MOTOR
COLORED DIAL
VOLTAGE
READINGS
FOR 6 VOLT
SYSTEMS
VOLTAGE
READINGS
FOR 12 VOLT
SYSTEMS
AMPERES
OR
VOLTAGE
READINGS
VOLTAGE
READINGS
FOR GROUND
LOSS TESTS
RA PD 312548
Figure 46— Test Connections for Low Voltage Circuit Tester
109
TM 9-808
39
3/4 -TON 4x4 TRUCK (DODGE)
subparagraph i which follows. Place knob of voltage selector switch
at 6 or 12 volts, depending on the electrical system voltage of the
vehicle being checked. The voltage can be determined by examining
the name plate attached to the generator or regulator cover. The
plate for 6- volt systems is red; for 12 -volt systems, green. Turn
utility switch to "Regulator Tests" position. Turn meter polarity
switch to suit ground polarity of vehicle being checked. (All vehicles
covered by this manual are equipped with negative ground electrical
systems.) Place regulator test selector switch in "No. 1" position.
Connect the ammeter test leads in series with regulator terminal
marked "BAT" and connect the shunt clip to that terminal. Move
SWITCH POSITION NO. 1
BAHERY VOLTS WITH STARTER LOAD
REGULATOR TEST SELECTOR
BAHERY LEADS
TO BAHERY POSTS
GRD. TO GRD. TERM.
CRANKING MOTOR
GRD.
RA PD 318328
Figure 47— Battery Test
the horn feed wire to one side. Then connect the wire just removed
from regulator terminal marked "BAT" to the end terminal of shunt
clip. This is important as the shunt clip must be in series with circuit
to be tested. The shunt clip contains a built-in meter shunt to which
the tester is calibrated. Connect voltmeter test lead tagged "ARM"
to armature terminal (largest terminal) of the generator and the
lead tagged "GRD" to generator frame. Connect battery lead marked
"GRD" to ground (negative) post of battery and the other lead to
positive battery post. These connections must be made by driving the
pins securely into the center of the battery posts in order to make a
good connection. False readings will be obtained if the connections
are not tight.
110
TM 9-808
39
TROUBLE SHOOTING
(2) Engine Temperature. In order to make accurate tests of
generator output and battery voltage, run the engine long enough
to establish normal operating temperature (about 145°F) especially
in cold climates, because all test specifications given are based on
normal engine operating temperatures.
b. Test Battery (fig. 47).
(1) General. Battery condition affects generating system oper-
ation. An old battery, one partially charged or one subjected to
SWITCH POSITION NO. 2 A
VOLTMETER LEADS
BLACK TO GEN. GRD.
RED TO GEN. "A"
VOLTAGE LOSS
GENERATOR
BAHERY
GROUND
CIRCUIT
BATTERY LEADS
TO BATTERY POSTS
GRD. TO GRD. TERM.
REGULATOR TEST SELECTOR
GENERATOR i
GRD.
RA PD 52965
Figure 48— Voltage Loss Test (Generator and Battery
Ground Circuit)
excessive heat will cause a high charging rate; while one subjected
to excessive cold, hard plates, high resistance separators, and sulpha-
tion will cause a low charging rate. If there is any doubt about the
condition of the battery, substitute temporarily for . test purposes,
a battery of the same size and capacity known to be fully charged
and in good condition.
(2) Test Procedure. Place regulator test selector switch in "No.
1" position and operate the cranking motor with ignition off. The
voltage should not drop below 5.01 volts on 6-volt systems (read
yellow scale), or 10.02 volts on 12-vblt systems (read red scale) while
cranking the engine. If the voltage drops below these limits, check
the gravity of the electrolyte in each battery cell. A variation of
more than 20 points between cells indicates a defective battery. If
the gravity of all cells is alike, but below 1.270 (1.225 in hot climates,
par. 88), a partially charged battery is indicated and the battery
111
TM 9-808
39
3/4 -TON 4x4 TRUCK (DODGE)
should be recharged. A voltage reading below 4.5 volts on 6- volt
systems, or 8.5 on 12 -volt systems, with the cranking motor cranking
the engine, usually indicates a discharged or defective battery. If the
battery is fully charged and in good condition, however, the cranking
motor may be the cause of excessive voltage drop. See paragraph
34 b.
(3) Possible Causes of Discharged Battery.
(a) Excessive use of cranking motor, or electrical accessories.
(b) Ignition switch left on with engine not running,
SWITCH POSITION NO. 2 A
VOLTAGE LOSS
VOLTMETER LEADS
BLACK TO GEN. GRD.
RED TO GEN. "A"
REGULATOR
TEST SELECTOR
REGULATOR
REGULATOR
GROUND
BATTERY LEADS
TO BATTERY POSTS
GRD. TO GRD. TERM.
GRD.
RA PD 52822
Figure 49— Voltage Loss Test (Regulator Ground Circuit)
(c) Broken or loose fan belt.
(d) Short circuits or voltage loss which will be determined on
tests which follow.
(e) Improper operation of generator regulator which will be de-
termined by tests which follow.
(f) Generator not charging due to improper operation of the
generator which will be determined by tests which follow.
(g) Battery in such condition that it will not take or hold a
full charge.
c. Voltage Loss Test (Generator and Battery Ground Circuit)
(fig. 48).
(1) Test Procedure. Place regulator test selector switch in "No.
2 A" position. Run engine at about 2,000 revolutions per minute
112
TiVt 9-808
39
TROUBLE SHOOTING
(approximately half speed), then press black push button marked
"PRESS TO READ." The meter reading should not exceed 0.05
volt (one division) on the green scale if the ground circuit is in good
condition. A reading higher than this indicates a loss of voltage due
to poor ground connections.
(2) Possible Causes of Voltage Loss in Generator and
Battery Ground Circuit.
(a) Poor contact between generator housirjg and engine due to
accumulation of grease, paint, or rust.
SWITCH POSITION NO. 2 B
VOLTAGE LOSS
VOLTMETER LEADS
BLACK TO GEN. GRD.
RED TO GEN. "A"
CHARGING CIRCUIT
REGULATOR TEST SELECTOR
BATTERY LEADS
TO BATTERY POSTS
GRD. TO GRD. TERM.
REGULATOR
:GRD.
FIELD 3^ mfMMMJW >M/j///»/ »f/j ^ f7jffyj/ j r^yrTi77 rJtt>rrnimimmia
1
VEHICLE
AMMETER
SHUNT CLIP
GENERATOR
RA PD 52823
Figure 50— Voltage Loss Test (Charging Circuit)
(b) Battery ground cable corroded or loose.
(c) Generator charging rate too high, causing increased voltage
loss in proportion to excessive charging rate. This will be determined
on tests which follow.
d. Voltage Loss Test (Regulator Ground Circuit) (fig. 49).
(1) Test Procedure. Leave regulator test selector switch in
"No. 2A" position with the engine running. Disconnect the voltmeter
"GRD" test cable which was connected to the generator frame and
connect it to the regulator base and again press the black button.
Reading should not exceed 0.05 volt (one division) on the green
scale. A higher reading indicates voltage loss in the regulator ground
113
TM 9-808
39
%■
TON 4x4 TRUCK (DODGE)
^es^ leave "GRD" cable in
circuit. NOTE: After completing this
this position for all succeeding tests.
(2) Possible Causes of Voltage Loss in Regulator Ground
Circuit. Poor ground at either end of wire shielding at regulator and
generator. Tighten wire shielding securely and repeat test.
e. Voltage Loss Test (Charging Circuit) (fig. 50).
(1) Test Procedure. Determine charging rate (subpar. f below).
Place regulator test selector switch in "No. 2B" position with the
engine running. PresS the black button and note voltage loss on the
SWITCH POSITION NO. 3
CURRENT
REGULATOR
READ
OUTPUT
ON
BLACK SCALE
REGULATOR
GENERATOR
RA PD 52824
Figure 51— Current Regulator Test
yellow scale. Maximum loss should not exceed 0.35 volt for each
10 amperes of current flowing in the circuit.
(2) Possible Causes of Voltage Loss in Charging Circuit.
(a) Damaged battery cable, loose or corroded terminals or con-
nections between positive battery post, generator and regulator.
(b) Loose or corroded connections at ammeter; or high internal
resistance in ammeter. To test ammeter, place a jumper wire across
ammeter and repeat test.
(c) Internal trouble within the generator regulator assembly
itself.
(d) Use of undersize replacement cables or wires between bat-
tery, generator and regulator.
114
TM 9-808
39
TROUBLE SHOOTING
(e) Generator charging rate too high, causing increased voltage
loss in proportion to excessive charging rate.
f. Current Regulator Test (fig. 51). Set regulator test selector
switch to "No. 3" position. Run engine at about 2,000 revolutions
per minute and press the black push button. Note charging rate
(amperes) on black scale. Charging current should approximatelj'
coincide with the rated capacity of the generator as shown on rating
plate on regulator. If charging current is higher or lower than
capacity of generator, the fan belt is loose or the current regulator
is incorrectly set. If no charge, or a low charge is indicated, make
FIELD RHEOSTAT HOOKUP
^^ RAISE >,^
RHEO. LEADS
CONNECT IN SERIES
WITH GEN. FIELD
SWITCH POSITION
NO. 4
CUTOUT CLOSING
VOLTAGE
REGULATOR TEST SELECTOR
VOLTMETER LEADS
BLACK TO GEN. GRD.
RED TO GEN. "A"
GRD. •SS
ARM
BAT,
FIELD S]
Ojaa
0]
TO GEN.
REGULATOR
FIELD
REGULATOR
SHUNT CLIP
TO BATTERY
ARM.
GENERATOR __
RA PD 52825
Figure 52— Circuit Breaker Closing Voltage rest
the following test to determine whether the generator or generatoi
regulator is at fault. Connect a jumper between "A" and "F"
terminal regulator iand operate the engine at slow speed. Under this
condition the generator may produce a dangerously high output if
the speed is carried too high, and if run for too long a period of
time, may result in burned armature or field.
(1) If the ammeter indicates no amperage is flowing in the cir-
cuit, it will be necessary to take a voltage reading to determine
whether the generator or the regulator is at fault. To take a voltage
reading, place the utility switch in the "voltrammeter" position.
Turn the volt-ammeter scale selector to "18 VOLTS" range. NOTE:
Operate the engine at slow speed, as too high a speed may damage
generator armature or field, as explained in subparagraph f above.
115
TM 9-808
39
3/4 -TON 4x4 TRUCK (DODGE)
(2) If the voltmeter (red scale) indicates a voltage in excess of
8.0 volts for 6-volt systems or 15.0 volts for 12-volt systems, the
generator is functioning properly and the fault is in the generator
regulator.
(3) With no voltage indication or with a voltage reading below
6.4 volts for 6-volt systems or 13.0 volts for 12-volt systems, the
generator is at fault. After making this test, remove jumper wire
across "A" and "F" terminals and change utility switch and volt-
ammeter scale selector back to original setting for all succeeding
tests.
•VOLTMETER LEAD TAGGED "GRD.
■ TESTER SHUNT CLIP
TERMINAL STAMPED "BAT."
FIELD FILTER TERMINAL
WIRE DISCONNECTED FROM FIELD FILTER. TERMINAL
'WIRE DISCONNECTED FROM TERMINAL STAMPED "BAT."
RA PD 52830
Figure 53— Field Rheostat Connections
g. Circuit Breaker Reverse Current Test (fig. 51). Leave regu-
lator test selector in "No. 3" position. Gradually reduce engine
speed and note reverse current on the black scale. If the circuit
breaker is opening properly, the reverse current should not exceed
0.5 to 4.0 amperes (6-volt systems) or 0.5 to 6.0 amperes (12-volt
systems) before the points open and reverse current stops. It may
be necessary to stop the engine and read the discharge current as
the engine slows down to a stop. If it is known that the circuit
breaker is not functioning properly, replace the generator regulator
assembly.
h. Circuit Breaker Closing Voltage Test (figs. 52 and 53).
Place regulator test selector switch in "No. 4" position. Connect field
rheostat in series with the field terminal of the generator at the
116
TM 9-808
39
TROUBLE SHOOTING
regulator as shown in figure 53. The field rheostat is provided for
controlling the voltage of generators at idling speed to check the
circuit breaker closing voltage. Maintain engine speed at fast idle.
Then gradually increase generator output with field rheostat by
rotating knob in the direction of arrow until meter pointer kicks
back slightly. The position on the dial where the meter pointer kicks
back and remains steady is the closing voltage which should be
6.4 to 6.8 volts for 6-volt systems (read yellow scale) or 12.8 to
13.6 volts for 12-volt systems (read red scale). CAUTION: Circuit
breaker closing voltage shbulfl always be above that of the battery
and at least 0.5 volt under voltage setting of generator regulator.
If the setting is incorrect, replace regulator.
SWITCH POSITION NO. 5 B
VOLTAGE REGULATOR BATTERY LOAD
AMMETER LEADS
CONNECT IN SERIES
W ITH REG. " B" TERM
1
REGULATOR TEST SELECTOR
VOLTMETER LEADS
BLACK TO GEN. GRD.
RED TO GEN. "A"
7
REGULATOR
VOLTAGE READING-
REGULATOR BATTERY
TERMINAL TO GROUND
RECONNECT
BAT. LOAD
GENERATOR
GRD.
RA PD 52827
Figure 54— Voltage Regulator Test
i. Voltage Regulator Test (figs. 51 and 54). Disconnect the field
rheostat used in previous test (subpar. h above) and reconnect the
field terminal at the regulator. Set regulator test selector switch in
"No. 3" position (fig. 51) and run engine at about 2,000 revolutions
per minute for approximately 15 minutes with the hood closed, as
engine and regulator must be at normal operating temperature to
make accurate tests. Run engine until the charging rate drops below
15 amperes, as battery must be fully charged for accurate check.
Then move regulator test selector switch to "No. . 5B" position (fig.
54). Read the yellow scale for 6-volt systems or the red scale for
12-volt systems. The voltage should check within 7.2 to 7.3 volts
for the 6-volt systems and 14.3 to 14.5 volts on the 12-volt systems
117
TM 9-808
39-40
3/4 -TON 4x4 TRUCK (DODGE)
at normal room temperature. If the voltage does not check within
these limits, replace generator regulator assembly.
40. LIGHTING SYSTEM.
a. General Information. If the engine cranks and starts there
will be current in the lighting circuit at least as far as the ammeter,
and light failure will be caused by some difficulty in the lighting
circuit, lights, bulbs or switches. (See wiring diagram in sec. XXV.)
b. All Lights Inoperative (with Main Lighting Switch On).
(1) Feed Wire Disconnected from Circuit Breaker. The
circuit breaker is mounted on the main lighting switch. Connect wire.
(2) Circuit Breaker Points Not Making Contact. If points
do not make contact, replace circuit breaker.
(3) All Light Bulbs Burned Out. Replace bulbs.
(4) Main Lighting Switch Inoperative. If causes listed under
steps (1) through (4) are not evident, replace the main lighting
switch.
c. One Light Inoperative.
(1) Bulb Burned Out. Replace bulb.
(2) Poor Ground Between Light Assembly and Mounting.
Clean mounting surfaces and tighten mounting nuts.
(3) Feed Wire Loose, Broken, or Disconnected. Inspect con-
nections at light, terminal block on frame side member, junction
block and main lighting switch. If connections are clean and tight,
test feed wire from switch to light for current and, if broken, replace
affected wiring assembly (sec. XXVI).
d. Circuit Breaker Clicking (Lights Flash Off and OnX,.
(1) Short Circuit in Wiring to Lights. Watch each light that
should be operating. The light not operating at intervals indicates
the circuit in which a short circuit exists, Inspect connection at
inoperative light for feed wire contacting light body. If headlight
is inoperative, clean and inspect terminal block on frame front cross
member. If trouble cannot be corrected at light end of feed wire,
disconnect the same color wire from the junction block. If other
lights then burn steadily, the feed wire in the lower wiring assembly
is grounded. Replace wiring assembly (par, 127). Temporary repairs
can be made by leaving both ends of the grounded wire discon-
nected and running another wire from junction block to light
connection.
e. Lamp Bulbs or Sealed Beam Units Fail Repeatedly.
(1) Generator Regulator Inadequately Grounded. Tighten
wire shielding to regulator base and generator.
(2) Generator Regulator Improperly Adjusted. Test regu-
lator (par. 39) and replace if faulty.
f. Sealed Beam Unit or Bulb Burns Out Immediately After
Installed with Light Switch On.
(1) Six- VOLT Bulb Used with 12-volt System. Install correct
bulb (par. 104).
118
TM 9-808
40
TROUBLE SHOOTING
(2) Generator Regulator Not Controlling Charging Rate.
Test regulator (par. 39) and replace if faulty.
g. Headlights Dim.
(1) Headlights Improperly Aimed. Aim (par. 105).
(2) Low Voltage at Headlight (fig. 55). Lighting system volt-
age may be checked with the low voltage circuit tester. Change the
tester controls so that the instrument can be used as a voltmeter.
(a) Remove the headlight door and partially pull out the sealed
beam unit from the wire connector. With the sealed beam unit
mounted in its correct position, the top prong supplies current for
the low beam. The right prong supplies current for the high beam
and the left prong is the ground connection. Connect the negative
lead of the voltmeter to the ground connection in the headlight
AMMETER ALWAYS CONNECTED
IN SERIES WITH LOAD
VOLTMETER ALWAYS CONNECTED IN
PARALLEL WITH LOAD
AMMETER LEADS
CONNECT IN SERIES
TO REG. "B" TERM.
VOLTMETER LEADS
BLACK TO GEN. GRD.
RED TO GEN. "A"
SHUNT CLIP
HEADLIGHT OR
ANY OTHER TYPE
OF LOAD TO BE
TESTED FOR
TO BATTERY
HEADLIGHT OR
ANY OTHER TYPE
OF LOAD TO BE
TESTED FOR
VOLTAGE
-VOLTMETER TEST
RA PD 312549
figure 55— Volt-ammeter Tests
body and the positive voltmeter lead to the right prong which sup-
plies current for the high beam.
(b) After the lights have burned, for five minutes (engine not
running), the voltage at the headlights, with the high beam filament
burning, should not be less than 5.25 volts on vehicles with a 6-volt
battery or less than 10.5 volts on vehicles with a 12-volt battery.
With the lights burning, and the engine warmed up and running at
a speed equivalent to a vehicle speed of about 20 miles per hour, the'
voltage at the headlights should not be less than 6.3 volts with
6-volt battery or 12.6 volts with 12-volt battery; nor more than
119
TM 9-808
40-41
3/4 -TON 4x4 TRUCK (DQDGE)
6.9 volts with 6-volt battery or 13.8 volts with 12-volt battery, with
battery and generator at room temperature of approximately 70°F.
(c) If voltage is low at either headlight socket, with only stand-
ard equipment in the circuit, test voltage output of battery— it
should be 6.0 to 6.5 volts with 6-volt battery (12.0 to 13.5 volts
with 12-volt battery). Clean and tighten battery terminals and
ground cable. Check wires and connections to all lamps, also main
lighting and blackout switch and headlight beam control switch for
high resistance.
(d) When a voltmeter is placed between the ground and input
side of a switch and then between the ground and output side of
the switch, with the lights burning, the difference, in the readings
will represent the voltage drop in the switch. The same method may
be used in checking voltage drop in wires by taking a reading at
each end of the wire. If a switch shows a voltage drop of more
than two-tenths of a volt or a wire connection shows a voltage drop
of one-tenth of a volt, replace the switch or wire. If any wire in
the lighting circuit has been replaced with other than standard
equipment wire, it may lack capacity and cause voltage drop.
(3) Sealed Beam Unit Defective. Replace unit.
41. INSTRUMENTS, GAGES, HORN, HEATER, AND ROOF
VENTILATOR.
a. Fuel Gage Inoperative..
(1) Instrument Panel Unit Inoperative.
(a) Disconnect the wire from the left side of th6 unit and con-
nect a temporary jumper wire to the terminal. If thf gage shows
full, with the ignition switch on and the loose end of the jumper
wire grounded, the wiring or the tank unit is at fault.
(b) If the instrument panel unit does not register full when test
(a) above is made, connect another temporary wire between the
right side of the gage unit and the right post of the ignition switch.
If the gage does not register full, with the ignition switch on and the
temporary wire from the left side of gage unit grounded, replace
the fuel gage instrument panel unit (par. 72).
(2) Tank Unit Inoperative. If test (1) (a) above proved that
the instrument panel unit is operating, disconnect wire from the
tank unit and ground the wire to bare metal of the chassis. If the
gage does not show full, with the ignition switch on and the tank
unit wire grounded, the wire is broken. If the gage does show full,
replace the fuel gage tank unit (par. 72).
b. Oil Gage Inoperative.
(1) No Oil Pressure. See paragraph 33 n.
(2) Small Orifice in Gage Connection Clogged with Dirt
or Ice. Remove connection, blow out, clean, and dry thoroughly.
(3) Gage Damaged. Replace (par. 117).
120
TM 9-808
41
TROUBLE SHOOTING
c. Thermometer Inoperative.
(1) Thermometer Head, Tube or Bulb Damaged. Replace
(par. 118).
d. Speedometer Does Not Register Speed or Mileage.
(1) Speedometer Cable Broken. Replace (par. 119).
e. Speedometer Registers Either Speed or Mileage, But Not
the Other.
(1) Speedometer Head Inoperative. Replace (par. 119).
f. Horn Does Not Operate.
(1) Wire Connector Between Horn and Steering Column
Pulled Apart. Push connector together.
(2) Horn Wire Disconnected from Horn Button. Remove
horn button and resolder wire.
(3) Horn Feed Wire Loose or Disconnected. Tighten or con-
nect wire.
(4) Horn Out of Adjustment. Adjust (par. 120).
g. Horn Operates Continually. To temporarily stop continuous
horn operation, pull connector at bottom of steering gear apart.
Leave rubber insulator on wireleading to horn.
(1) Horn Button Stuck or Grounded. Remove button and
repair or replace (par. 120).
(2) Horn Wire Grounded in Steering Column. Replace horn
button and wire (par. 120).
h. Heater Motor Does Not Run (Ambulance).
(1) Feed Wire Connection Loose at Heater or Heater
Switch. Inspect and tighten wire connections.
(2) Heater Switch Inoperative. Replace (par. 121).
(3) Heater Motor Inoperative. Replace (par. 121).
i. Heater -Does Not Supply Normal Amount of Heat.
(1) Temperature of Engine Cooling Solution Below 150°F.
Test engine cooling system thermostat for proper operation (par. 84).
(2) Heater Shut-off Valve at Cylinder Head Closed. Open
shut-off valve.
(3) Heater Radiator Air-bound. Bleed air from heater (par.
121).
j. Heater Defroster Does Not Function.
(1) Defroster Blower Does Not Run. Tighten wire connec-
tions at defroster and switch. If blower then does not operate, re-
place switch or defroster (par. 121).
(2) Defroster Outlet Tubes Disconnected. Connect tubes.
k. Roof Ventilator Does Not Run.
(1) Wire Connection Loose at Ventilator or Switch.
Tighten or connect wires.
(2) Ventilator Switch Inoperative. Replace ventilator switch
(par. 122).
(3) Ventilator Assembly Inoperative. Replace (par. 122).
121
TM 9-808
42
3/4 -TON 4x4 TRUCK (DODGE)
42. RADIO INTERFERENCE SUPPRESSION.
a. Causes of Interferences. Electrical interference of the type to
be dealt with by suppression on the vehicle has two general causes.
It may be caused by sparks in the normal operation of the vehicle's
ignition system or the generator or voltage regulator. It may be a
static discharge between component parts of the vehicle, especially
the body and its attachments, while the vehicle is in motion or
for a brief period after it comes to a halt. In either case it may be
recognized by the type of noise it causes in the radio receiver.
NOTE: // radio interference is repeated during operation, the driver
will cooperate with the radio operator in locating its sources (par. 42).
h. Location and Possible Elimination of Interference.
(1) Static Interference. If the interference is in the form of
a "frying" or "scratching" sound or irregularly spaced "pops" or
"clicks" which stop when the vehicle (engine running) comes to a halt,
or shortly after, it is probably caused by static discharges between
component parts of the vehicle. This type of interference is elimi-
nated by bonding, which consists of grounding or electrically con-
necting the various vehicle components. Bonding-braid straps are
used in making this connection. Make sure that both ends of
bonding straps are thoroughly clean and securely fastened. When
replacing a bonding strap or when tightening a loose strap, remove
all grease and dirt from the end of the strap, then thoroughly
scrape it so that it will make a good electrical connection or, if
available, use a toothed lock washer between the parts. Clean all nuts
and washers used in fastening the strap and replace them in exactly
the same position as originally found. Bonding straps should be
found at the following locations:
(a) Front fenders to splash aprons at rear.
(b) Headlights to frame.
(c) Hood bumper to lower hood section.
(d) Hood, across center hinge and to cowl.
(e) Lower hood sections to upper hood sections.
(f) Ignition coil and steering column to dash.
(g) Splash shield to frame.
(h) Steering column to instrument panel.
(i) Throttle rod, thermostat cable, speedometer cable, choke rod
to dash.
(j) Body to rear bumperette (Ambulance and Carryall).
(k) Battery tray to splash shield and generator cable shielding
to battery hold-down bolt (Weapon Carrier and Ambulance).
(1) Cylinder head to dash at rear of head.
(m) Frame to motor support (clutch hrousing), right side.
(n) Cab to frame, both sides.
(o) Rear of body to chassis, both sides.
(2) Bonding is also formed by use of toothed lock washers in
many other places on the vehicle, particularly in the fastening of
122
TM 9-808
42
TROUBLE SHOOTING
sheet metal and electrical units. This type washer "bites" into metal
surfaces and forms a good ground. Be sure to install washers of this
type in their original positions. See figures 112 through 120 for loca-
tion of all bonds.
(3) Ignition and Generating System Interference. If inter-
ference is present in the receiver when the vehicle is stationary with
the engine running, it is probably due to improper suppression of
sparks involved in the operation of the engine or generator. Sup-
pression filters and condensers are used at or near the point of
origination to eliminate or at least reduce interference (par. 103).
The following steps should be taken to determine causes of ignition
or generating system interference:
(a) Clean and tighten battery terminals. Replace cables if dam-
aged due to corrosion.
(b) Clean spark plugs and adjust gaps to 0.025 inch.
(c) Clean distributor cap if dirty; replace if cracked.
■ (d) Inspect distributor rotor; replace if burned or cracked.
(e) Inspect and clean distributor breaker points; adjust to 0.020
inch.
({) Inspect resistor-suppressors installed on each of the six spark
plug wires at plugs; also resistor-suppressor installed in high-tension
wire connected to center terminal of distributor cap. Remove any
moisture present by wiping dry with cloth; if corrosion or oxidation
is present, clean and scrape. Test by substituting suppressors known
to be satisfactory; if faulty, replace. ScreW suppressors firmly on
wires to completely seat connections.
(g) Test ignition coil; replace if faulty.
(h) Inspect and clean generator commutator and brushes.
(i) Inspect shielding on generator armature and field wires for
frayed, broken, or loose connections; inspect for broken or damaged
wires between generator and regulator; tighten shielding ground con-
nections or replace wires.
(j) Inspect for loose ground or terminal connections at filter and
regulator; tighten connections and mounting bolts.
(k) Inspect for broken wires in generator and ignition circuits;
repair or replace.
(1) Inspect switches for faulty contacts; replace if faulty.
(m) Inspect filters for shorted or open circuits. Test for con-
tinuous circuit by connecting test unit to each terminal of filter. If
current does not pass through filter, an open circuit is indicated;
replace filter with identical new part. Test for short by disconnecting
wiring from filter and connecting test unit from either terminal to
filter body. Passage of current between terminal and body indicates
a short within filter; replace unit. This same procedure can be used
to test condensers.
123
TM 9-808
43
3/4 -TON 4x4 TRUCK (DODGE)
43. CLUTCH.
a. Clutch Chatter.
(1) Grease on Disk, Flywheel, or Pressure Plat?. Replace
disk (par. 131) and thoroughly clean other parts.
(2) Binding of Clutch Release Linkage. Clean and free up
linkage.
(3) Disk Facings Loose on Disk. Replace disk (par. 131).
(4) Broken Pressure Plate. Replace pressure plate assembly
(par. 131).
(5) Release Levers Out of Adjustment. Replace pressure
plate assembly (par. 131).
(6) Engine Mountings Loose. Tighten engine mounting bolts
(par. 67 b).
b. Clutch Crabbing.
(1) Grease on Disk, Flywheel, or Pressure Plate. Replace
disk (par. 131) and thoroughly clean other parts.
(2) Clutch Disk or Pressure Plate Broken. Replace dam-
aged parts (par. 131).
(3) Hub of Disk Not Sliding Freely on Splined Shaft. Re-
move and free up.
(4) Release Linkage Binding. Free up linkage.
c. Clutch Slippage.
(1) Lack of Pedal Free Play. Adjust pedal free play (par.
130).
(2) Release Linkage Binding. Free up linkage.
(3) Pressure Springs Weak or Broken. Replace pressure plate
assembly (par. 131).
(4) Disk Facings Worn. Replace disk (par. 131).
(5) Pressure Plate Worn. Replace (par. 131).
d. Clutch Dragging.
(1) Excessive Pedal Free Play. Adjust pedal free play (par.
130).
(2) Clutch Disk Bent or Dished. Replace disk (par. 131).
(3) Clutch Disk Facings Loose or Broken. Replace disk (par.
131).
(4) Release Levers Improperly Adjusted. Replace pressure
plate assembly (par. 131).
(5) Friction in Crankshaft Pilot Bushing. Notify higher
authority.
e. Gear Clash. Gear clash caused by the spinning of the clutch is
frequently confused with clutch dragging. A clutch disk which re-
leases perfectly will naturally spin under its own weight and
momentum immediately after being released, if the transmission
gears are in the neutral position. When shifting from neutral to
first speed, or to reverse, wait for the clutch to stop to avoid gear
clash.
124
TM 9-808
44
TROUBLE SHOOTING
44. TRANSMISSION.
a. Hard Gear Shifting.
(1) Too Much Clutch Pedal Free Play. Adjust (par. 130).
(2) Clutch Disk Hub Binds on Drive Pinion Splines. Remove
disk and free up (par. 92).
(3) Clutch Disk or Other Clutch Parts Damaged. Replace
disk or clutch pressure plate assembly (par. 131).
b. Slips Out of High Gear.
(1) Transmission Case Not Tight on Clutch Housing.
Tighten attaching cap screws.
(2) Dirt Between Transmission and Clutch Housing Faces.
Remove transmission (par. 133) and clean surfaces.
(3) Transmission Parts Worn or Damaged; Clutch Hous-
ing Damaged. Notify higher authority.
c. Slips Out of Gear Other Than High.
(1) Transmission Internal Parts Worn or Damaged. Notify
higher authority.
d. Engagement of Two Speeds.
(1) Interlock Pin or PLUNGERS^rN Transmission Missing.
Notify higher authority.
e. Lubricant Leakage.
(1) Lubricant Level too High in Transmission. Correct level
is from lower edge of filler hole (hot) to ^ inch below (cold).
(2) Leak Around Bearing Retainer Cap Screws. Remove
screws, dip in white lead or paint,' and install.
(3) Mainshaft Rear Bearing Oil Seal Worn or Damaged;
Gasket at Drive Pinion Bearing Retainer Damaged. Notify
higher authority.
(4) Power Take-off Loose on Transmission Case. Tighten
attaching cap' screws.
(5) Gaskets Between Power Take-off and Transmission
Defective. Notify higher authority.
(6) Power Take-off Case Damaged; Bearing Cap Gaskets
OR Oil Seals Leaking. Notify higher authority.
f. Power Take-off Overheats.
(1) Transmission Lubricant Low. Replenish lubricant.
(2) Improper Clearance Between Power Take-off Gear
and Transmission Gear ; Bearings Adjusted too Tightly. Notify
higher authority.
g. Power Take-off Slips Out of Gear.
(1) Gearshift Rod Improperly Adjusted Not Allowing Full
Mesh of Gears. Adjust gearshift rod (par. 134).
(2) Power Take-off Parts Worn or Damaged. Notify higher
authority.
125
TM 9-808
45-46
3/4 -TON 4x4 TRUCK (DODGE)
45. TRANSFER CASE.
a. Excessive Noise. Due to the severe operating conditions under
which the vehicle must necessarily operate, the transfer case is
sturdily constructed for dependability rather than for quietness of
operation. Consequently, some gear noise will be audible, especially
when the engine is under load with the transmission in high gear at
low or medium speeds, and should be considered normal.
(1) Lubricant Low. Replenish lubricant.
(2) Internal Parts Worn or Damaged. Notify higher
authority.
b. Hard Shifting To or From Front Axle Drive.
(1) Control Lever Seized to Support Pin on Transmission
Cover. Free up and lubricate lever.
(2) Shifter Rail Tight in Case. Free up rail by lubricating
without disassembling.
(3) Internal Parts Worn or Damaged. Notify higher
authority.
c. Lubricant Leakage.
(1) Lubricant Level too High. Correct level is from lower edge
of filler hole (hot) to % inch below (cold).
(2) Vent on Top of Case Clogged. Remove and clean vent.
(3) Oil Seals or Gaskets Leak; I'ropeller Shaft Companion
Yoke Scored or Grooved; Bearings Loose or Damaged. Notify
higher authority.
d. Overlfeating. The normal operating temperature of the trans-
fer case is high, therefore, the assembly should not be considered as
overheated unless an abnormal gear noise or lubricant leakage past
the oil seals develop.
(1) Lubricant Level too High or too Low. Drain or fill to
proper level.
(2) Vent on Top of Case Clogged. Remove vent and clean.
(3) Bearings Adjustment too Tight. Notify higher authority.
e. Front Axle Drive Disengages.
(1) Control Rod Improperly Adjusted. Adjust rod (par. 136).
(2) Transfer Case Parts Worn or Damaged. Notify higher
authority.
f. Backlash.
(1) Tansfer Case Loose in- Mounting Brackets. Tighten cap
screws.
(2) Propeller Shaft Companion Yoke Loose on Transfer
Case Shaft. Notify higher authority.
(3) Transfer Case Parts Worn or Damaged. Notify higher
authority.
46. PROPELLER SHAFTS.
a. Backlash or Noise in Joint.
(1) Cross Bearings or Yoke Worn or Damaged. Replace
propeller shaft assembly (par. 139).
126
TM 9-808
46-47
TROUBLE SHOOTING
b. Lubricant Leaks from Joint.
(1) Oil Seals Defective. Replace propeller shaft assembly (par.
.159).
(2) Lubricant Fitting Leaks or Lost. Replace fitting.
c. Vibration in Propeller Shaft.
(1) Worn or Damaged Universal Joints; Propeller Shaft
Sprung. Replace propeller shaft assembly (par. 139).
(2) Assembly Arrows on Shaft and Splined Yokes Not in
Line. Une up arrows (par. 139).
47. FRONT AND REAR AXLES.
a. General. The differential and carrier assemblies used in the
front and rear axles are identical. Both axles are of the full-floating
type (driving power through axle drive shafts).
b. Lubricant Leakage at Drive Pinion.
(1) Lubricant Level too High. Correct level is from lower edge
of filler hole (hot), 54 inch below (cold).
(2) Axle Housing Vent Clogged. Remove and clear vent (par.
145).
(3) Pinion Bearing Oil Seal, Slinger, or Propeller Shaft
Companion Yoke Worn or Damaged. Notify higher authority.
c. Differential Lubricant Passes into Front Axle Universal
Drive Joint Housing.
(1) Differential Lubricant Level too High. Drain to level
of Yi inch below filler plug hole.
(2) Axle Housing Vent Clogged. Remove and clear vent.
(3) Universal Drive Shaft Oil Seal Worn or Damaged.
. Replace seal.
d. Lubricant Leakage into Brake Drum.
(1) Loose Wheel Bearings. Adjust bearings (par. 142 or 147).
(2) Wheel Bearing Oil Seal (Inner) Worn or Damaged.
Replace oil seal (par. 142 or 147).
(3) Wheel Bearings Packed with Improper or Excessive
Lubricant. Clean and repack wheel bearings (par. 24).
(4) Front Axle Only: Differential and/or Universal Joint
Lubricant Leaking Past Steering Knuckle Bushing Causing
Excessive Lubricant in Wheel Bearings. Check lubricant level
in differential ; if correct, replace bushing.
(5) Rear Axle Only: Differential Lubricant Leaking Past
Wheel Bearing Oil Seal (Outer) Causing Excessive Lubricant
IN Wheel Bearings. Clean bearings and hub; repack with lubricant;
replace oil seal (par. 147).
e. Backlash Between Propeller Shaft and Wheels.
(1) Propeller Shaft Universal Joint Worn or Damaged.
Replace propeller shaft assembly (par. 139).
(2) Propeller Shaft Companion Yoke Loose on Pinion
Shaft. Remove universal joint and tighten yoke.
127
TM 9-808
47-48
3/, .TON 4x4 TRUCK (DODGE)
(3) Front Axle Only: Universal Drive Assembly Worn or
Damaged. Notify higher authority.
(4) Rear Axle Only: Axle Drive Shaft Flange Loose.
Tighten or replace flange nuts.
(5) Worn or Damaged Parts in Differential Carrier.
Notify higher authority.
f. Noise in Axle. Certain road surfaces cause tire noise that may
seem to come from the axle. Before attempting to eliminate axle
noise be sure the noise is not caused by the tires. A certain amount
of gear noise in the transfer case is also normal (par. 45), and
should not be confused with axle noises. Do not attempt to locate
axle noise by operating the vehicle with the wheels off the ground.
(1) Lack of Lubrication. Replenish lubricant.
(2) Wheel Bearii^gs Worn or Damaged. Replace (pars. 142
and 147).
(3) Interference Between Brake Parts and Wheel Hub or
Drum. Remove wheel and inspect for loose or damaged parts (par.
153).
(4) Worn or Damaged Parts in Differential Carrier As-
sembly. Notify higher authority.
48. FOOT BRAKES.
a. Brakes Fail Completely (Pedal Goes to Floorboard and Fails
lo Give Braking Effect).
(1) Mechanical Linkage Between Pedal and Master Cylin-
der, Piston Disconnected or Broken. Connect or replace linkage.
(2) Fluid Line or Hose Broken. Replace line or hose.
(3) Piston Cup in Master or Wheel Cylinder Damaged. In-
spect for leakage of fluid at boot on rear end of master cylinder.
Inspect for leakage at wheel cylinders. Replace master cylinder (par.
155) or wheel cylinder (par. 154).
b. Brakes Fail on First Pedal Operation but Function After
Several Quick Operations.
(1) Brake Shoe Clearance Excessive. Adjust brake shoe cams
(par. 151).
(2) Fluid Passing Piston Cup in Master or Wheel Cylinder.
Inspect for leakage of fluid at boot on rear end of master cylinder.
Inspect for leakage at wheel cylinders. Replace master cylinder (par.
155) or wheel cylinder (par. 154).
(3) Fluid Line, Connection, or Hose Leaking. Tighten or
replace necessary part.
c. Hard Pedal and Poor Brakes.
(1) Anchor Bolts Improperly Adjusted. Adjust (par. 151).
(2) Brake Lining Worn or Glazed. Replace brake shoe and
lining assemblies (par. 153).
(3) Brake Drums Excessively Scored. Replace drums (par.
153).
128
TM 9-808
48-49
TROUBLE SHOOTING
d. Spongy Brake Pedal.
(1) Anchor Bolts Improperly Adjusted. Adjust (par. 151).
(2) Insufficient Fluid in Brake System. Replenish and bleed
brake system (par. 152).
e. Pedal Goes Slowly to Floor under Application.
(1) Fluid Line, Connection or Hose Leaking. Tighten or
replace necessary part.
(2) Fluid Passing Piston Cup in Master or Wheel Cylinder.
Inspect for leakage of fluid at boot on rear end of master cylinder.
Inspect for leakage at wheel cylinders. Replace master cylinder (par.
155) or wheel cylinder (par. 154).
f . Brakes Crab, Chatter, or Brake Unevenly.
(1) Grease or Brake Fluid on Brake Lining. Replace shoes
and lining (par. 153).
(2) Lining Loose on Shoe. Replace shoe and lining (par. 153).
(3) Anchor Bolts Improperly Adjusted or Loose. Adjust
(par. 151).
(4) Shoes Not All Equipped with Same Kind of Lining. Use
shoes with one make and type of lining.
(5) Wheel Cylinder Pistons Sticking. Replace wheel cylinder
(par. 154).
(6) Spring Clips Loose. Tighten clips.
g. Brakes Drag.
(1) Shoes Adjusted too Close to Drum. Adjust brake shoe
cams and anchor bolts, if necessary (par. 151).
(2) Shoe Return Spring Broken. Replace spring (par. 153).
(3) Shoes Sticking on Anchor Bolts. Free shoes on bolts.
(4) Wheel Bearings. Loose. Adjust wheel bearings (par. 142
or 147).
(5) Wheel Cylinder Piston Sticking. Replace wheel cylinder
(par. 154).
(6) Master Cylinder Piston Cup Held Over Relief Port.
Check brake pedal free travel adjustment (par. 151). If there is no
free travel, the master cylinder piston cup will cover relief port and
brakes will not release.
49. HAND BRAKE.
a. Hand Brake Does Not Hold Parked Vehicle.
(1) Brake Band Improperly Adjusted. Adjust (par. 157).
(2) Brake Lining Worn or Damaged. Replace band and lining
(par. 158).
(3) Brake Drum Scored. Replace brake drum (par. 160).
b. Hand Brake Drags and Overheats.
(1) Brake Partially Applied. Release lever fully.
(2) Band Improperly Adjusted. Adjust (par. 157).
(3) Lining Loose and Damaged. Replace band and lining (par.
158).
129
TM 9-808
50-51
3/4 -TON 4x4 TRUCK (DODGE)
50. WHEELS AND TIRES,
a. Abnormal Tire Wear.
(1) Use of Four-wheel Drive on Hard Surfaced Roads and
AT Speeds in Excess of 25 Miles Per Hour. Use four wheel drive
only when maximum traction is needed at speeds below 25 miles per
hour (par. 7).
(2) Tire Pressure Low. Keep tires inflated to 40 pounds pres-
sure.
(3) Improper Toe-in. If front wheels, adjust toe-in (par. 141) ; if
rear wheels notify higher authority.
(4) Wheel and Tire Assemblies Out of Balance. Notify
higher authority.
(5) Front and Rear Axles Not Paralleled with Each
Other. Inspect for broken spring center bolt; if broken, replace
spring (par. 175).
(6) Damaged Axle Housing or Frame. Notify higher authority.
51. STEERING.
a. Backlash in Steering.
(1) Drag Link Ends Improperly Adjusted. Adjust drag link
ends (par. 169).
(2) Steering Gear (Pitman) Arm Loose. Tighten steering
gear arm nut.
(3) Steering Gear Adjusted too Loosely. Adjust (par. 167).
(4) Worn or Damaged Parts in Steering Gear. Notify higher
authority.
b. Hard Steering.
(1) Tires Underinflated. Test tire pressure with reliable gage.
(2) Lack of Lubrication. Lubricate steering gear, knuckles and
linkage (par. 24).
(3) Steering Gear Adjusted too Tightly. Adjust (par. 167).
(4) Excessive Friction in Steering Post Bracket. Aline
steering post (par. 167); if this does not correct, notify higher
authority.
c. Shimmy. (An oscillating motion of the front wheels making it
difficult to hold the steering wheel steady.)
(1) Underinflated Tires. Inflate tires to 40 pounds pressure.
(2) Steering Gear Loose on Frame. Tighten attaching bolts.
(3) Drag Link or Tie Rod Ends Loose. Adjust link ends (par.
169) or replace tie rod ends (par. 144).
(4) Front Spring Leaves Broken. Replace springs (par. 175).
(5) Spring Bolts, Bushings or Shackles Worn. Replace worn
parts.
(6) Spring Clips (U-bolts) Loose or Broken. Tighten or
replace.
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TM 9-808
51-52
TROUBLE SHOOTING
(7) Spring Center Bolt Broken. Replace spring (par. 175).
(8) Shock Absorbers Not Functioning. Service shock ab-
sorbers (par. 176).
(9) Steering Knuckle Flange Bearings Loose; Wheel and
Tire Assemblies Out of Balance; Axle Housing or Frame Dam-
aged. Notify higher authority.
d. Steering Wander. (A tendency of the vehicle to steer itself off
a straight course.) '
(1) Excessive Friction in Steering Mechanism. Locate and
eliminate excessive friction (par. 167).
(2) Wheel Bearings Loose. Adjust wheel bearings (par. 142).
(3) Toe-in Incorrect. Adjust (par. 141).
(4) Steering Knuckle Flange Bearings Adjusted too
Tightly. Notify higher authority.
e. Steering Dive. (A tendency of the vehicle, when turned in any
direction, to turn more rapidly than intended.)
(1) Steering Gear Loose on Frame. Tighten attaching bolts.
(2) Front Spring Leaves Broken. Replace front springs (par.
175).
(3) Spring Bolts, Bushings or Shackles Worn. Replace worn
parts (pars. 173 and 174).
(4) Spring Clips (U-bolts) Loose or Broken. Tighten or
replace.
(5) Spring Center Bolt Broken. Replace spring (par. 175).
(6) Axle Housing or Frame Damaged. Notify higher authority.
52. SPRINGS AND SHOCK ABSORBERS.
a. Spring Breakage.
(1) Extremely Rough Handling of Vehicle Over Rough
Terrain. Reduce vehicle speed over rough terrain when possible.
(2) Loose Spring Clips (U-bolts). Keep clips tightened, to pre-
vent breakage between clips. -
(3) Excessive Friction at Spring Bolt or Shackles. Free up
and lubricate bolts and shackles and adjust front shackles if too
tight to prevent breakage at or near spring eye (par. 173).
(4) Lack of Shock Absorber Control, Service shock absorbers
(par. 176).
(5) Overlubrication of Spring Leaves. Lubricate bolts and
shackles only.
b. Noise in Springs or Shock Absorbers;
(1) Spring Shackles Worn or Damaged. Replace worn or
damaged parts (par. 173).
(2) Spring Bolts Worn. Replace bolt (par. 174).
(3) Shock Absorber Link Bushing Worn or Damaged. Re-
place link and eye assembly (par. 176).
131
TM 9-808
52-53
3/4 -TON 4x4 TRUCK (DODGE)
(4) No Fluid in Shock Absorbers. Refill shock absorbers (par.
176).
c. Lack of Spring Control.
(1) No Fluid in Shock Absorber. Refill shock absorber (par.
176).
(2) Shock Absorber Linkage Broken. Replace link and eye
assembly (par. 176).
(3) Shock Absorber Inoperative. Replace shock absorber (par.
176).
(4) Chassis Springs Overlubricated. Do not lubricate spring
leaves.
53. WINCH.
a. Winch Fails to Operate.
(1) Power Take-off Not Engaged. Engage power take-off
(par. 10).
(2) Sliding Clutch Disengaged. Move clutch shifter lever to
forward position and engage pin in hole.
(3) Shear Pin Broken. Replace (par. 169).
b. Noisy Operation of Winch.
(1) Insufficient Lubrication of Cable Drum Shaft. Lubri-
cate through fittings (par. 24).
(2) Lubricant Low in Worm Housing. Fill housing to level of
filler plug.
(3) Too Much or too Little Clearance Between Power
Take-off and Transmission Gears Causing "Hum" or "Whine."
Notify higher authority.
(4) Excessive End Play in Winch Worm Shaft. Notify higher
authority.
132
TM 9-808
54
Section XIV
ENGINE-DESCRIPTION, MAINTENANCE, AND
ADJUSTMENT IN VEHICLE
Paragraph
Description and tabulated data 54
Engine tune-up 55
Manifold heat control valve 56
Valves and springs 57
Cylinder head gasket 58
Manifolds and gaskets 59
Oil pan 60
Oil pressure relief valve and oil pump 61
Oil filter 62
Oil tubes (external) 63
Breather pipe air cleaner 64
Crankcase ventilator 65
54. DESCRIPTION AND TABULATED DATA.
a. General Description (figs. 56 and 57). The engine is a six-
cylinder, L-head gasoline burning engine. The operating temperature
of the engine is controlled by a liquid cooling system. The engine
is lubricated by oil drawn from the oil pan by the oil pump and
forced under pressure through drilled passages in the cylinder block
to the crankshaft and camshaft bearings. Passages are drilled in the
crankshaft to allow oil to be forced through the crankshaft bearings
to the connecting rod bearings. A limited amount of oil is forced
from the camshaft front bearing to the chain case to lubricate the
timing chain and sprockets. The cylinder walls, the pistons, the
piston pins, and valve tappets, are lubricated by an oil spray from
the connecting rod bearings.
b. Engine Numbers. The engine number is stamped on a boss on
the left side of the engine block opposite No. 1 cylinder (U, fig. 56).
The letters in the circular bosses on the block are for the use of
factory inspectors only, and are not to be used with the engine
number.
c. Tabulated Data.
Engine type L-head
Number of cylinders 6
Bore 31^ in.
Stroke 4f^ in.
Displacement 230.2 cu in.
Compression ratio .• 6.7 to 1
Engine governed speed ', . 3200 rpm
Engine firing order 1-5-3-6-2-4
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3/4-TON 4x4 TRUCK (DODGE)
E E G H I J.
A— RADIATOR FILLER CAP
B— FAN SHROUD
C— FAN BLADE
D— RADIATOR INLET HOSE
E— CYLINDER WATER OUTLET ELBOW
AND THERMOSTAT
F-BREATHER PIPE AIR CLEANER
G— ENGINE OIL FILLER CAP
H— IGNITION CABLE TUBE AND
BRACKET
I— ENGINE OIL FILTER
J— HORN
K— GENERATOR REGULATOR
L— CONTROL TUBE DASH
GROMMET— CLAMP TYPE
M— FUEL LINE FILTER
N-IGNITION COIL
O— CRANKING MOTOR SWITCH
P— CRANKING MOTOR
Q— OIL LEVEL INDICATOR
R— DISTRIBUTOR
S— BREATHER PIPE
T— BATTERY
U— ENGINE SERIAL NUMBER
V— GENERATOR
W— WATER PUMP
X— FAN AND GENERATOR BELT
RA PD 312550
Figure 56— Engine— Left Side View
55. ENGINE TUNE-UP.
a. Clean Engine. Clean the exterior of the engine with dry-clean-
ing solvent.
b. Service Air Cleaner (par. 69).
c. Tighten Cylinder Head, Manifolds, and Oil Pan. Tighten the
cylinder head stud nuts and cap screw, in the order shown in figure
69, to 52.5 to 57.5 foot-pounds, while the engine is warm. Tighten
134
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ENGINE-DESCRIPTION, MAINTENANCE, AND ADJUSTMENT
IN VEHICLE
A— WINDSHIELD WIPER HOSE
B— CARBURETOR AIR CLEAt^R
C- CARBURETOR
D— CARBURETOR GOVERNOR
E— INTAKE MANIFOLD
F— CYLINDER WATER OUTLET ELBOW
AND THERMOSTAT
G— EXHAUST MANIFOLD
H— RADIATOR WATER OUTLET HOSE
I -RADIATOR WATER OUTLET TUBE
J— FUEL PUMP
K— OIL PUMP
L_MANIFOLD HEAT CONTROL
M— CRANKCASE VENTILATOR
METERING VALVE
N— THROTTLE CONTROL LINKAGE
RA PD 312551
Figure 57 -Engine-Right Side View
the manifold stud nuts. Tighten carburetor to manifold nuts. Tighten
oil pan attaching screws.
d. Adjust Valve Tappets (par. 57).
e. Test the Battery and Line Voltage (par. 88) .
f. Test Compression (fig. 58).
(1) Procedure. Run the engine long enough to establish normal
operating temperature. If the battery is not fully charged, install a
fully charged battery. Remove all spark plugs. Insert compression
gage into No. 1 cylinder. Hold throttle wide open and crank
135
TM 9-808
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3/4 -TON 4x4 TRUCK (DODGE)
engine with cranking motor until maximum reading is obtained.
Note the compression reading of the cylinder being tested, then open
the valve cap on the side of the gage to release the pressure. Repeat
the operation on the other five cylinders.
(2) Interpretation of Gage Readings. Compression pressure
depends upon cranking speeds, engine temperature, and compression
ratio. If the compression is reasonably high (98 to 118 lb), not
varying more than 10 pounds between cylinders, compression pres-
sure can be considered normal. If the pressure in any cylinder is
COMPRESSION GAGE
■VALVE CAP
-WINDSHIELD WIPER MANIFOLD TUBE
VcARBURETOR idle adjusting SCREWn
ADAPTER J
RA PD 52874
figure 58— Compression Test
VACUUM GAGE
RA PD 52875
figure 59— Vacuum Test
weak, inject oil in the spark plug hole on top of the piston with
piston down. Wait a few minutes for oil to run down and seal rings
and to prevent oil getting on valves. Then repeat test (subpar. (1)
above). A low reading on the first test, which remains low on the
second test, indicates leaky valves. A low reading on the first test,
which becomes a high reading on the second test, indicates leaky
rings. If either of these conditions is found, notify higher authority.
An extremely low compression reading on two adjacent cylinders
indicates a leaking cylinder head gasket. A gasket which has blown
out between cylinders will cause erratic explosions between the two
cylinders.
g. Service Ignition System. Clean and adjust spark plugs (par.
100). Inspect distributor breaker points and adjust or replace (par.
136
TM 9-808
55-56
ENGINE-DESCRIPTION, MAINTENANCE, AND ADJUSTMENT
IN VEHICLE
101). Clean the distributor cap with a cloth and inspect for cracks
and corrosion. Replace if either condition is found. Check the dis-
tributor rotor for cracks and corrosion or burning. Replace rotor if
either of these conditions is found. Adjust ignition timing (par. 99).
h. Test Vacuum (fig. 59). Disconnect the windshield wiper hose
at the tube leading to the intake manifold. Connect vacuum gage to
the tube. Start the engine and allow it to run at idling speed. A
steady reading of more than 17 inches of vacuum at sea level with a
reduction of approximately 3^4 inches for each 5,000 feet altitude
indicates normal performance of the engine at idling speed. Fluctu-
SUMMER POSITION
WINTER POSITION''
RA PD 52809
figure 60— Manifold Hetit Control
ation of the pointer of the gage indicates too rich or too lean a fuel
mixture. Adjust the idle adjusting screw on the carburetor (par. 70).
If this adjustment does not cause a normal reading on the vacuum
gage, notify higher authority.
56, MANIFOLD HEAT CONTROL VALVE.
a. The heat control valve plate located in the exhaust manifold
regulates the amount of hot exhaust gases bypassed around the
intake manifold heat body. The valve plate is manually controlled.
Loosen locking plate cap screw and turn position of valve plate
according to season. Summer and winter positions are marked on
the locking plate (fig. 60).
137
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3/4 -TON 4x4 TRUCK (DODGE)
57. VALVES AND SPRINGS.
a. Removal. If it is necessary to replace a valve or valve spring
in an emergency, notify higher authority so that repairs can be com-
pleted by a higher echelon.
(1) Remove Cylinder Head and Gasket (par. 58).
(2) Remove Right Front Wheel (par. 163).
(3) Remove Right Front Fender Splash Shield (par. 178).
■ VALVE GUIDE
rVALVE SPRING-COILS CLOSE TOGETHER AT TOP
VALVE-
VALVE SPRIN
VALVE SPRING
RETAINER-
VALVE SPRING^
RETAINER A
LOCKS It
-VALVE TAPPET -^ VALVE SPRING RETAINER
VALVE SPRING RETAINER LOCKS
RA PD 52886.
figure 6 1 —Valves and Springs
(4) Remove Valve Springs (fig. 62). If valve to be remo\
in front half of engine, remove fuel pump heat shield. If valve to
be removeid _is in rear half of engine, remove ventilator outlet pipe
and air cleaner. Remove the valve spring cover. If cover studs
interfere with use of lifter on valve to be removed, lock two nuts
together on the stud and remove the stud. Tuck small cloth in the
oil return hole in the valve tappet compartment to prevent valve
spring retainer locks falling into crankcase. If valve is not all the
way down on its seat, turn engine until it is. Insert jaws of valve
lifter between the lower end' of the valve spring and the cylinder
block, with the cupped jaw up. Hold the valve down and screw up
valve lifter until valve spring is fully compressed. Remove the two
valve retainer locks from the lower end of the valve stem. Lower and
remove the valve lifter and lift the valve out. Raise the lower end
138
TM 9-808
57
ENGINE-DESCRIPTION, MAINTENANCE, AND ADJUSTMENT
IN VEHICLE
of the valve spring above the tappet screw and pull the spring
retainer and the spring out between the tappet screw and the lower
end of the valve stem guide.
b. Installation.
(1) Install Valve Springs (figs. 61 and 62). Turn the crank-
shaft to bring the tappet down. Insert the valve spring and retainer
into position with the coils which are closest toward cylinder head.
Be sure the spring retainer is in position between the spring and
the top of the spring seats in the recess in the cylinder block. Oil the
valve stem and install the valve. Raise the valve spring and retainer
with valve lifter and insert the split locks, large ends down, against
-VALVE SPRING RETAINER LOCKS
VALVE LOCK KEY REPLACER
VALVE LIFTER
Figure 62—lnsfalling Valve Spring Retainer Locks
the stops on the valve lock key replacer, and move the locks into
position on the valve stem. Lower the valve spring until the valve
spring retainer slides down over the top of the locks. Remove replacer
from the valve stem. Lower the valve spring and remove the lifter.
CAUTION: Remove the small cloth from the oil return hole.
(2) Adjust Valve Tappets (fig. 63). Run the engine at idling
speed until it reaches normal temperature. Hold the tappet with
wrench and adjust the screw until a 0.010-inch feeler gage will not
go between the adjusting, screw and valve stem, but a 0.012-inch
feeler gage will not go between the adjusting screw and valve stem
on both intake and exhaust valves.
139
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3/4 -TON 4x4 TRUCK (DODGE)
(3) Install Valve Covers. Screw the valve spring cover stud
into the cylinder block, if it was removed. Install the cover with a
new gasket on the cover and the screw and stud to prevent oil
leakage. Tighten the screw, install a plain washer over the gasket
on the end stud, and tighten the nut. Install ventilator outlet pipe
and air cleaner if removed. Install fuel pump heat shield if removed.
(4) Install Right Front Fender Splash Shield (par. 178).
(5) Install Right Front Wheel (par. 163).
(6) Install Cylinder Head and Gasket (par. 58).
ALVE TAPPET ADJUSTING SCREW
RA PD 52876
VALVE TAPPET-'
Figure 63— Adjusting Valve Tappet
58. CYLINDER HEAD GASKET,
a. Removal.
(1) Drain Cooling System (par. 81).
(2) Remove Air Cleaner (par. 69).
(3) Disconnect Electrical Connections. Disconnect batterv
cable (par. 88). Lift spark plug wires off spark plugs. Remove cap
screw located in right rear cylinder head cap screw and disconnect
ground strap.
(4) Disconnect Water Hose. If vehicle is equipned with heater,
release heater hose clamps at shut-off valve at rear of cylinder head
and pull hose off connections on cylinder head. Loosen the two
clamps and slide cylinder head outlet elbow to radiator water hose
farther down outlet elbow. Disconnect bypass elbow from top of
water pump.
140
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58
ENGINE-DESCRIPTION, MAINTENANCE, AND ADJUSTMENT
IN VEHICLE
(5) Disconnect Horn, Thermometer Bulb, and Choke Wire.
Remove the two nuts which hold horn to mounting bracket. Open
' cHp which holds horn wire at oil filter bracket and move horn to
one side. Open clip on cylinder head which holds thermometer wire,
and remove thermometer bulb from cylinder head. Disconnect choke
control wire and guide housing at the carburetor.
(6) Remove Cylinder Head. Remove 20 cylinder head nuts and
one cap screw. Lift off oil filter and bracket assembly, spark plug
cable tube and bracket and clip for thermometer wire. Loosen
breather bracket to breather pipe nut and slide bracket up pipe
until it clears stud on cylinder block. Remove No. 5 spark, plug
and install lifting eye. Lift cylinder head from block and remove
gasket.
m
V-
A^S W^ '^"^ ^^ ^7
¥4h.M^'' k?m/W^
RA PD 312552
figure 64— Cylinder Head Nut Tightening Sequence
h. Cleaning and Inspection. Loosen carbon from cylinder head,
block, and tops of pistons with a stiff wire brush and carbon scraper.
Thoroughly clean loose carbon from the cylinder walls, tops of the
pistons, cylinder and block surfaces. Inspect for cracked or damaged
surfaces.
c. Installation (fig. 64).
(1) Install Gasket and Cylinder Head. Wipe the surfaces of
the cylinder head and block with a clean cloth. Apply a thin coating
of engine oil to the gasket surface of the cylinder block. Put the new
gasket on the block and coat the top of the gasket with oil. Place
the cylinder head in position on the block. Install spark plugs. Place
filter and horn bracket assembly on studs 9 and 15, figure 64. Place
toothed lock washer on stud 6, then put breather pipe bracket in
place. Place toothed lock washer on stud 3, place spark plug cable
tube and bracket on stud, and another toothed lock washer on
bracket. Place thermometer wire clip on stud 19. Slide cylinder head
outlet to radiator hose into place and tighten clamps. Install new
gasket between bypass and water pump and attach bypass connec-
tion. Install the cylinder head nuts and cap screw. Tighten nuts and
141
TM 9-808
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3/4 -TON 4x4 TRUCK (DODGE)
cap screw in the order shown in figure 64 with a torque wrench to
52.5 to 57.5 foot-pounds.
(2) Connect Ground Strap, Choke Wire, and Thermometer
Bulb. Place a toothed lock washer on each side of ground strap and
attach with cap screw to head of cap screw in cylinder head. Con-
nect choke guide housing in clamp. Push choke button all the way
in and back off about y^g inch. Then, with choke valve fully open,
attach choke wire to choke valve at carburetor. Insert thermometer
wire in clip and bend clip over. Install thermometer bulb in place
and tighten.
(3) Attach Heater Hose (If So Equipped), Horn, and Spark
Plug Cables. Connect lower heater hose to valve at rear of cylinder
block and tighten clamp. Then attach support clamp to stud at air
cleaner support. Connect upper heater hose to take-off pipe at bypass
and tighten clamp. Attach horn mounting bracket to filter bracket.
Connect spark plug cables to spark plug terminals.
(4) Install Air Cleaner and Connect Battery Terminal.
Place air cleaner body on carburetor elbow and install screws and
lock washers. Place oil reservoir in body. See that oil reservoir is
clean and contains sufficient oil. Install cover and tighten wing nut.
Connect cable to battery.
(5) Fill Cooling System. Close radiator drain cock and fill
cooling system with water. Run engine until it reaches normal tem-
perature (approximately 20 minutes). Retighten cylinder head. If
antifreeze solution is necessary in the radiator, drain the water and
fill radiator with antifreeze solution. Make sure sufficient antifreeze
solution is used to protect the cooling system at the lowest antici-
pated temperature (par. 81). Install radiator cap and tighten securely.
59. MANIFOLDS AND GASKETS,
a. Removal.
(1) Drain Cooling System and Disconnect Heater Hose (If
Vehicle Is Equipped with Heater). Open radiator drain cock and
release radiator cap. If cooling solution contains antifreeze, drain
in pan and save. Remove nut at top air cleaner bracket and dis-
connect lower heater hose support clamp. Disconnect heater hose
at shut-off valve at rear of cylinder head and at bypass.
(2) Disconnect Fuel Line and Throttle and Choke Wires.
Unscrew fuel pump to carburetor fuel line connection at carburetor.
Remove hand throttle control wire and guide housing at carburetor.
Disconnect hand choke control wire and guide housing at carburetor.
(3) Disconnect Windshield Wiper Hose and Bell Crank
Rod. Pull windshield wiper rubber hose from tube at manifold. Re-
move cotter pin from end of bell crank rod at bell crank and remove
bell crank rod spring.
(4) Disconnect Exhaust Pipe and Loosen Fuel Pump Heat
Shield. Remove the four nuts and two bolts which hold the exhaust
pipe to the manifold. Remove the two nuts at muffler front support
142
TM 9-808
59
ENGINE-DESCRIPTION, MAINTENANCE, AND ADJUSTMENT
IN VEHICLE
to allow the exhaust pipe flange to clear manifold. Loosen wing nut
which holds fuel pump heat shield to the pump.
(5) Remove Manifold Assembly. Remove the 13 nuts and 8
washers which hold manifolds to cylinder block. Slide manifold
assembly off studs and place upright on bench. Remove gaskets
from cylinder block arid/or manifolds. If gaskets only are' being
replaced, proceed with installation of parts removed (subpar. c (3)
below).
(6) Remove Carburetor from Manifold. Remove air cleaner
support bracket cap screw at the manifold and remove bracket.
Remove cotter pin which holds throttle control rod to bell crank
and disconnect. Remove the two manifolds to carburetor stud nuts
while lifting off carburetor and air cleaner assembly from manifold.
Remove gaskets. Stand air cleaner and carburetor assembly in
upright position to prevent oil spilling from air cleaner.
(7) Disassemble Exhaust and Intake Manifolds. Remove
the four cap screws on bottom side of exhaust manifold and pull
manifolds apart. Remove gasket. Remove windshield wiper tube
and connections from intake manifold. Remove throttle control wire
and guide housing bracket nut, bell crank, throttle control lever and
lever stud.
b. Installation.
(1) Assemble Intake and Exhaust Manifolds. See that mat-
ing surfaces of intake and exhaust manifold are clean. Install new
gasket and connect manifolds together with the four cap screws.
Bring cap screws up snug but not tight. Install windshield wiper
tube and fittings. Hold throttle control wire and guide housing
bracket in position and install cap screw and lock washer closest to
the dash; then install lever type stud and lock washer. Place bell
crank in position on stud lever, then throttle control lever, spring
washer, plain washer, and cotter pin.
(2) Install Carburetor and Air Cleaner Assembly. Install
new gasket between carburetor and manifold. Before lowering car-
buretor assembly flush with manifold, start nut on outside stud;
then install both nuts. Attach manifold to air cleaner bracket with
cap screw at manifold. Attach bell crank to carburetor throttle
control rod and insert cotter pin.
(3) Install Manifolds on Cylinder Block. Clean mating
surfaces of manifold and cylinder block. Place new gaskets over
manifold studs and slide manifolds into position over studs. Slide
fuel pump heat shield into position. Install 13 nuts and 8 lock
washers, as shown in figure 65, and tighten. Tighten the four cap
screws that hold the intake and exhaust manifolds together. Tighten
wing nut that holds fuel pump heat shield.
(4) Attach Exhaust Pipe to Manifold Flange. Install new
gasket between exhaust pipe and manifold flange. Then install bolts,
nuts and lock nuts which connect these parts together. Install the
' two nuts that attach the front muffler bracket to the frame.
143
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59
3/4 -TON 4x4 TRUCK (DODGE)
(5) Connect Windshield Wiper Hose, Choke Control, Bell
Crank Rod, Throttle Control, and Fuel Line. Slide windshield
wiper flexible hose on manifold tube. Connect hand choke control
guide housing in clamp, push choke button all the way in and back
off about yi6 inch. With choke valve fully open, attach choke wire
to choke valve, at carburetor. Put spring on bell crank rod, insert
rod in bell crank and install cotter pin. Connect hand throttle con-
trol guide housing in clamp. With throttle control button on dash
pushed all the way in, hold throttle control lever back against its
stop, insert wire in hole and tighten. Connect fuel pump to carburetor
fuel line at carburetor.
RA PD 52722
Figure 65— Manifold Stud Nut and Washer Locations
(6) Attach Heater Hose (If So Equipped). Connect lower
heater hose to shut-off valve at rear of cylinder head and tighten
clamp. Attach hose support clamp to stud at air cleaner elbow and
install plain washer, lock washer, and stud nut. Connect upper heater
hose to take-off pipe at bypass and tighten. clamp.
(7) Fill Cooling System. Close radiator drain cock and fill
cooling system. If antifreeze solution was drained out, use it again,
but make sure sufficient antifreeze solution is .Used to protect
cooling system at the lowest anticipated temperature (par. 81).
Install radiator cap and tighten securely.
144
TM 9-808
60
ENGINE-DESCRIPTION, MAINTENANCE, AND ADJUSTMENT
IN VEHICLE
60. OIL PAN.
a. Removal. Remove drain plug and drain engine oil in pan. As
soon as the oil is drained, install drain plug and tighten securely.
Remove oil level indicator. Remove the oil pan attaching cap screws.
Remove center screws last and lower pan. Pull out cotter pin and
remove oil strainer (fig. 66) from oil pump suction pipe. Open the
lips on the strainer plate.
IL STRAINER
COTTER PIN
'OIL STRAINER CAP SCREW RA PD 312531
Figure 66— Floating Oil Strainer
h. Cleaning. Scrape all traces of the old gaskets from the oil pan.
Clean and wash strainer and oil pan thoroughly with dry-cleaning
solvent.
c. Installation.
(1) Install Oil Strainer (fig. 66). Position plate on strainer
and close the plate lips. Then connect strainer to the oil pump
suction pipe and insert new • cotter pin. Make sure the strainer is
positioned so that its movement is not restricted by the oil pan
baffles. Aline strainer assembly so that pipe is in relation to crank-
shaft rear bearing cap screw as shown in figure 66.
(2) Install Oil Pan Gaskets and Oil Pan (fig. 67). Install
new gaskets on the pan. Install the end gaskets first. They will pro-
trude Ys inch to Yn inch above the oil pan. Do not cut off. the ends of
the gaskets as they will compress into place when the oil pan screws
are tightened. Place side gaskets over the ends of end gaskets. Hold
145
TM 9-808
60-61
3/4 -TON 4x4 TRUCK (DODGE)
the side gaskets in place with heavy cup grease or tie in place with
light string through several bolt holes. Lift the pan into position,
being careful that the pan gaskets remain in position and that the
felt dust seal at the clutch housing is not interfered with. Install and
tighten the attaching cap screws with lock washers. Remove the
breather pipe air cleaner and fill the crankcase with engine oil (par.
24). Install oil level indicator.
DO NOT CUT OFF.
, ENDS WILL COMPRESS WHEN OIL PAN
SCREWS ARE TIGHTENED.
., Gasket -LEFT
GASKET -RIGHT
GASKET -FRONT'AND REAR
HOLD SIDE GASKETS IN PLACE WITH
HEAVY CUP GREASE WHEN INSTALLING
OIL PAN.
RA PD 52780
PLUNGER
SPRING J GASKET J CAP-
RA PD 52889
Figure 67-^Oil Pan Gaskets
Figure 68—Olt Pressure Relief
Valve
61. OIL PRESSURE RELIEF VALVE AND OIL PUMP.
a. Removal of Relief Valve (fig. 68). The oil pressure relief
valve is located directly below the oil filter at juncture of oil pan and
cylinder block. Remove oil pressure relief valve cap, gasket, and
plunger spring. Insert sharp end of small prick punch into opening
in plunger and remove.
b. Cleaning and Inspection. Clean and inspect plunger spring
and plunger seat for proper seating.
c. Installation of Relief Valve. Install plunger, flat end first and
place plunger spring in position. Then install new gasket and original
cap.
d. Removal of Oil Pump. Remove the two cap screws which
attach the engine dust pan to frame side member. Remove the two
nuts from the bolts which hold the dust pan and front spring torque
146
TM 9-808
61
ENGINE-DESCRIPTION, MAINTENANCE, AND ADJUSTMENT
IN VEHICLE
-COMPRESSION GAGE
. IN NO. 1 SPARK PLUG HOLE
INDICATOR ONOHAIN CASg COVER
1- LOCATING COMPRESSION
STROKE IN NO. 1 CYLINDER
COUNTER-CLOCKWISE
SLOT IN
DRIVE SHAFT
OIL PUMP AND
DISTRIBUTOR
DRIVE GEAR
ATTACHING SCREW HOLES
3-LINING UP SLOT IN
OIL PUMP SHAFT
'"DC" MARKING ON FAN PULLEY
— LOWER
2 — LOCATING TIMING MARK
ON FAN PULLEY
-DISTRIBUTOR LOCK PLATE
DISTRIBUTOR ROTOR
IN SEVEN O'CLOCK POSITION
4— INSTALLING DISTRIBUTOR
AFTER INSTALLING OIL PUMP
RA PD 312553
Figure 69— Installation of Oil Pump
147
TM 9-808
61
3/4 -TON 4x4 TRUCK (DODGE)
arrester to frame side member. Lower dust pan sufficiently to permit
removal of oil pump. Remove the two cap screws from the oil pump
mounting flange and remove pump.
e. Installation of Oil Pump (fig. 69).
(1) Set Crankshaft in Proper Position. Remove distributor
cap and disconnect the primary lead wire at the distributor. Remove
the distributor lock plate screw and lift out the distributor. Remove
No. 1 spark plug. Crank engine by hand and check for compression
on No. 1 cylinder by holding thumb tightly over spark plug hole or
by installing a compression gage in hole. When compression is felt by
thumb or shows on gage, turn crank until indicator points to "DC"
on crankshaft fan pulley (fig. 69).
CARTRIDGE
OPENING
DRAIN PLUG
Figure 70-OII Filter
RA PD 312532
(2) Install Oil Pump, Turn pump drive shaft until the slot in
end of drive shaft lines up with the bolt holes in mounting flange.
Then turn drive shaft gear one tooth counterclockwise. Install pump
in cylinder block, being careful not to turn pump drive gear.
(3) Install Distributor. Install distributor with the lock plate
in position. Turn distributor rotor so that it points to- seven o'clock.
Rotate the rotor a little one way or the other to allow the distributor
shaft to mesh with the oil pump shaft. Install the distributor lock
plate screw. Attach distributor primary lead wire to distributor filter
and install distributor cap. Install spark plug. Adjust ignition timing
(par. 99).
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TM 9-808
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ENGINE-DESCRIPTION, MAINTENANCE, AND ADJUSTMENT
IN VEHICLE
(4) Install Right Engine Dust Pan. Install two cap screws
and lock washer in frame side member. Hold the front spring torque
arrester in position, install the two toothed lock washers and nuts on
the bolts and tighten.
62. OIL FILTER.
a. Removal of Cartridge (fig. 70). Unscrew the cover retaining
nut, remove cover and lift out cartridge.
INLET\ c
ELBOW
TUBE UNION
ENGINE- TO OIL GAGE HOSE
OIL FILTER TO ENGINE HOSE
I
OIL PRESSURE RELIEF VALVE
RA PD 52781
Figure 71— Oil filter and Oil Gage Hose and Tubing
b. Cleaning. Remove drain plug from bottom of oil filter body
and clean inside of filter body with rag wet with dry-cleaning solvent.
Be sure oil outlet hole in filter outlet tube is open (fig. 70), and.
replace drain plug.
c. Installation of Cartridge. Install new cartridge in filter body.
Place cover gasket and cover irx place, and tighten retaining nut
firmly to prevent leakage.
d. Removal of Oil Filter Assembly (fig. 71). Disconnect oil
filter inlet hose at top of filter body. Disconnect oil filter outlet hose
at crankcase. Remove two front bolts which attach the oil filter
clamp to the oil filter bracket. Loosen oil filter clamp bolt until filter
body is free to lift out. Remove outlet hose from filter body. Screw
lower end of outlet tube into inlet fitting and tighten to avoid damage
to inlet fitting and remove fitting.
149
TM 9-808
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3/4 -TON 4x4 TRUCK (DODGE)
e. Installation of Oil Filter Assembly (fig. 71). Install inlet
fitting in top of filter body and remove outlet hose from inlet fitting.
Then install outlet hose to bottom of filter body. Place filter assem-
bly in bracket with inlet fitting facing front of vehicle. Tighten oil
filter clamp bolt. Insert clamp to bracket attaching bolts with
toothed lock washec under head of each bolt. Install another toothed
lock washer under nuts and tighten. Attach oil filter inlet hose to
fitting at top of filter body. Attach oil filter outlet hose to fitting in
crankcase.
63. OIL TUBES (EXTERNAL).
a. Removal.
(1) Remove Oil Filter Inlet Tube. Disconnect oil inlet tube
from inlet hose. Remove cylinder head stud nut. Hold breather pipe
•bracket and remove filler pipe by tapping up on the bracket. On
later models, the tube is flanged at the bottom and held in place with
two cap screws which must be removed. Disconnect the inlet tube at
cylinder block.
(2) Remove Oil Gage Lower Tube. Remove oil level indicator.
Disconnect oil tube at crankcase. Disconnect the oil tube from oil
gage hose.
(3) Remove Oil Gage Upper Tube. Disconnect tube at the gage
hose. Remove the self-tapping cap screws which hold the two upper
tube brackets to dash. Disconnect the oil tube at oil gage. Pull tube
through the dash.
b. Repair.
(1) Cut New Tube with Tube Cutter. Measure tube for length
desired and cut with tube cutter.
OIL TUBE LENGTHS
Oil gage lower tube 8^/^ in.
■ Oil filter inlet tube 12 in.
Oil gage upper tube (except Ambulance and Carryall) 26^ in.
Oil gage upper tube (Ambulance and Carryall) 34 in.
(2) Bend Tubing with Tubing Bender. Use removed tube as
a template or guide and form the tube to the same shape as the tube
removed.
(3) Flare Ends of Tube with Flaring Tool. Slide the attach-
ing nuts on each end of the oil tube and flare each end of the tube
with flaring tool.
c. Installation.
(1) Install Oil Filter Inlet Tube. Connect inlet tube at
cylinder block. Hold breather pipe and bracket in position with
bracket over cylinder head stud, and tap breather pipe into crank-
case, if it is the "slip-in" type. Install "slip-in" type pipes with offset
to the rear on vehicles with 6-volt generator and with offset to front
on vehicles with 12 -volt generator. Later models are equipped with
breather pipes which are flanged at the bottom. Two types are used:
for vehicles with 6-volt generator, install with offset to the rear; for
150
TM 9-808
63-64
ENGINE-DESCRIPTION, MAINTENANCE, AND ADJUSTMENT
IN VEHICLE
vehicles with 12 -volt generator, install with offset to front. Install
cylinder head stud nut and tighten to 52.5 to 57.5 foot-pounds with
torque wrench. Connect oil inlet tube to inlet hose.
(2) Install Oil Gage Upper Tube. Push oil tube through the
dash and connect at oil gage. Install the two brackets which hold the
upper tube to the dash with the self-tapping cap screws, and toothed
lock washer between each bracket and the dash. Connect tube to the
gage hose.
(3) Install Oil Gage Lower Tube. Connect oil tube at crank-
case. Then connect the oil tube to the oil gage hose. Place oil level
indicator in position.
BREATHER PIPE
AIR CLEANER
BREATHER PIPE AIR CLEANER BODY
FILTER ELEMENT ,- WING NUT
OILED MESH TYPE
RESERVOIR CUP
OIL BATH TYP6
RA PD 318326
Figure 72— Breather Pipe Air Cleaners
64, BREATHER PIPE AIR CLEANER.
a. Cleaning Procedure (Oiled Mesh Type) (fig. 72). Lift the air
cleaner off the breather pipe and remove cotter pin from the attach-
ing chain. Wash the filter element in dry-cleaning solvent and dry.
Dip the element in fresh engine oil and drain off the surplus oil.
Connect the attaching chain and install the cleaner on the breather
pipe.
b. Cleaning Procedure (Oil Bath Type) (fig. 72). Hold the oil
cup and turn the wing nut on the cleaner counterclockwise to release
the oil reservoir cup and the filter element. Wash the filter element
151
TM 9-808
64-65
3/4 -TON 4x4 TRUCK (DODGE)
in dry-cleaning solvent and dry. Fill the oil reservoir cup to the level
mark with fresh engine oil. Install the filter element over the stud in
oil reservoir cup. Insert the stud into the cleaner body, install the
wing nut, and tighten securely.
65, CRANK CASE VENTILATOR.
a. Cleaning Procedure (Outlet Pipe Type with Air Cleaner)
(fig. 73). Remove the outlet pipe bracket to crankcase cap screw.
Remove the air cleaner to crankcase. cap screw. Lift the filter element
from the filter body. Wash the element and filter body in dry-cleaning
solvent. Dip the element in fresh engine oil and drain off surplus oil.
SCREW
LOCK WASHER
PLAIN WASHER
GASKET
AIR CLEANER
AIR CLEANER BODY
CLAMP
CRANKCASE
VENTILATOR
OUTLET PIPE
.ar.
METERING VALVE ♦- VENT TUBE
POSITIVE TYPf
RA PD 53021
OUTLET PIPE TYPE
Figure 73— Crankcase Ventilators
Place the filter element into the cleaner body. Insert the screw
through the cleaner with a plain washer next to the element and a
lock washer under the screwhead. Install the oil cleaner-to-crankcase
cap screw. Install the outlet pipe bracket-to-cylinder head cap screw.
b. Cleaning Procedure (Positive Type Connected to Intake
Manifold) (fig. 73).
(1) Remove Metering Valve. Remove the cap screw and plain
washer which attaches the tube to the crankcase. Disconnect the tube
from the metering valve. Screw the metering valve assembly from the
manifold connection and remove the connection from the manifold.
152
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ENGINE-DESCRIPTION, MAINTENANCE, AND ADJUSTMENT
IN VEHICLE
(2) Clean Metering Valve and Vent Tube. Clamp the lower
end of the metering valve in a vise and screw off the upper part of
the body. Wash the valve, vent tube, and the manifold connection,
with dry-cleaning solvent and remove any carbon or gum. Assemble
the metering valve in the valve body with the pintle end up and
screw the upper part of the valve body into place.
(3) Install Metering Valve. Screw the manifold connection
into the manifold. Install the metering valve with the arrow up.
Place the vent tube connection in position at the rear of the crank-
case and install the attaching cap screw with plain washer under the
head of the cap screw. Connect, the forward end of the vent tube to
the metering valve.
153
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66
3/4 -TON 4x4 TRUCK (DODGE)
'Section XV
ENGINE REMOVAL AND INSTALLATION
Paragraph
Removal 66
Installation . . .' 67
66. REMOVAL.
a. Remove Hood (par. 178).
b. Drain Cooling System (par. 81).
c. Remove Fenders, Radiator Shell, and Core Assembly.
(1) Disconnect Radiator. Disconnect the tie rods at the radi-
ator shell. Loosen the front tie rod nut at the cowl bracket. Hold the
rear niit and turn the tie rod out of the nut. Loosen the upper radiator
hose clamp at the cylinder head water outlet elbow and the lower
radiator hose clamp at the water pump. Leave the hose attached to
the radiator core. Remove radiator drain cock, if vehicle is equipped
with a winch.
(2) Disconnect or Remove Battery. Remove battery if vehicle
.is equipped with 6-volt electrical system (par. 88). Disconnect cable
from battery if vehicle is equipped with 12-volt electrical system.
(3) Disconnect Generator to Regulator Wiring at GENERr
ATOR. Disconnect the wiring clip from the generator. Disconnect the
two wires of the generator to regulator wiring assembly at the regu-
lator and also remove the wiring to regulator clip screw. Leave the
generator to regulator wiring assembly attached to the left front
fender splash shield.
(4) Disconnect Light Wires. Pull the blackout light wires from
their sockets on each side at the connections near the terminal blocks
on the front cross member. Remove the nuts attaching the light
wires to the terminal blocks. Remove the wires from the clips on the
cross member.
(5) Disconnect Splash Shield Ground Strap and Battery
Tray. Disconnect the ground strap at the front of the fender splash
shield. Remove the nut from the bolt attaching the battery tray to
fender splash shield ground strap at the splash shield. If vehicle is
equipped with 6-volt electrical system, remove the 3 bolts that attach
the battery tray to the frame.
(6) Disconnect Splash Shields and Fenders (fig. 74). Dis-
connect the left and right front fender splash shield at frame rear
brackets. Disconnect the front fender rear supports at the front
fender rear support brackets. Disconnect the radiator shell assembly
at the frame front cross member.
(7) Vehicles Equipped with Fan Shroud. Remove fan and
pulley (par. 85).
(8) Remove Assembly (fig. 74). Attach chain fall to the radiator,
shell, and fender assembly, and lift it off the vehicle. Have a helper
1S4
TM 9-808
66
ENGINE REMOVAL AND INSTALLATION
RA PD 312533
Figure 74— Removing fenders and Radiator
155
TM 9-808
66
3/4 -TON 4x4 TRUCK (DODGE)
at the rear of each front fender to assist in guiding the assembly
while it is being removed. If there are any spacing washers between
the radiator support and the frame cross member, be sure they are
not lost as they will be needed to install the radiator in the same
relative position for proper hood alinement.
d. Remove Transmission Assembly (par. 133). The engine
assembly may be removed with transmission attached after dis-
connecting, propeller shaft, removing transmission gearshift lever
housing, hand brake lever, transfer case lever and winch shifter lever
(if so equipped).
e. Disconnect Distributor Wiring. Disconnect the coil to dis-
tributor filter wire at the filter. Pull the high tension cable out of the
distributor cap.
f. Disconnect Oil Cage Tube and Filter Flexible Hoses. Dis-
connect the oil gage tube at the flexible hose connection. Disconnect
the oil filter inlet flexible hose at the filter and outlet flexible hose at
the crankcase.
g. Remove Horn Assembly (par. 120).
h. Disconnect Thermometer, Cranking Motor Pedal, and Wir-
ing. Spread the thermometer wire clip to release the wire at cylinder
head stud. Unscrew the gland nut and disconnect the thermometer
wire at the cylinder head. Move the wire out of the way to prevent
damage when the engine is removed. Pry off the clip or retainer which
holds the cranking motor pedal rod pin in place on the cranking
motor shift lever yoke and remove pin. Remove the wires from the
cranking motor switch. Disconnect the ground strap at the rear of the
cylinder head.
i. Disconnect Flexible Hose at Fuel Pump. Hold the elbow and
unscrew the attaching nut.
j. Remove Carburetor Air Cleaner (par. 69).
k. Disconnect Throttle and Choke and Windshield Wiper.
Disconnect the throttle wire and guide housing at the throttle bell
crank which is mounted on the manifold bracket. Loosen the screws
and disconnect the choke wire and guide housing at the carburetor.
Disconnect the windshield wiper flexible hose at the manifold vacuum
tube.
1. Remove Exhaust Pipe and Right Engine Dust Pan. Dis-
connect the exhaust pipe at the manifold. Remove the torque arrester
from the underside of the frame side member. Pry open the fender
lamp cable clip at the screw attaching the pan to the front cross
member and move the cable out of the way, then remove the screw.
Remove the two front pan screws' and remove dust pan.
m. Disconnect Engine Ground Straps. Disconnect the ground
straps between the clutch housing and the right and left sides of the
frame. The strap on the left is attached with one of the screws holding
the clutch pedal bracket. The ground strap on the right side is
attached to the clutch housing.
156
TM 9-808
66
ENGINE REMOVAL AND INSTALLATION
-LIFTING PLATE IN POSITION FOR REMOVING OR
INSTALLING ENGINE WITH TRANSMISSION
LIFTING PLATE IN POSITION FOR REMOVING OR
INSTALLING ENGINE LESS TRANSMISSION
RA PD 312554
Figure 75— Removing Engine
157
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66-67
3/4 -TON 4x4 TRUCK (DODGE)
n. Remove Clutch and Brake Pedal Bracket Assemblies. Re-
move the cotter pin from the clutch operating rod pin. Remove the
remaining screws which connect the clutch pedal and bracket as-
sembly to the clutch housing. Disconnect the clutch pedal pull-back
spring from the frame bracket with brake spring pliers and remove
the assembly from the vehicle. Remove the rear end of the brake
puU-back spring from the pull-back spring bracket with brake spring
pliers, and unhook the spring from the brake pedal pull-back spring
extension. Remove the cotter pin from the push rod end pin and
remove the pin. Remove the bolts that attach the brake pedal and
bracket assembly to the frame and remove the assembly from the
vehicle.
SUPPORT
PLATE
SCREW
LOCK WASHER
WASHER
LOCK WASHER
SUPPORT -=^
ENGINE FRONT SUPPORT
figure 76— Engine Supports
CLUTCH
HOUSING
BOLT
NUT
COHER PIN
WASHER
SPRING
SPACER—
BETWEEN
CLUTCH
HOUSING
AND
SUPPORT
BRACKET
SUPPORT
BRACKET
ENGInE^AR SUPPORT
RA PD 312555
o. Lift Engine From Frame (figs. 75 and 76). Install engine
lifting fixture. Attach chain fall to fixture and relieve the weight of
the engine from the engine support bolts. Remove the cotter pin from
the rear engine support bolts. Hold the support bolt nuts and remove
the bolt. Remove the front engine support cap screws. Lift the engine
out of. the vehicle. Exercise care in lifting the engine to prevent
damaging the attaching parts and accessories.
67. INSTALLATION.
a. Install Engine in Chassis (figs. 75 and 76). Place the two
small fabric pads or spacers on the rear motor support frame
158
TM 9-808
67
ENGINE REMOVAL AND INSTALLATION
brackets. Install engine lifting fixture. Attach chain fall to fixture.
Lift the engine and move the assembly into place so that the rear
engine support bolts as well as the front engine support screws can be
inserted. Guide the accelerator rod into the body opening as the
engine is moved into the frame. Be careful that none of the parts are
damaged or broken as a few minutes of careful handling will save a
greal deal of trouble.
b. Install Mounting Bolts (fig. 76). Insert the rear engine sup-
port bolts through the frame brackets and engine support from
underneath and install the rear support bolt springs, washers, and
nuts. Hold the bolts and tighten the castellated nuts sufficiently so
that the cotter pins can be installed. Install the front engine support
screws with a toothed lock washer, a plain washer, and another
toothed lock washer and tighten.
c. Install Brake Pedal and Bracket Assembly. Place the brake
pedal bracket on the frame side member. Install toothed lock washer
under each bolt head and one under each nut. Install the master
cylinder push rod on the brake pedal lever and install the push rod
end pin and cotter pin. Attach the brake pull-back spring to the
brake pull-back spring extension and connect it to the brake pedal
pull-back spring bracket with brake spring pliers. NOTE: Due to a
slight change that may take place in the position of the engine mount-
ings when installing an engine assembly, it may be necessary to adjust
the brake pedal free travel (par. 151) and the clutch pedal free play
(par. 130).
d. Install Clutch Pedal and Bracket. Position the clutch pedal
and bracket assembly on the rear motor support. Insert one of the
short screws with lock washer in the upper right hole, the one long
screw with lock washer in the lower left hole and another short screw
with lock . washer in the lower right hole. Tighten the three screws.
The fourth screw attaches the ground strap. Place toothed lock
washer on each side of the ground strap and tighten screw. Connect
the clutch pedal pull-back spring to the frame bracket with brake
spring pliers. Connect the clutch operating rod. Insert the operating
rod pin in the yoke and install the cotter pin. Connect the engine to
frame ground strap to the right side of the clutch housing. Assemble
a toothed lock washer on each side of the strap and install the screw.
e. Install Right Engine Dust Pan. Attach the dust pan to the
frame side member at the front with two screws- and lock washers.
Then attach the pan at the front cross member and at the same tirne
fasten the light wire clip. Move the light wire under the clip and
bend the clip over the wire. Install the torque arrester and tighten
the two front dust pan screws.
f . Install Exhaust Pipe. Lift the exhaust pipe into position with
a new exhaust pipe flange gasket and install the lock washers, nuts,
and lock nuts.
g. Connect Throttle, Choke, Windshield Wiper, and Cylinder
Head Ground Strap. Insert the choke control wire in the choke air
shutter lever swivel and the guide housing in the clip on the bracket
159
TM 9-808
67
3/4 -TON 4x4 TRUCK (DODGE)
so that the housing is flush with the forward end of the clip. Tighten
the clip. Connect the throttle control wire and- guide housing to the
manifold and tighten the clip screw. Insert the throttle control wire
in the block on the throttle control bell crank. See that the throttle
button on the dash is pushed in completely and tighten the set screw
on the block. Connect the windshield wiper flexible hose to the
manifold vacuum tube. Connect dash to cylinder head ground strap
to cylinder head screw with toothed lock washers on top and bottom
of strap.
h. Install Carburetor Air Cleaner (par. 69).
i. Connect Flexible Hose at Fuel Pump. Hold the elbow with
wrench and connect the attaching nut.
j. Connect Thermometer, Cranking Motor Pedal and Wiring
at Cranking Motor Switch. Place the ammeter and cranking motor
filter wires on the cranking motor switch terminal and tighten the
terminal nut. Position the cranking motor pedal rod in the cranking
motor shift lever yoke. Insert the pin and install the pin retainer.
Slide the thermometer bulb into the cylinder head fitting and tighten
nut. Attach the tube to the clip at cylinder head stud and close
the clip.
k. Install Horn Assembly (par. 120).
1. Connect Oil Gage and Distributor Wires. Connect the oil
gage tube at the flexible hose connection. Connect the oil filter inlet
flexible hose at the filter and the outlet flexible hose at the crankcase.
Connect the coil to distributor filter wire at the filter. Push the high
tension cable into the distributor cap.
m. Install Transmission Assembly (par. 133).
n. Install Fenders, Radiator Shell and Core Assembly.
(1) Lower Assembly Into Position (fig. 74). If there were any
spacing washers between the radiator support and the frame cross
member when- the fenders, radiator shell, and core assembly were
removed, slip them into place as the assembly is being lowered.
Attach chain fall to the assembly and lower it into position. Have a
helper at the rear of each front fender to assist in guiding the
assembly into place.
(2) Connect Radiator, Fenders, and Splash Shields. .Install
toqthed lock washers and start the nuts on the studs which attach
the radiator shell assembly to the frame front cross member, but do
not tighten until after the hood has been installed. Install the six
screws with toothed lock washers that fasten the front fender rear
supports to the front fender rear support brackets. Install the screws
with toothed lock washers that attach the left and right fender splash
shields to the front fender rear support.
(3) Connect Battery Tray and Ground Straps. If the vehicle
is equipped with 6-volt electrical system, install the three bolts that
hold the battery tray to the frame, and at the same time slip the
fuel tube clip on the center bolt with a toothed lock washer under
the bolt head and one under the nut. Attach the battery tray to
160
TM 9-808
67
ENGINE REMOVAL AND INSTALLATION
fender splash shield ground strap at the splash shield with a toothed
lock washer under the bolt head and one behind the nut. Connect the
ground strap with the screw and toothed lock washers to the frame
side member at the front of the left fender splash shield.
(4) Connect Light Wires. Push the blackout parking lamp
wires into their sockets on each side of the connections near the
terminal blocks on the front cross member. Place the light wires on
the terminal block. Connect each wire to the terminal that carries
the same color wire at block on the frame. Place the wire in the clip
to hold the wire to the cross member and close the clip.
(5) Connect Generator to Regulator Wiring at Generator.
Connect the wiring clip at the generator. Connect the two wires of
the generator to regulator assembly at the regulator. Install the small
green wire to the terminal marked "GEN" and the larger red wire to
the terminal marked "ARM." Install wiring to regulator clip screw.
(6) Connect or Install Battery. Connect battery cable if
vehicle is equipped with 12-volt electrical system. Install battery if
vehicle is equipped with 6- volt electrical system (par. 88).
(7) Connect Water Hose. Tighten the upper radiator hose
clarnp at the cylinder head water outlet elbow and the lower radiator
hose clamp at the water pump. Install radiator drain cock, if vehicle
is equipped with a winch.
(8) Vehicles Equipped with Fan Shroud. Install fan and
pulley (par. 85). Adjust fan belt (par. 82).
o. Install Hood (par. 178).
p. Install Radiator Tie Rods. Attach the front end of the tie
rods to the radiator shell and install the radiator shell bolts and nuts
with a toothed lock washer under each bolt head and one behind each
nut. Tighten nuts. Place the nuts with toothed lock washers on the
rear end of the tie rods at the dash bracket. On vehicles not equipped
with a fan shroud, adjust the radiator tie rods so that the clearance
between fan and flange on radiator top tank is at least %(j inch, and
the hood lines up with the radiator core shell equally on both sides.
On vehicles equipped with a fan shroud, adjust tie rods so that hood
lines up properly at both ends. Tighten the radiator shell support
stud nuts.
q. Fill Cooling System (par. 81).
r. Fill Engine Crankcase With Engine Oil (par. 24).
161
TM 9-808
68
3/4 -TON 4x4 TRUCK (DODGE)
>s
"3
3
Ik
I
N
-N
O
k
a
0)
162
TM 9-808
68
Section XVI
FUEL SYSTEM
Paragraph
General description 68
Air cleaner : 69
Carburetor and governor -= 70
Fuel tank 71
Fuel gage 72
Fuel pump 73
Fuel filter ■ 74
Fuel tubes 75
©.
.RADIO INTERFERENCE FILTER
AMMETER'
"-IGNITION SWITCH— MUST BE TURNED ON
TO COMPLETE THE FUEL GAGE CIRCUIT
FUEL GAGE (TANK UNIT)
'■
FUEL GAGE (PANEL UNIT)
BAHERY
RA PD 312556
Figure 78— Fuel Gage Circuit Diagram
68
GENERAL DESCRIPTION.
a. Fuel System (fig. 11). Pi. diaphragm type fuel pump is mounted
on the right side of the engine crankcase and is actuated by an
eccentric on the camshaft. The fuel pump draws fuel from the fuel
tank, through the filter on the dash, and delivers it to the carburetor
under 3 to Sy^ pounds pressure. Fuel is maintained at a determined
level in the carburetor bowl and discharge jets by a float actuated
valve. Air enters the combustion chambers through the air cleaner,
carburetor, and intake valves. As the air passes through the carburetor
it picks up fuel from the discharge jets and enters the combustion
chambers as a mixture of air and gasoline. The ratio of air and
163
TM 9-808
68
3/4-TON 4x4 TRUCK (DODGE)
FILTER
ELEMENT
CAUTION
LEVEL
-NORMAL
LEVEL
OIL
RESERVOIR,
CARBURETOR AIR CLEANER ASSEMBLY
CARBURETOR ASSEMBLY
(ZENITH)
/ CARBURETOR TO ELBOW GASKET
CARBURETOR AIR CLEANER ELBOV/
ELBOW TO AIR CLEANER GASKET
ELBOW TO AIR
CLEANER GASKET
CARBURETOR AIR
CLEANER ELBOW
CARBURETOR TO ELBOW GASKET
CARBURETOR AIR
CLEANER ASSEMBLY
CARBURETOR ASSEMBLY
(CARTER)
RA PD 312558
figure 79— Carburetor Air Cleaner
164
TM 9-808
68-69
FUEL SYSTEM
gasoline in the fuel mixture is governed by the amount of air passing
through the air cleaner, the height of the float level, and the calibra-
tion of the carburetor jets.
b. Fuel Gage (fig. 78). The electrically operated fuel gage con-
sists of two units; a float unit mounted in the tank and the gage unit
mounted on the instrument panel.
c. Tabulated Data.
Carburetor Zenith (Series 29) or Carter (ETWl)
Fuel pump A-C model 153771S
Fuel Hne filter Zenith F36B-2
Air cleaner AC-A20263B
Fuel gage:
Panel unit Auto-Lite NG10020-D
Tank unit Auto-Lite NG9967-T
69. AIR CLEANER.
a. Removal of Filter Element (fig. 79). Back off the wing nut
and lift out the filter element which is attached to the cover. Do not
allow the oil collected on the baffle to drip into the air cleaner elbow.
Lift out the oil reservoir.
b. Cleaning of Filter Element. Wash the filter element thor-
oughly in dry-cleaning solvent and dry. Empty the old oil and clean
out accumulation of dirt in the oil reservoir.
c. Installation of Filter Element (fig. 79). Place the oil reservoir
in the cleaner body and fill to the marked level with fresh engine oil.
Install the filter element and cover assembly. Tighten the wing nut.
d. Removal of Air Cleaner Assembly (fig. 79).
(1) Remove Air Cleaner. Remove filter element (subpar. a
above). Remove the four screws which attach the air cleaner body
to the air cleaner elbow and stud assembly and lift off the cleaner
body.
(2) Remove Air Cleaner Elbow. Remove the nut from the
stud that holds the air cleaner elbow support bracket to the elbow
and the screw that attaches the support bracket to the manifold.
Remove the nuts from the carburetor studs which hold the air cleaner
elbow to the carburetor and slide the elbow off the studs.
e. Installation of Air Cleaner Assembly (fig. 79).
(1) Install Air Cleaner Elbow. Place the gasket on the car-
buretor studs and assemble the elbow to the carburetor. Fasten the
elbow in place with the lock washers and nuts. Slide the support
bracket on the elbow stud, and install the screw with a toothed lock
washer which attaches the bracket to the intake manifold. If vehicle
is equipped with a heater, place the heater hose clamp on elbow stud,
then the plain washer, lock washer, and nut.
165
TM 9-808
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3/4 -TON 4x4 TRUCK (DODGE)
(2) Install Air Cleaner. Place a new air cleaner body to elbow
gasket on the elbow, then the cleaner body. Install the four cleaner
body to elbow screws with toothed lock washers. Install the filter
element (subpar. c above).
70. CARBURETOR AND GOVERNOR.
a. Throttle Stop Screw and Idling Adjustments (fig. 80). The
idle adjusting screw controls the mixture of air and fuel used for
closed throttle operation. Run the engine until the normal operating
temperature is reached. Disconnect the windshield wiper hose at the
tube leading to the intake manifold, and attach vacuum gage to the
ARBURETOR
IDLE
ADJUSTING
SCREW
ARBURETOR
THROTTLE
STOP SCREW
CARBURETOR CARBURETOR
(ZENITH) (CARTER)
RA PD 312539
Figure 80— Carburetor Adlustments
tube. On the Zenith carburetor, turn the idle adjusting screw clock-
wise to make a richer mixture of fuel or counterclockwise to make
a leaner mixture of fuel. On the Carter carburetor, turn screw
counterclockwise for richer mixture; clockwise for leaner mixture.
Turn the idling adjusting screw until the pointer on the gage shows
maximum reading. If this changes the idling speed of the engine,
adjust the throttle stop screw to obtain desired idling speed (clock-
wise to increase the engine idling speed or counterclockwise to
decrease speed).
b. Adjustment of Governor on Engine.
(1) Warm Up Engine and Test Manifold Vacuum. Run
engine until normal operating temperature is reached. Manifold
166
TM 9-808
70
FUEL SYSTEM
COMPENSATING CHANNEL PLUG
-GOVERNOR SEAL
GOVERNOR AND CARBURETOR
%.. .
r COMPENSATING SPRING
ADJUSTING SCREW
COVERSHOWN CUTAWAY
MAIN CHANNEL PLUG ^MAINSPRING ADJUSTING SCREW
CARBURETOR (ZENITH)
ADJUSTING SCREW PASSAGE PLUG
GOVERNOR SEAL
SCREWDRIVER ENGAGING
SLOT IN ADJUSTING SCREW
GOVERNOR AND CARBURETOR ^ GOVERNOR ADJUSTING NUT WRENCH
CARBURETOR (CARTER)
RA PD 312582
Figure 81— Governor Adjustments with Wrench 41-W-3734
167
TM 9-808
70
3/4 -TON 4x4 TRUCK (DODGE)
vacuum should be at least 16 inches with engine operating at full
throttle (governor operating) and at least 17 inches at idling speed,
with an allowable reduction for altitude. The adjusting screw, which
is attached to the spring, controls the maximum engine speed.
(2) Adjustments of Engine Speed (fig. 81). Remove the adjust-
ing screw passage plug and turn the screw clockwise to decrease, or
counterclockwise to increase the maximum engine speed. Adjust the
governor to maximum engine speed of 3,000-3,200 revolutions per
minute or a road speed of 6^/^ to 7^ miles per hour, low gear with
no load. NOTE: The screw adds to or subtracts from the number of
active coils in the spring when it is turned, automatically calibrating
the tension and-fitability of the spring so that it is generally possible
to regulate the maximum eogine speed over a considerable range by
means of the adjusting screw.
(3) Adjustment for Surge (Carter). If surge (continued
rapid rise and fall of engine speed over a considerable range by
means of throttle at full throttle) is present or occurs through change
of the screw adjustment, eliminate as follows:
(a) Move the adjusting nut clockwise Yn turn at a time with
special wrench (41-W-3734), correcting the engine speed with the
adjusting screw, until the surge is eliminated.
(b) If Governor is Slow Acting (governor too "flat")- Move the
adjusting nut counterclockwise J4 turn at a time, correcting the engine
speed with the adjusting screw until surge is apparent, then remove
surge as outlined (2) above. Engines operate most efficiently when
the governor is adjusted to the point which just eliminates surge at
full throttle. Do not forget to install adjustment passage plug and
sealing wire after making adjustment.
(4) Adjustment of Engine Speed (Zenith) (fig. 81). Remove
the seal and main channel plug. Turn the main spring adjusting screw
clockwise to increase engine speed and counterclockwise to decrease
engine speed. Adjust the governor to a maximum engine speed of
3,200 revolutions per minute or to a road speed of nine miles per hour
in low gear with no load.
(5) Adjustment for Surge (Zenith) (fig. 81). The compensat-
ing spring adjusting screw which is located under the compensating
channel plug provides an adjustment to eliminate surge (continued
rapid rise and fall of engine speed). If surge is experienced at full
throttle and no engine deficiencies are responsible, remove the seal
and plug and adjust the compensating spring adjusting screw ^ turn
at a time until the surge is just eliminated. The governor operates
most efficiently when the adjusting screw is turned clockwise only
far enough to eliminate the surge. If the screw is turned too far clock-
wise, the governor will lag at full throttle. When the adjustment is
satisfactory, install plug and seal with new lock wire.
c. Removal of Carburetor Assembly. Remove air cleaner as-
sembly (par. 69). Disconnect and remove the choke control wire and
tube at the carburetor. Disconnect the fuel tube at the carburetor.
Disconnect the throttle control bell crank to carburetor rod from
168
TM 9-808
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FUEL SYSTEM
air shutter lever pull-b"ack spring
'<:arburetor assembly (zenith)
choke control^button and wire housing bracket
CHOKER CONTROL LEVER AND SHAFT / PULL-BACK SPRING
CARBURETOR ASSEMBLY (CARTER)
RA PD 312530
Figure 82-^Choke Control Linkage
169
TM 9-808
70
3/4 -TON 4x4 TRUCK (DODGE)
the carburetor throttle lever. Remove the nuts from the carburetor
to manifold studs and remove the carburetor and governor assembly
from the engine.
d. Installation of Carburetor Assembly. Install a new carburetor
flange gasket and place the carburetor over the manifold studs with
the carburetor air intake facing the rear of the vehicle. Install the
lock washers and nuts on the carburetor flange studs and tighten.
Attach the throttle control bell crank to carburetor rod at the car-
buretor throttle lever. Install the lock washer and nut and tighten
(fig. 83). Connect the fuel tube to the carburetor and tighten. Insert
the choke control wire in the choke shutter lever swivel and the
housing in the clip on the bracket so that the housing is flush with
A— ACCELERATOR SHAFT AND BRACKET
B— ACCELERATOR SHAFT TO BELL CRANK ROD AND SPRING
C— THROTTLE CONTROL SPRING
D— HAND THROTTLE CONTROL WIRE AND HOUSING
E— HAND THROTTLE CONTROL BRACKET AND WIRE HOUSING CLIP
F— BELL CRANK TO CARBURETOR ROD
G— HAND THROHLE CONTROL LEVER
H— BELL CRANK
figure 83— Throfffe Control Linkage
the forward end of the clip. Tighten the clip. Push the control button
all the way in and back off about Vie inch, then tighten the wire in
the air shutter swivel. Install air cleaner assembly (par. 69). Adjust
engine idling speed (subpar. a above).
e. Removiil of Choke Control Wire (fig. 82). Disconnect battery
cable to prevent short circuit. Disconnect choke control wire, and
housing at the carburetor. Pull wire and housing from the short
piece of loom holding the choke housing to the throttle housing.
Straighten the housing and pull the control button and wire from
the housing.
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FUEL SYSTEM
f. Installation of Choke Control Wire (fig. 82). Push control
wire through the housing, starting at the instrument panel end. Then
push the housing and wire through the loom on throttle control
housing and into its original position. Insert the choke control wire
in the choke air shutter lever swivel and the housing in the clip on
the bracket so that the housing is flush with the forward end of the
clip. Tighten the clip. Push dash control button all the way in and
back off about i/^e inch. Hold the choke air shutter lever forward and
tighten the wire in the air shutter swivel. Connect battery cable.
Adjust engine idling speed (subpar. a above).
g. Removal of Throttle Control Wire (fig. 83). Disconnect bat-
tery cable to prevent short circuit. Disconnect the throttle wire and
housing at the throttle bell crank which is mounted on the manifold
bracket. Then pull the wire and housing from the short piece of
loom holding the throttle housing to the choke housing. Straighten
the housing. and pull the control button and wire from the housing.
h. Installation of Throttle Control Wire (fig. 83). Push control
wire through the housing, starting at the instrument panel end. Push
the housing and wire through the loom on choke housing and into its
original position. Connect the throttle control wire and housing to
the manifold and tighten the clip screw. Insert the throttle control
wire in the block on the throttle control bell crank. With the throttle
button on the dash pushed in and the throttle closed, tighten the set
screw on the block. Connect battery cable. Adjust engine idling speed
(subpar. a above).
71. FUEL TANK.
a. Removal. Remove the fuel tank drain plug and drain the fuel
from the tank. Disconnect the filler tube hose between the tank and
the filler tube by loosening the clamp screws and separating the hose
from the tank connection and filler tube. Disconnect the fuel filter to
tank tube at the fuel tank. Remove the fuel tank rear support strap
cap screws. Disconnect the fuel gage wire as the tank is being removed.
b. Installation. Connect the fuel gage wire and lift the tank into
place. Install the fuel tank rear support lock washers and cap screws.
Install the drain plug. Connect the tank to fuel filter tube at the tank.
Insert filler tube and hose. Connect the hose to the filler tube and
tank connection and tighten the two clamp screws. Make sure that
the filler pipe is installed in the flexible hose connection, so that at
least ^ inch to % inch space exists between the filler pipe and the
fuel tank connection, particularly on the Ambulance model.
72. FUEL GAGE.
a. Removal of Instrument Panel Unit. Disconnect wires from
the gage. Remove the two nuts which hold the mounting bracket to
the instrument panel and remove the gage from driver's side of the
instrument panel.
171
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3/4 -TON 4x4 TRUCK (DODGE)
b. Installation of Instrument Panel Unit (fig. 84). Place gage
in the instrument panel from the driver's side and install the mount-
ing bracket on the two studs of the gage. Install the two attaching
nuts with a standard lock washer under each nut. Connect the small
blue wire to the left post of the gage unit. On all models except the
Ambulance, connect green and white wire to the right post of the
unit. On the Ambulance, connect green and white wire, also red and
white wire, to right post of the unit.
RIGHT TERMINAL POST
FUEL GAGE
(PANEL UNIT)
EFT TERMINAL
POST
rFUEL GAGE (TANK UNIT) AND GASKET
INSPECTION PLATE GAGE WIRE-
WIRING ASSEMBLY
(UPPER)
. WIRING ASSEMBLY
(BODY SECTION)
RA PD 52901
RA PD 52794
Figure 84— Fuel Gage Terminals
Figure 85— Fuel Gage
(Tank Unit)
c. Removal of Tank Unit (fig. 85). Remove the screws which
hold the fuel gage inspection plate. Disconnect the gage wire and
remove the five screws from gage. Lift the gage out through the
inspection hole.
d. Installation of Tank Unit (fig. 85). It is important that the
gage gasket form a tight seal in order to piVevent fuel leakage. If the
gasket is not in good condition, use a new one. Assemble the tank
unit to the fuel tank and tighten the fastening screws. Connect the
wire and install the inspection plate.
73. FUEL PUMP.
a. Cleaning of Strainer Bowl and Screen (fig. 86). Loosen the
strainer bowl bail screw by hand and swing the bowl bail out of the
172
TM 9-808
73
FUEL SYSTEM
way. Remove bowl, gasket, and screen from the fuel pump body.
Wash the strainer screen and bowl in dry-cleaning solvent. Assemble
the screen in the pump top cover, making certain that it fits snugly
around the gasoline inlet and the edges of the casting. Then place a
new bowl gasket next to the screen. Hold the bowl firmly to the
gasket, move the bail in place, and tighten the bail screw securely by
hand.
b. Removal of Fuel Pump Assembly. Remove the heat shield
stud wing nut and loosen the nut on the exhaust manifold stud. Dis-
connect the fuel pump to carburetor tube at the fuel pump. Discon-
FILTER ELEMENT RETAINER CUP AND NUT
FILTER ELEMENT /HEAD /STUD
STRAINER BOWL BOWL'GASKFT
STRAINER SCREEN
RA PD 52793
BOWL STUD NUT AND GASKET
BOWL BOWL GASKET
RA PD 52791
figure 86— Removing Fuel Pump Figure 87—HemoYing Fuei Line
Bowi and Strainer Screen Filter Element
nect the fuel filter to fuel pump flexible tube at the fuel pump. Re-
move the fuel pump mounting cap screws and lift off the fuel pump.
c. Installation of Fuel Pump Assembly. Place the fuel pump
in position on the engine with a new gasket between fuel pump flange
and cylinder block. Install the lock washers and cap screws and
tighten. Connect the fuel filter to fuel pump flexible tube at the fuel
pump. Connect the fuel pump to carburetor tube at the fuel pump.
Slide the heat shield into position between the manifold stud washer
and manifold stud flange, also over the stud on the fuel pump. Hold
shield in place and tighten manifold stud nut. Install the lock washer
and wing nut on fuel pump stud.
173
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74-75
3/4 -TON 4x4 TRUCK (DODGE)
74. FUEL FILTER.
a. Draining of Filter. Remove drain plug in filter bowl to drain
accumulated water or dirt from bowl.
b. Cleaning of Filter Element (fig. 87). Remove the filter bowl
nut and pull filter bowl and gasket off filter. Turn the filter element
knurled nut counterclockwise until the element can be removed
from the element stud. Wash the element in dry-cleaning solvent.
Separate the disks to remove all dirt and lint between the disk sur-
faces. Do not disassemble the element. Assemble the filter element
to the filter head and tighten the element nut fingertight. Use no
tools and never twist the element. Install a new gasket on the filter
bowl and install bowl. Insert the bowl nut gasket over the stud and
install and tighten the bowl nut.
c. Removal of Fuel Filter Assembly. Disconnect the two flexible
tubes at the filter. Open the clip held by the filter mounting flange
cap screw and move the wires out of the way. Remove the two cap
screws from the fuel filter mounting flange.
d. Installation of Fuel Filter Assembly. Insert the right cap
screws through mounting flange with a toothed lock washer under the
cap screw head. Insert the left cap screw through mounting flange
with the wire clip between the toothed lock washer and mounting
flange. Place toothed lock washer on each cap screw so that it will be
between the mounting flange and dash. Hold the filter in place against
dash and tighten cap screws. Bend the clip over wiring. Connect the
two flexible tubes to the filter.
75. FUEL TUBES.
a. Removal of Tank to Fuel Filter Tube (Rear Section). Dis-
connect the fuel tube at the tank. Disconnect the tube at the union
near the brake pedal pivot bracket. Open the three clips holding the
fuel tube to the lower flange of the frame side member and remove
tube.
b. Installation of Tank to Fuel Filter Tube (Rear Section).
Place the fuel tube in position and bend the three clips over the tube.
Connect the tube at the tank. Connect the tube rear section to the
front tube union near the brake pedal pivot bracket.
c. Removal of Tank to Fuel Filter Tube (Front Section). Dis-
connect the fuel tube at the union near the brake pedal pivot bracket.
Disconnect the fuel tube from the flexible hose near the filter. Open
the clip holding the fuel tube at master cylinder bracket. Back off
the front wheel brake shoe cams so that the brake pedal can be de-
pressed to the floor panel. Push the brake pedal all the way down and
pull out the cotter pin and clevis pin which connects brake master
cylinder push rod end to the brake pedal. Release the brake pedal
and slide the push rod clevis end off its connection at the pedal and
174
TM 9-808
75
FUEL SYSTEM
push it back past the pedal so that the front end of the push rod can
be lowered slightly, creating sufficient clearance to permit the removal
of the tube without bending or distorting it.
d. Installation of Tank to Fuel Filter Tube (Front Section).
Position the fuel tube and connect at the union near the brake pedal
pivot bracket. Connect the tube at the flexible hose near the filter.
Then bend the clip over the tube located at the master cylinder
bracket. Move brake pedal and push rod end forward so clevis pin
can be installed. Insert new cotter pin in clevis pin and spread cotter
pin. Adjust front wheel brake shoes (par. 151).
e. Removal of Fuel Filter to Fuel Pump Tube.
(1) Remove Battery (6-volt System Only) (par. 88).
(2) Remove Hood (par. 178).
(3) Remove Water Pump Assembly (par. 85).
(4) Remove Radiator Core (par. 86).
(5) Remove Fuel Tube. Disconnect fuel tube from the flexible
hose at the fuel filter end. Disconnect fuel tube from the flexible hose
at the fuel pump end. Remove the two fuel tube clip self-tapping cap
screws at the frame front cross member. If vehicle is equipped with
6-volt electrical system, remove the fuel tube clip bolt and nut at
the battery tray and remove the tube. If vehicle is equipped with 12-
volt electrical system, remove the fuel tube clip bolt and nut from the
frame left side member and remove the tube.
f. Installation of Fuel Filter to Fuel Pump Tube.
(1) Install Fuel Tube. Work the fuel pump end of the tube
down between engine and left dust shield and up between the engine
and right dust shield, then push in position over frame front cross
member. Install the two fuel tube clip self-tapping cap screws with
a toothed lock washer between each screw head and clip. Connect
the fuel tube to the flexible hose at the fuel filter end. Connect fuel
tube to the flexible hose at water pump end. If vehicle is equipped
with 6-volt electrical system, install the fuel tube bolt and nut with
a toothed lock washer under the bolt head and a toothed lock washer
under the nut at the battery tray. If the vehicle is equipped with 12-
volt electrical system, install the fuel tube bolt and nut with a toothed
lock washer under the bolt head and a toothed lock washer under the
nut at the frame left side member.
(2) Install Radiator Core (par. 86).
(3) Install Water Pump Assembly (par. 85).
(4) Install Battery (6-volt System Only) (par. 88).
(5) Install Hood (par. 178).
g. Fuel Tube Repair.
(1) Cut New Tube with Tube Cutter. Measure tube for length
desired and cut \yith tube cutter.
175
TM 9-808
75
3/4 -TON 4x4 TRUCK (DODGE)
FUEL TUBE LENGTHS
Fuel pump to carburetor tube 22 in.
Fuel filter to fuel pump tube 46^4 in.
Fuel tank to fuel filter front tube 31 in.
Fuel tank to fuel filter rear tube 91^ in. (Carryall)
Fuel tank to fuel filter rear tube 983^ in. (Ambulance)
Fuel tank to fuel filter rear tube 75^ in.
(Command and
Weapon Carrier)
(2) Bend Tubing with Tubing Bender. Use removed tube as a
template or guide and form the tube to the same shape as the tube
removed.
(3) Flare Ends of Tube with Flaring Tool. Slide the attach-
ing nuts on each end of the fuel tube and flare each end of the tube
with flaring tool.
176
TM 9-808
76-79
Section XVII
EXHAUST SYSTEM
Paragraph
General description 76
Tail pipe 77
Muffler 78
Exhaust pipe 79
76. GENERAL DESCRIPTION.
a. The purpose of the exhaust system is to carry the burned gases
away from the vehicle and reduce exhaust noise.
77. TAIL PIPE.
a. Removal (fig. 88). Remove the muffler tail pipe bracket and
the lower part of the muffler rear support bracket. Remove the sup-
port clamp bolts and pull the tail pipe off muffler.
b. Installation (fig. 88). SHde the tail pipe on the muffler flange
and fasten the tail pipe bracket to the frame side member. Assemble
the lower half of the muffler rear bracket to the frame side member
and install the rear support clamp bolts, lock washers, and nuts.
78. MUFFLER.
a. Removal (fig. 88). Remove the muffler tail pipe (par. 77).
Remove the U-clamp at the front of the muffler and pull the muffler
from the exhaust pipe.
b. Installation (fig. 88). Slide the muffler flange on the exhaust
pipe and assemble the U-clamp in the muffler front bracket, being
sure that the saddle is in place between the exhaust pipe and the
bracket. Install the lock washers and nuts on the U-clamp and
tighten. Install the muffler tail pipe (par. 77).
79. EXHAUST PIPE.
a. Removal (fig. 88). Disconnect the exhaust pipe at the mani-
fold. Remove the two nuts from the U-bolt at the front of the
muffler and pull out the exhaust pipe.
b. Installation (fig. 88). Slide the end of the exhaust pipe into
the muffler flange and attach the exhaust pipe to the manifold flange.
Assemble the U-bolt in the muffler front bracket, being sure that
the saddle is in place between the exhaust pipe and the bracket.
177
TM 9-808
79
%
■TON 4x4 TRUCK (DODGE)
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178
TM 9-808
80
Section XVIII
COOLING SYSTEM
Paragraph
General description 80
Maintenance 81
Fan belt 82
Hose 83
Thermostat 84
Water pump and fan 85
Radiator 86
80. GEIVfERAL DESCRIPTION.
a. General (fig. 89). The purpose of the cooling system is to
maintain efficient operating temperature of the engine. This is
accomplished by thermostatically controlling the circulation of
coolant around the cylinder walls and through the radiator.
RADIATOR FILLER CAP"
RADIATOR-
THERMOSTAT
RADIATOR FILLER CAP ■
RADIATOR -
^THERMOSTAT
ENGINE COLD- VALVE
CLOSED BY THERMOSTAT
ALLOWS WATER TO CIRCULATE
THROUGH THE ENGINE BUT
NOT THE RADIATOR.
CLOSED
ENGINE WARM— VALVE
OPENED BY THERMOSTAT
ALLOWS WATER TO CIRCULATE
THROUGH THE ENGINE
AND THE RADIATOR
OPENED
RA PD 58353
Figure 89— Cooling System Thermostat Operation
h. Thermostat Control (fig. 89). When a cold engine is started,
a thermostat prevents the circulation of the cooling solution through
the radiator. A bypass allows the coolant to circulate only in the
water jackets of the engine until normal operating temperature has
179
TM 9-808
80-81
3/4 -TON 4x4 TRUCK (DODGE)
been reached. When the temperature as shown by the thermometer
on the instrument panel reaches approximately 157°F, the thermo-
stat starts to open, allowing some of the coolant to circulate through
the radiator. At approximately 183°F the thermostat is fully open,
allowing unrestricted circulation of the coolant.
c. Radiator Cap. The radiator cap is spring-loaded, forming a
closed cooling system to prevent loss of cooling liquids. Should
excessive pressure develop, the radiator cap releases at a pressure
from II/2 to 254 pounds allowing the system to vent through the
overflow pipe in the radiator filler neck above the radiator cap seat.
81. MAINTENANCE.
a. Draining Cooling System (fig. 90).
(1) Drain Radiator. Remove the filler cap slowly to permit
pressure to escape through the vent in the cap if the radiator is hot.
DRAINING COOLING SYSTEM
OPEN THE RADIATOR DRAIN COCK - A
AT FRONT, UOWER RIGHT HAND
CORNER OF RADIATOR CORE AND THE
jCYLINDER BLOCK DRAIN COCK- B AT/'
THE LOWER LEFT SIDE OF ENGINE. -
RA PD 52790
figure 90— Cooling System Drain Cauflon Plate
Open the radiator drain cock at front lower right-hand corner of
radiator core. If cooling system contains antifreeze, drain in pan
and save.
(2) Drain Cylinder Block. Open the drain cock at the lower
edge of the water jacket on the left side of the engine. NOTE: Drain-
ing the radiator alone will not completely drain the cylinder block.
b. Filling Cooling System. Close the radiator drain cock as well
as the drain cock at the lower edge of the water jacket on the left side
of the engine. Fill the system with coolant to a level 2J4 inches below
the top of the filler neck. The capacity of the cooling system is 18
quarts. Turn filler cap all the way to the right to seal the system.
c. Flushing Cooling System. If dirty water has been used in the
cooling system, the system can be flushed to some extent if water
'supply and hose are available.
(1) Remove Radiator Hose— Upper and Lower (par. 83).
(2) Remove Thermostat from Cylinder Head (par. 84). Then
install thermostat housing without thermostat.
180
TM 9-808
81-82
COOLING SYSTEM
(3) Flush Radiator Core and Engine Water Jackets. Place
end of water hose in radiator filler opening and wrap cloth around
connection to hold some of the water pressure. Turn- on water and
allow water to flow through radiator until water is clean as it leaves
radiator. Place end of water hose in opening at the thermostat hous-
ing and allow water to flow through the engine water jackets until
water is clean as it leaves water jackets.
(4) Install Thermostat (par. 84).
(5) Install Radiator Hose— Upper and LOwer (par. 83).
(6) Fill Cooling System (subpar. b above).
.V2-IN. SLACK
GENERATOR ADJUSTING STRAP SCREW
ENERATOR MOUNTING BOLTS (PIVOT)
RA PD 312536
figure 91— Adjusting Fan Belt
82, FAN BELT.
a. Adjustment of Fan Belt (fig. 91). If the fan belt has slack
greater than I/2 inch, it should be adjusted. Loosen the generator
mounting bracket pivot bolts. Then l90sen the adjusting strap lock-
ing screw or bolt. Pull out on the generator until the belt is just snug.
Hold the generator in this position and tighten the adjusting strap
lock screw and the generator bracket pivot bolts. Do not overtighten
the belt by moving the generator with a pj-ybar, as too tight a belt
will damage the generator or water pump bearings.
b. Replacement of Fan Belt. Loosen the generator to mounting
bracket pivot bolts and adjusting strap screw or bolt. Push the gener-
ator toward the engine as far as it will go and remove belt. Then
install new belt and adjust as explained in subparagraph a above.
181
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83-84
3/4 -TON 4x4 TRUCK (DODGE)
83. HOSE.
a. Replacement Procedure.
(1) Drain Radiator (par. 81).
(2) Replace Inlet and Outlet Hose (fig. 92). Loosen hose
clamp screws and pull off hose. Install new hose and tighten clamp
scfews securely.
(3) Replace Bypass Hose. Loosen the two hose clamp screws
connecting the hose to water pump bypass elbow and the cylinder
head water outlet elbow. Remove bypass elbow cap screws and puU
the bypass elbow off the cylinder head water outlet elbow. Slide a
new hose on the bypass elbow, then the two clamps over the hose.
Slide the hose on the water outlet elbow and tighten the two clamp
screws. Install the bypass elbow cap screws and lock washers.
(4) Fill Radiator (par. 81).
•RADIATOR HOSE— INLET. ■^RADIATOR HOSE— OUTLET— UPPER fRADIATOR OUTLET
TUBE
WATER PUMP BY-PASS HOSE-' RADIATOR HOSE— OUTLET-- LOWER
RA PD 52919
Figure 92— Cooling System Hose
84. THERMOSTAT.
a. Removal (fig. 93). Drain the radiator (par. 81). Loosen the
radiator inlet hose clamp screws. Remove the two bypass elbow to
water pump cap screws. Then remove the two cylinder head water
outlet elbow cap screws and remove the elbow assembly, being care-
ful not to damage the thermostat. Lift the thermostat from, the cylin-
der head (fig. 93).
b. Testing. Heat a pan of water to 160"F by the thermometer,
suspend thermostat in water and note whether it begins to open.
182
TM 9-808
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COOLING SYSTEM
Remove thermostat, heat the water to 185°F and suspend thermostat
in water. If it opens fully, it is functioning properly.
c. Installation (hg. 93).
(1) Install Thermostat. Place a new outlet elbow gasket on
cylinder head; also a new bypass elbow gasket on the water, pump.
Install the thermostat in the cylinder head, bellows down. Turn the
thermostat so that the bypass openings face toward the radiator and
to the rear of the vehicle, leaving the two wide faces to the right and
left. Place the upper gasket on the top shoulder of the thermostat.
(2) Install Water Outlet and Bypass Assembly. Place the
water outlet elbow and bypass elbow assembly in position and slide
the radiator inlet hose in place. Install the bypass elbow to water
FRONT— STAMPED ON THERMOSTAT;
THERMOSTAT GASKE'
- THERMOSTAT
THERMOSTAT
WATER OUTLET ELBOW
BY-PASS ELBOW GASKET7
/ 1
i-WATER OUTLET ELBOW GASKET
WATER PUMP ASSEMBLY'
RA PD 312537
figure 93— Installing Thermostat
pump cap screws and lock washers. Then install the water outlet
elbow cap screws and lock washers. Tighten the radiator inlet hose
clamp screws.
(3) Fill Cooling System (par. 81).
85. WATER PUMP AND FAN.
a. Removal of Water Pump and Fan (Vehicles without Fan
Shroud).
(1) Drain Radiator and Disconnect Water Hose. Open the
radiator drain cock and drain radiator. Disconnect radiator inlet hose
183
TM 9-808
85
3/4 -TON 4x4 TRUCK (DODGE)
FAN PULLEY
'FAN
WATER PUMP BODY STUD WATER PUMP""- PUMP TO BLOCK GASKET
VEHICLES WITHOUT FAN SHROUD
FAN PULLEY. FAN SHROUD
WATER PUMP FAN SHROUD
VEHICLES WITH FAN SHROUD
RA PD 312538
Figure 94— Removing Water Pump
184
TM 9-808
85
COOLING SYSTEM
at radiator and radiator outlet hose at water pump. Also disconnect
heater hose at water pump if vehicle is equipped with heater.
(2) Remove Generator Adjusting Strap and Fan Belt.
Loosen the generator mounting pivot bolt nuts. Remove the adjust-
ing strap from the water pump mounting stud. Push the generator
toward the engine and remove the fan belt.
(3) Remove Cylinder Head Water Outlet Elbow Assembly.
Remove the bypass elbow to water pump cap screws. Remove the
two cap screws from cylinder head water outlet elbow and carefully
lift off the elbow assembly. Do not damage the thermostat.
(4) Remove Water Pump and Fan Blade Assembly (fig. 94).
Install two nuts on each stud and lock the nuts together. Turn the
inside nut counterclockwise and screw the studs out of the block.
Lift the water pump and fan blade assembly from the cylinder block.
(50 Remove Fan Blade Assembly from Water Pump. Remove
the fan hub cap screws and lift the fan blade assembly and pulley
from the water pump.
b. Installation of Water Pump and Fan (Vehicles without Fan
Shroud).
(1) Install Fan Blade Assembly on Water Pump. Place the
pulley and fan blade with reinforcing plate toward pulley on the fan
hub, install lock washers and attaching cap screws and tighten the
cap screws.
(2) Install Water Pump and Fan Assembly. Hold the pump
and fan blade assembly in place and screw the studs into the cylinder
block. Place the short stud nearest the manifold, the medium length
stud at bottom center, and the long stud at the point where the gener-
ator adjusting strap is fastened. Tighten each of the studs by locking
two nuts together. Place the generator adjusting strap on the water
pump mounting stud. Install a toothed lock washer and nut on the
mounting stud holding the adjusting strap, but do not tighten. Then
place a lock washer and nut on the other two studs and tighten.
(3) Install Cylinder Head Water Outlet Assembly. Place a
new outlet elbow gasket on cylinder head, also a new bypass elbow
gasket on the water pump. See that the upper gasket on the top shoul-
der of the thermostat is in good condition, then place the water outlet
elbow and bypass elbow assembly in position and slide the radiator
inlet hose in place. Install the bypass elbow to water pump cap screws
and lock washers and tighten. Then install the water outlet elbow
cap screws and lock washers and tighten.
(4) Install Generator Adjusting Strap and Fan Belt.
Attach the adjusting strap to the generator bracket with toothed lock
washer between the cap screw and generator bracket. If a bolt and
nut is used, install a toothed lock washer between bolt head and
strap and one between bolt nut and generator bracket. . Tighten the
strap at the water pump mounting stud. Push the generator toward
the engine as far as it will go, and install and adjust fan belt (par.
82).
185
TM 9-808
85
3/4 -TON 4x4 TRUCK (DODGE)
(5) Connect Water Hose and Fill Radiator. Connect and
tighten radiator inlet hose at radiator, and outlet hose at water pump.
Connect and tighten heater hose at water pump if vehicle is equipped
with heater. Close radiator drain cock and fill with coolant.
c. Removal of Water Pump and Fan (Vehicles with Fan
Shroud).
(1) Drain. Radiator and Disconnect Hose. Drain the radiator.
Remove upper radiator hose and disconnect lower hose fror^ water
pump. Remove two cap screws which hold the bypass hose elbow to
this top of the water pump.
(2) Remove Fan and Pulley (fig. 94). Remove fan belt. Dis-
connect the right radiator tie rod at the radiator. Remove cap screws
-RADIATOR FILLER CAP
(FIRST TYPE)
■radiator FILLER CAP
(SECOND TYPE)
IVi«-IN.
Ttizr i
. RADIATOR FILLER NECK
(FIRST TYPE)
^RADIATOR FILLER NECK
(SECOND TYPE)
RA PD 52918
Figure 95— Radiator Filler Caps
which hold fan and pulley to fan pulley hub. Move the fan assembly
toward radiator and remove pulley. Tip fan blade assembly as shown
in figure 94 and lift it out.
(3) Remove Water Pump (fig. 100). Remove the nuts and lock
washers from the water pump attaching studs and move the pump
forward and off the studs.
d. Installation of Water Pump and Fan (Vehicles with Fan
Shroud).
(1) Install Water Pump. Slide the pump over the attaching
studs and install standard lock washers and nuts.
186
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COOLING SYSTEM
(2) Install Fan Blades (fig. 94). Place pulley in position. In-
sert fan between radiator shroud and water pump as shown in figure
94, with reinforcing plate toward pulley. Move fan into position over
water pump hub and install four attaching cap screws with standard
lock washer under the head of each cap screw. Attach radiator tie
rod to radiator. Install fan belt.
(3) Connect Hose and Fill Radiator. Install the two cap
screws which hold the bypass elbow to the water pump. Connect
lower hose to water pump and install upper hose. Fill cooling system
(par. 81).
RADIATOR FILLER CAP .
r radiator filler neck
radiator core —
radiator shell-j
1
RETAINER
RA PD 52920
RA PD 52787
figure 96— Installing Radiator
Cap
Figure 97— Installing Rodiator
Core
86. RADIATOR.
a. Radiator Cap. Radiators of all vehicles covered by this manual
are equipped with pressure control radiator caps. Very little loss of
coolant will result if the normal operating temperature is not ex-
ceeded. The radiator cap is equipped with a spring-loaded valve that
seals the overflow pipe opening from the radiator proper, when the
correct cap is installed with the gasket in the radiator filler neck.
The spring-loaded valve must be tight against the gasket to seal the
cooling system. The valve in the cap remains on its seat until the
pressure in the cooling system exceeds 1^4 to 2% pounds per square
inch. Only when the pressure is great enough to raise the valve from
its seat, can any vapor escape through the overflow from the cooling
187
TM 9-808
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3/4 -TON 4x4 TRUCK (DODGE)
system. Whenever the cooling system is filled or a vehicle inspected,
note the condition of the gasket and tighten cap securely. Replace the
gasket whenever it becomes warped or when the valve is not making'
complete contact with the gasket.
b. Types of Filler Caps Used (fig. 95). Two types of pressure
■control caps have been used on vehicles covered by this manual. The
correct type cap must be used to prevent loss of coolant. The first
type pressure control cap has a rneasurement of ly^g inches from the
top of the cap engaging lugs to the bottom of the sealing flange that
contacts the gasket in the radiator filler neck. The second type pres-
sure control cap has 'a measurement of ^4 inch from the top of the
cap engaging lugs to the bottom of the sealing flange that contacts
the gasket in the radiator filler neck. CAUTION: Other types of
caps have been used on previous model vehicles. Do not attempt to
use these on vehicles covered by this manual.
c. Replacement of Cap (fig. 96). To replace the pressure control
cap, grip the retainer in the filler neck with a pair of pliers, turn the
retainer' so that both ends will pass through the filler neck and lift
out. It is not necessary to compress or bend the retainer to remove
or install it.
d. Removal of Radiator Core (Vehicles without Fan Shroud).
(1) Drain Radiator (par. 81).
(2) Remove Hood (par. 178).
(3) Remove Water Pump Assembly (par. 85 a).
(4) Remove Radiator Core (fig. 97). Remove the six cap
screws that hold the core to the support. Lift up on upper part of
shell at filler neck hole to permit core filler neck to clear hole in shell,
then push top of core toward engine and lift out.
e. Installation of Radiator Core (Vehicles without Fan
Shroud).
(1) Install Radiator Core (fig. 97). Lower core between shell
and engine, placing bottom of core in position, then lift up on upper
part of shell at filler neck hole to permit core filler neck to clear hole
in shell and pull top of core forward into place. Install three toothed
lock washers and cap screws at each side of core.
(2) Install Water Pump Assembly (par. 85).
(3) Install Hood (par. 178).
f. Removal of Radiator Core (Vehicles with Fan Shroud).
(1) Drain Radiator (par. 81).
(2) Remove Hood (par. 178).
(3) Remove Fan Blades (par. 85 c (2)).
(4) Remove Radiator Core. Remove hose at top and bottom
of radiator core. Disconnect both radiator tie rods at the radiator.
Remove the six cap screws that hold the fan shroud and radiator
core to the support and remove the shroud. Lift up on the upper part
188
TM 9-808
86
COOLING SYSTEM
of shell at filler neck hole to permit core filler neck to clear hole in
shell, then push top of core toward engine and lift out (fig. 97).
g. Installation of Radiator Core (Vehicles with Fan Shroud).
(1) Install Radiator Core. Lower core between shell and
engine, placing bottom of core in position, then lift up on upper part
of shell at filler neck hole to permit core filler neck to clear hole in
shell and pull top of core forward into place (fig. 97). Install the fan
shroud. Install three toothed lock washers and cap screws at each
side of shroud and tighten shroud and core to support. Install hose
at top and bottom of radiator. Connect left radiator tie rod.
(2) Install Fan Blades (par. 85 d (2)).
(3) Install Hood (par. 178).
(4) Fill Radiator (par. 81).
189
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87
3/4 -TON 4x4 TRUCK (DODGE)
Section XIX
BATTERY
Paragraph
General description 87
Battery 88
Battery cables 89
SIX VOLT
TWELVE VOLT BAHERY
TWELVE VOLT
RA PD 58355
figure 98— Battery Location
87. GENERAL DESCRIPTION.
a. The vehicles covered by this manual are equipped with either
6-volt or 12 -volt batteries as listed below:
6-VOLT ELECTRICAL SYSTEM
Type of Vahicle Model
Weapon carrier WC-51
Weapon carrier with
winch WC-52
Ambulance WC-54
Telephone maintenance WC-59
Emergency repair WC-60
190
12-VOLT ELECTRICAL SYSTEM
Type of Vehicle Model
Carryall WC-53
Command WC-56
Command with winch . . WC-57
TM 9-808
87-88
BATTERY
b. Battery Location (fig. 98). The location of the battery offers
a simple means of determining the voltage of the electrical system. On
vehicles with 6-volt systems, the battery is located under the engine
■ hood on the driver's side. On vehicles with 12 -volt systems, the battery
is mounted on the rear end of the running board on the side opposite
the driver.
c. Data.
Battery capacity, ampere hour:
6-volt , 116 (20 hr rate)
12-volt 204 (20 hr rate)
Battery terminal grounded negative
88. BATTERY.
a. Battery Tests.
(1) Hydrometer Test. The following hydrometer readings show
the charge condition of the battery:
Fully charged . 1.275 to 1.300
Half charged 1.225 ■
Dangerously low 1.150
(2) Specific Gravity for Hot Climates. In hot climates (95°F
and above), lower specific gravity electrolyte (1.245) is recommended
to avoid excessive deterioration of plates and separators. When trans-
ferring batteries that have previously been in service in a temperate
climate, to a tropical climate, first make sure the battery is fully
charged. Then remove electrolyte to top of plates and fill with pure
water. Charge the battery for two hours at 10 to 15 amperes and re-
peat procedure until a specific gravity of 1.245 is obtained.
(3) Voltage Test. To test the voltage output of the battery
with a voltmeter, connect the positive lead from the voltmeter to the
positive post of the battery and negative lead from the meter to the
negative post of the battery. Read the voltage output on the volt-
meter. A reading of 6.0 to 6.5 volts on a 6-volt battery or 12.0 to 13.5
volts on a 12-volt battery indicates normal voltage output.
b. Electrolyte Level. Add pure water to the battery as often as
necessary to keep the battery plates covered with the electrolyte
solution.
(1) Batteries with Vent Plugs. Six-volt batteries and some
12-volt batteries are filled by removing the filler plugs and placing
them over the vents. Fill each cell with pure water to top of filler
opening. Then remove the filler caps from the vents and the electro-
lyte solution will drop to the proper level.
(2) Batteries without Vent Plugs. Twelve-volt batteries not
equipped with vent plugs are filled by removing the filler plugs and
adding sufficient pure water to each cell to bring the level of the
electrolyte solution ^^ inch abo'fre the top of the battery plates.
191
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3/4 -TON 4x4 TRUCK (DODGE)
c. Temperature at Which Battery Will Freeze. A fully charged
battery with a specific gravity of 1.260 to 1.300 will not freeze except
in temperatures below — 75°F but a discharged battery with specific
gravity of 1.100 to 1.120 will freeze at 14°F to 18°F, above zero. For-
this reason, the battery should be kept fully charged when tempera-
tures fall below freezing (32 °F).
d. Removal of Battery,
(1) Disconnect Cables from Battery. CAUTION: Always
remove ground cable first.
(a) Six-volt Battery. Loosen terminal bolt nuts and lift terminals
off battery posts.
GROUND, .M.UST BE CLEAN AND TIGH
" " six VOLT
TWELVE VOLT
GROUND
MUST BE
CLEAN AND
TIGHT
RA PD 58360
Figure 99— Battery Ground (Negative) Cable
(b) Twelve-volt Battery. Remove two cap screws which hold bat-
tery cover in place and swing cover down. Then loosen battery termi-
nal wing nut and lift off terminal.
(2) Remove Battery from Mounting. Remove two hold-down
clamp bolt nuts, clamp or clamps. Then lift out battery.
e. Installation of Battery.
(1) Install Battery in Mounting.
(a) Six-volt Battery. Set battery in mounting with negative post
forward and install hold-down clamp. Install toothed lock washer on
front hold-down bolt and toothed lock washer on rear hold-down
192
TM 9-808
88-89
BATTERY
bolt. Install generator wire bracket over front hold-down bolt with
another toothed lock washer on top of bracket. Install and tighten
nuts on both hold-down bolts.
(b) Twelve-volt Battery. Set battery in mounting with posts
forward and install hold-down clamps. Install toothed lock washer on
each hold-down clamp bolt. Then install and tighten nuts on both,
hold-down bolts.
(2) Connect Battery Cables.
{a) Six-volt Battery. Lubricate terminals with a thin coating of
chassis grease. Press terminals down on battery posts and tighten,
terminal bolt nuts.
(b) Twelve-volt Battery. Lubricate terminals with a thin coat-
ing of chassis grease. Install smaller single cable and longer one of
pair of cables on negative terminal of battery. Install larger single
cable and shorten one of pair of cables on positive terminal of bat-
tery. Then put wing nuts on battery terminal screws and tighten.
Close battery cover. Install cap screws with toothed lock washer under
the head of each cap screw and tighten coyer.
89. BATTERY CABLES.
a. Removal of Battery Ground Cable.
(1) Disconnect Cable from Battery (par. 88 d (1)).
(2) Disconnect Grounded End of Cable (fig. 99).
(a) Six-volt Battery. Remove nut from generator hinge bracket
stud and remove cable.
(b) Twelve-volt Battery. Remove nut and bolt from frame side
member and remove cable.
b. Installation of Battery Ground Cable (fig. 99).
( 1 ) Attach Grounded End of Cable.
(a) Six-volt Battery. Install one toothed lock washer, then cable
terminal on generator hinge bracket stud. Install another toothed
lock washer and nut on stud and tighten securely.
(b) Twelve-volt Battery. Place one toothed lock washer on attach-
ing bo^t, then insert bolt through cable terminal and frame side
member. Install another toothed lock washer and nut and tighten
securely.
(2) Connect Cable to Battery (par. 88 e (2)).
c. Removal of Battery to Cranking Motor Cable.
(1) Disconnect Cable from Battery (par. 88 d (1)).
(2) Disconnect Cable from Cranking Motor Switch. Re-
move nut from cranking motor switch terminal and lift off ammeter
and radio interference wires and battery to cranking motor cable.
(3) Disconnect Clips Which Hold Cable to Chassis (12-
VOLT Battery Only). Remove clip on running board bracket. Open
193
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89
3/4 .TON 4x4 TRUCK (DODGE)
two clips on frame cross member over front of transfer case. Remove
clip on frame cross member at rear of transmission. Open clip on
engine crankcase and remove cable.
d. Installation of Battery to Cranking Motor Cable.
(1) Connect Cable to Cranking Motor Switch. Place cable
terminal on cranking motor switch with ammeter and interference
filter wire terminals on top of cable terminal. Install standard lock
washer and nut.
(2) Connect Cable to Battery (par. 88 e (2)).
(3) Connect Clips Which Hold Cable to Chassis (12-volt
Battery Only). Close clip on engine crankcase. Install clip on frame
cross member at rear of transmission. Close two clips on frame cross
member over front of transfer case. Install clip on running board
bracket.
194
TM 9-808
90-91
Section XX
STARTING SYSTEM
Paragraph
General description 90
Cranking motor switch 91
Cranking motor pedal 92
Cranking motor 93
90. GENERAL DESCRIPTION.
a. The starting system (fig. 100) consists of the battery, the
battery and ground. cables, the cranking motor switch and the crank-
ing motor. The starting system operates entirely independently of all
other electrical equipment and wiring of the vehicle.
b. Two different types of cranking motors are used, depending
on the voltage of the electrical system. The cranking motor used on
vehicles with 12-volt electrical systems has a green plate with voltage
shown on plate. Six-volt system cranking motors are equipped with a
red plate showing the voltage.
BATTERY TO CRANKING MOTOR CABLE
CRANKING MOTOR SWITCH
-CRANKING MOTOR
BAHERY GI^OUND CABLE RA PD 312534
Figure 1 00— Cranking Circuit Diagram
91. CRANKING MOTOR SWITCH,
a. Removal.
(1) Disconnect Cable from Battery (par. 88 d).
(2) Remove Switch. Remove terminal nut, ammeter, radio inter-
ference filter wires, and cable. Remove two screws which hold switch
to cranking motor. Outside screw also holds radio interference filter
in place.
195
TM 9-808
91-93
3/4 -TON
4x4 TRUCK (DODGE)
b. Installation.
(1) Install Switch. Install screws which hold switch to crank-
ing motor, place radio interference filter bracket under outer screw
with a toothed lock washer under bracket and a toothed lock washer
on top of bracket. Place cable, also ammeter and filter wire terminals,
on post of switch and install standard lock washer and nut.
(2) Connect Cable to Battery (par. 88 e).
92. CRANKING MOTOR PEDAL.
a. Removal Procedure. Unscrew button from end of rod and
spring will slip off. Disconnect rod from cranking motor switch lever
and pull rod from front of dash.
b. Installation. Insert rod through dash from the front and con-
.nect to cranking motor switch lever. Place spring over rod and install
button on end of rod.
SWITCH BUTTON
CRANKING MOTOR
SWITCH
1
CRANKING MOTOR
"-PINION
i-CRANKING MOTOR
RA PD 312580
figure 101 —Checking Crankiing Motor Pinion Clearance
93. CRANKING MOTOR.
a. Removal. Disconnect cable from battery to avoid damage
from short circuit. Remove nut from switch and lift off radio filter
wire, ammeter wire and battery cable. Disconnect wire running from
radio filter to coil, at the coil. Remove two screws which hold switch
and radio interference filter to cranking motor. Remove oil level
indicator and disconnect lower end of oil filter to engine hose. Dis-
connect 'engine to oil gage tube and hose at engine and dash, and
remove tube and hose. Disconnect cranking motor pedal rod at
clevis. Remove two cap screws which hold cranking motor to clutch
housing and lift out cranking motor.
196
TM 9-808
93
STARTING SYSTEM
b. Installation.
(1) Check Pinion Clearance (fig. 101). When the cranking
motor pinion is fully engaged, there should be Yk; to %■) inch clear-
ance between the pinion and the pinion housing. Push the shift yoke
assembly to its extreme limit of travel, or until the cranking motor
switch has made contact. Then measure the clearance between the
end. of the pinion and the rear thrust washer. The cranking motor
switch button may be screwed into or out of the switch assembly
as required for proper pinion adjustment. NOTE: Do not attempt to
change the cranking motor switch button adjustment without re-
moving the cranking motor to verify proper setting.
(2) Install Cranking Motor. Place motor in clutch housing
and install two cap screws which hold cranking motor in place. Con-
nect pedal rod at clevis. Install engine to oil gage tube and hose.
Connect lower end of oil filter to engine hose. Install oil level indicator.
Install screws which hold switch to cranking motor. Place radio
interference filter bracket under outer screw with toothed lock
washer under bracket and toothed lock washer on top of bracket.
Place cable, also ammeter and filter wire terminals, on post of switch
and install standard lock washer and nut. Connect wire running from
radio filter to coil at the coil. Connect cable to battery.
197
TM 9-808
94
%
-TON 4x4 TRUCK (DODGE)
Section XXI
GENERATING SYSTEM
Paragraph
General description 94
Generator (6-volt)- 95
Generator (12-volt-) 96
Generator regulator 97
94. GENERAL DESCRIPTION.
a. Types Used. The vehicles covered by this manual are equipped
with either a 6-volt or 12-volt generator. Six- volt generators can be
identified by the red plate mounted on the generator. Twelve-volt
RADIO INTERFERENCE FILTER
GENERATOR REGULATOR
RA PD 312559
figure 1 02— Generating Circuit Diagram
generators are equipped with a green plate. These plates show the
model number, amperage, and voltage of the generator.
b. Voltage Regulation. The output of the generator is controlled
in relation to the voltage requirements by the generator regulator,
mounted on the engine side of the dash, keeping the battery fully
charged and maintaining proper voltage under normal driving condi-
tions. This means that the pointer of the ammeter mounted on' the
instrument panel of the vehicle may gradually approach zero, as the
198
TM 9-808
94-95
GENERATING SYSTEM
battery becomes fully charged. This indicates that the generator out-
put has dropped to a small sustaining charge necessary for a fully
charged battery to prevent overcharge. The regulator contains three
units, each performing a distinct and independent function. The
three units of the regulator are known as the circuit breaker, the
voltage regulator and the current regulator.
c. Generating Circuit. The generating circuit for both 6-volt and
12 -volt vehicles is illustrated in figure 102.
ED AND WHITE
GROUN
ARMATUREJ FIELD
SIX VOLT
GROUND
TWELVE VOLT
\RMATURE
RA PD 58363
Figure 1 03— Six-volt and Twelve-volt Generators
95. GENERATOR (6-VOLT).
a. Removal (fig. 103). Disconnect wires from generator. Remove
wire bracket. Remove adjusting strap cap screw. Push generator
toward engine and remove belt. Remove two generator hinge bolts
and lift out generator.
b. Installation, (fig. 103).
(1) Install Generator Hinge Bolts. Place generator in mount-
ing bracket and install hinge bolts with standard lock washers and
nuts, but do not tighten securely. See that mounting brackets, hinge
bolts, and nuts are clean and free of grease, paint or rust, so that a
good ground connection will be made at these points.
(2) Install Fan Belt and Connect Wires. Install adjusting
strap cap screw with plain washer and standard lock washer under
199
TM 9-808
95-96
3/4 -TON 4x4 TRUCK (DODGE)
head of cap screw. Do not tighten. Put belt in pulley and swing
generator out to adjust belt (par. 82). When belt is adjusted tighten
cap screw in strap and securely tighten nuts on hinge bolts. Connect
wires to generator as shown in figure 103.. Attach wire bracket to
generator, placing one toothed lock washer under bracket and another
toothed lock washer on top of bracket. '
(3) Polarize Generator. After installing the generator and
before the engine is started, polarize the generator with the battery
by momentarily connecting a jumper wire from the starting motor
switch to the armature terminal (large terminal) on the generator.
96, GENERATOR (12- VOLT).
a. Removal (fig. 103). Disconnect wires from generator. Remove
wire bracket. Remove adjusting strap bolt and loosen two hinge
bolts. Push generator toward engine and remove belt. Remove two
generator hinge bolts, and lift out generator.
^GENERATOR REGULATOR y-BAT. TERMINAL r^RM. TERMINAL /-FIELD TERMINAL
^3i^
^TA«TE. com Rt5t,.:TOR
/ RA PD 52934
GENERATOR REGULATOR FIELD TERMINAL FILTER J
Figure 1 04— Generator Regulator
b. Installation (fig. 103).
(1) Install Generator Hinge Bolts. Place generator in mount-
ing bracket and install hinge bolts (from front). Insert front hinge
bolt through support strap as well as bracket, install standard lock
washers and nuts but do not tighten securely. See that mounting
brackets, hinge bolts and nuts are clean and free of grease, ruist or
paint so that a good ground connection will be made at these points.
200
TM 9-808
96-97
GENERATING SYSTEM
(2) Install Fan Belt and Connect Wires. Install adjusting
strap bolt and nut with one toothed lock washer under head of bolt
and another toothed lock washer under nut. Do not tighten. Put belt
in pulley and swing generator out to adjust belt (par. 82). When belt
is adjusted, tighten bolt in strap. Securely tighten nuts on hinge bolts.
Connect wires to generator as shown in figure 103, and attach wire
bracket to generator, placing one toothed lock washer under bracket
and another toothed lock washer on top of bracket.
(3) Polarize Generator (par. 95 b (3)).
97. GENERATOR REGULATOR.
a. Removal (fig. 104). Disconnect cable from battery to avoid
damage from short circuit. Disconnect wires and wire shielding
bracket from regulator. Identify or tag four wires as they are removed
to simplify installing in proper place. Remove attaching nuts and
lock washers from four mounting studs and remove regulator from
dash.
b. Installation (fig. 104). Place one toothed lock washer on each
of the four mounting studs and push washers against dash. Install
regulator assembly on mounting studs. Then place another toothed
lock washer on each stud, install attaching nuts and tighten. Place
attaching screw through wire shielding bracket, with a toothed lock
washer above and below bracket. Attach bracket to regulator body
and tighten screw. Connect four wires in proper places (fig. 104)
with lock washers under heads of terminal screws. Connect cable to
battery.
201
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98
3/4 -TON 4x4 TRUCK (DODGE)
Section XXII
IGNITION SYSTEM
Paragraph
General description 98
Ignition timing 99
Spark plugs and cables 100
Distributor 101
Ignition coil and switch 102
98. GENERAL DESCRIPTION.
a. The ignition system contains the battery, distributor, ignition
coil, spark plugs and necessary high- and low-tension wires, to com-
'DISTRIBUTOR CONDENSER
-DISTRIBUTOR DRIVE SHAFT CAM
, PRIMARY CABLE INSULATED TERMINAL
HE
T
CRANKING
MOTOR
RA PD 312560
Figure 1 05— Ignition Circuit Diagram
plete the circuit for these units of the ignition system. The complete
ignition circuit (fig. 105) consists of two separate circuits; t^'e
primary circuit and _ the secondary circuit. Briefly, these circuits
function as follows:
(1) With the ignition switch turned on and the distributbr
breaker points closed, current flows through the primary windiijg
of the ignition coil and builds up a strong magnetic field in the coil.
When the breaker points open, the primary circuit is broken, collape-
ing the magnetic field and inducing a high voltage in the secondary
202
TM 9-808
98-99
IGNITION SYSTEM
winding of the coil. This induced high voltage is distributed to the
spark plugs by the distributor cap and rotor and the high-tension
wiring between the distributor cap and spark plugs.
(2) To prevent arcing across the distributor breaker points as
they open, a condenser is connected in parallel with the points. The
purpose of the condenser is to provide a place for the primary cur-
rent to flow until the points have separated far enough to prevent an
arc across the points. The condenser brings the flow of current
through the primary circuit to a quick stop. The quick stop of the
current flow collapses the magnetic field and induces the high volt-
age necessary to provide a spark at the spark plug.
TIMING LIGHT
MINOR ADJUSTMENT LOCK SCREW
-CHALK MARK MAJOR ADJUSTMENT LOCK SCREW.
RA PD SJ937 RA PD 52938
Figure 106— Checking Ignition Figure 107— Ignition Timing
Timing Adjustments
b. Data.
Spark plugs:
Size 14 mm
Type Auto-Lite A7 or A5
Gap 0.025 in.
Distributor breaker point gap 0.020 in.
99. IGNITION TIMING,
a. Timing Specifications.
(1) . In low altitudes, gasoline of 70 octane rating will give best
engine performance with timing set at two degrees after top dead
203
TM 9-808
99-100
3/4 -TON 4x4 TRUCK (DODGE)
center. With this timing, there will be a trace of spark ping from 10
to 30 miles per hour when accelerating with wide-open throttle.
(2) When using lov^er grade fuels, or after carbon has accumu-
lated, spark ping may be excessive with the engine timed at two
degrees after top dead center. In such cases, retard the timing not to
exceed six degrees after top dead center.
(3) In high altitudes there is less tendency for spark ping, and
the same thing is true in low altitudes when using fuel with a higher
octane rating than 70. In such cases, improved performance may be
obtained by advancing the spark not to exceed two degrees before
top dead center.
(4) Within the foregoing limits, i.e., from two degrees before top
dead center to six degrees after top dead center, a good rule to follow
is to set the ignition timing at a point where a slight ping is audible
when accelerating from 10 miles per hour with wide-open throttle.
b. Checking Timing with Timing Light.
(1) Connect Timing Light (fig. 106). Connect one lead from
the timing light to a spark plug and the other lead to a convenient
ground. Place a chalk mark on crankshaft pulley at two degrees after
top dead center and run engine at idling speed. Point light at the
chalk mark on the pulley. The neon light will flash when the chalk
mark is opposite pointer over pulley, indicating position of piston
when firing occurs.
(2) Adjust Timing (fig. 107). To advance or retard the timing,
loosen the major adjustment lock screw and rotate distributor body
until correct timing is obtained. To make a minor change in ignition
timing, loosen the minor adjustment lock screw and rotate the dis-
tributor body slightly in the proper direction. Rotate distributor body
clockwise to retard, and counterclockwise to advance ignition timing.
100. SPARK PLUGS AND CABLES.
a. Adjustment of Spark Plugs. Adjust spark plug gaps to 0.025
inch with a round feeler gage. Make all adjustments on the side wire
of the plug. If the center electrode is bent, the porcelain may crack,
resulting in plug failure.
b. Installation of Spark Plugs. Use a new gasket and tighten
spark plugs with a torque-indicating wrench to 26 to 32 foot-pounds.
c. Removal of Spark Plug Cables. Unscrew suppressor from
spark plug end of cable. Raise terminal nipple and pull cable out
of distributor cap. Then pull cable through cable tube and nipple.
d. Installation of Spark Plug Cables. Slide terminal nipple,
small end first, over lower end of cable, attach terminal to lower end
of cable, then push cable through cable tube! Screw spark plug sup-
pressor on upper end of wire. Connect suppressors to spark plugs
and cables to distributor cap in the order shown in figure 117. Slide
terminal nipples down over connections at distributor cap.
204
TM 9-808
101
IGNITION SYSTEM
101. DISTRIBUTOR.
a. Adjustment of Breaker Points (fig. 108). Remove distribu-
tor cap and rotor and inspect points. If redressing is required, turn
engine until points are closed. Open points with finger and place the
contact point dresser between the points. Move the dresser back and
forth until the points are clean and excessive roughness is removed.
Turn the engine until distributor breaker point rubbing block is on
a high point of distributor cam. Loosen the lock screw and turn ad-
justing screw until the gap between the breaker points is 0.020 inch.
Tighten the lock screw and recheck the adjustment. Install distributor
rotor and cap. Breaker points may be adjusted by the "cam angle"
method if equipment is available. The cam angle is 38 degrees.
-ADJUSTABLE BREAKER POINT
\GAP .020-IN.-
BREAKER ARM SPRING CLIP AND SCREW
■ DISTRIBUTOR CAP
LOCK SCREW
DJUSTING SCREW
RA PD 52947
ROTOR
CONDENSER
RA PD 52948
Figure 1 08— Distributor Breal^er
Point Adjustment
Figure 1 09-Disfribufor Witlt
Cap and Rotor Removed
h. Removal of Breaker Points (fig. 109). Remove the distributor
cap and rotor. Remove the screw and clip which hold the condenser
lead wire and breaker arm spring to the distributor plate and lift the
breaker arm off its pivotal post. Remove the breaker point lock screw
and lift off the breaker point plate.
c. Installation of Breaker Points (fig. 108).
(1) Install Breaker Points. Place the breaker point plate over
the adjusting screw and install lock screw. Place breaker arm over
pivotal post and install screw which holds breaker arm spring and
205
TM 9-808
101
3/4 -TON 4x4 TRUCK (DODGE)
condenser lead wire to distributor plate. Put one drop of engine
oil on pivotal post:
(2) Adjust Breaker Points (subpar. a above).
(3) Adjust Breaker Arm Spring Tension. Turn the engine
until the breaker points are closed. Hook a spring scale to the point
end of the breaker arm and hold the scale at right angle to the point
surfaces. Pull the breaker points open with the scale. Adjust by
loosening the screw holding the end of the breaker point spring and
slide the end of the spring in or out of the clip so that 18 to 20 ounce
pull will be required to open the breaker points. When spring tension
has been properly adjusted, tighten screw securely and install dis-
tributor rotor and cap.
(4) Adjust Ignition Timing (par. 99).
d. Removal of Distributor Cap. Slide the terminal nipples up
the spark plug and coil cables. Pull the cables out of the distributor
cap. Unlatch the two distributor cap hold-down springs and lift off
the distributor cap.
e. Installation of Distributor Cap. Place distributor cap on
distributor body making sure that the section of the cap which is
not bored out. like the rest of the opening, registers with the notch
in the top of the distributor body. Latch the two distributor cap hold-
down springs. Place the terminal nipples on each cable and connect
the spark plug cables. Connect the cable from the coil to center of
distributor and move the terminal nipple down over connection.
f. Removal of Distributor Rotor. Unlatch the two distributor
cap hold-down springs and lift distributor cap and cable assembly
off distributor. Lift rotor straight off distributor drive shaft.
g. Installation of Distributor Rotor. Place rotor over dis-
tributor drive shaft with flat in bore of rotor registering with flat on
distributor drive shaft and push rotor into place. Place cap on dis-
tributor body so that notches register, and latch the two cap hold-
down springs.
h. Removal of Condenser. Unlatch the two distributor cap hold-
down springs and lift off distributor cap and cable assembly. Lift
rotor straight off distributor shaft. Disconnect condenser lead wire and
remove screw which holds condenser to distributor plate.
i. Installation of Condenser. Install condenser mounting screw
and connect lead wire to distributor plate. Adjust distributor breaker
arm spring tension (subpar. c (3) above). Install distributor cap
and cable assembly.
j. Removal of Distributor Assembly. Slide terminal nipples up
spark plug to coil cables, and pull cables out of distributor cap. Dis-
connect wire which runs from coil to distributor filter at the filter.
Remove distributor lock plate hold-down cap screw and lift dis-
tributor out.
206
TM 9-808
101-102
IGNITION SYSTEM
k. Installation Procedure.
(1) Set Crankshaft in Proper Position (fig. 110). Crank
engine by hand and check for compression on number one cylinder.
Hold thumb over spark plug hole while cranking or use compression
gage. When compression is indicated, turn crank until "DC" mark on
fan drive pulley registers with the pointer on the chain case. Number
one piston will then be at the top of its firing stroke.
(2) Install Distributor (fig. 111). Place distributor in position
with lock plate over hold-down screw hole. Remove distributor cap
and turn rotor until it points to about seven o'clock, then push dis-
tributor assembly down and move rotor back and forth slightly to
INDICATOR ON CHAIN CASE COVER
■DI'^TRIBUTCR LOCK riATf
"DC" MARKING ON FAN PUUEV
-LOWER ,^ p„ 52^3^
figure I T 0— Timing Mark
Location
DISTRIBUTOR ROTOR
IN SEVEN O'CLOCK POSITION
RA PD 52778
Figure 111 —Installing
Distributor
allow tongue on distributor shaft to engage in slot of oil pump drive
shaft. Install lock plate hold-down cap screw with a toothed lock
washer under head of screw. Connect coil wire to distributor filter.
(3) Install Distributor Cap and Cables (subpar. e above).
(4) Adjust Ignition Timing (par. 99).
102. IGNITION COIL AND SWITCH.
a. Removal of Coil. Disconnect, at the coil, wires which run from
filters at the dash and distributor. Disconnect the ground strap from
upper end of coil. Pull cable out of lower end of coil. Remove two
nuts which hold coil to mounting bracket studs.
207
TM 9-808
102
3/4 -TON 4x4 TRUCK (DODGE)
b. Installation of Coil. The voltage capacity of coil is shown on
the coil body. CAUTION: Be sure capacity of coil is correct for elec-
trical system of vehicle.
(1) Mount Coil on Bracket. Place coil on mounting bracket
studs and install the nuts with wire clip and standard lock washer
under nut on the outer stud and standard lock washer under nut on
the inner stud.
(2) Connect Wires and Ground Strap. Push cable which runs
to center of distributor cap into lower end of coil. Connect ground
strap to post at upper end of coil, placing toothed lock washer between
coil and strap and another toothed lock washer between strap and
nut. Connect wire which runs from filter at distributor to inner post
at lower end of coil, placing standard lock washer under nut. Place
wire which runs from filter on dash in clip at coil mounting stud and
close the clip. Then connect that wire to outer post at lower end of
coil, placing standard lock washer under nut.
c. Removal of Switch. Unscrew switch mounting nut on face of
instrument panel using screwdriver as drift to loosen ring. Disconnect
wire from switch.
d. Installation of Switch. Connect single wire from ammeter to
left post of switch with standard lock washer under nut. Connect two
wires, one which runs to radio interference filter on dash and one
which runs to fuel gage, to right post of switch (nearest throttle con-
trol button), placing standard lock washer under nut. Place switch
in instrument panel so that small lip on switch body enters notch in
panel. Screw mounting nut onto switch body, using screwdriver as
drift to tighten ring.^
208
TM 9-808
103
Section XXIII
RADIO INTERFERENCE SUPPRESSION
Paragraph
Radio interference suppression 103
103. RADIO INTERFERENCE SUPPRESSION.
a. General. When the engine of a vehicle is running, the electrical
system of that vehicle is a source of radio interference; it is actuallj"^
broadcasting radio waves in various frequencies and wave form that
interfere with the radio receiving equipment in that vehicle as well
as in nearby radio-equipped vehicles or signal apparatus. In order
to reduce such interference, vehicles covered by this manual are
equipped with a suppression system consisting of various types of
suppression units incorporated throughout the vehicle. These units are
described in the following steps:
(1) Resistor-suppressors (fig. 112). The resistor-suppressor is
a high resistant element designed to suppress ignition noise. It is
mounted securely in an insulated housing having accessible electrical
connections in both ends. Seven resistor-suppressors are installed in
the ignition circuit. Six are installed on the spark plug wires (one
at each plug) and one is installed in the high tension wire (center
terminal) two inches from the distributor cap.
(2) Filters and Condensers (fig. 112). The purpose of the
filters and condensers is to decrease interferences set up by the igni-
tion and electrical systems. Three filters are mounted in a metal hous-
ing, located on the left side of the dash above the clutch and brake
pedals. The housing is mounted with cadmium plated bolts and nuts
and toothed lock washers in direct contact with the metal of the dash.
These three filters are connected in the circuit as follows:
(a) One filter (Signal Corps Type FL-12 or 19) is located in
generator regulator battery B terminal lead to ammeter.
(b) One filter (Signal Corps Type FL-12 or 19) is located in the
ammeter lead to cranking motor terminal.
(c) One filter (Signal Corps Type FL-14 or 19) is located in the
ignition switch to coil primary circuit.
Additional filters are located as follows:
(d) One filter (Signal Corps Type FL-13) is connected in the
generator field lead to regulator at the regulator.
(e) On early model vehicles, one distributor filter (Signal Corps
Type FL-15) is mounted on the side of the distributor housing and is
connected in series with the coil primary distributor lead.
(f) One condenser (0.5 microfarad) is connected to the positive
battery terminal (12-volt battery-reconnaissance only).
(g) One condenser (0.5 microfarad) is connected from the crank-
ing motor frame to the switch terminal.
(h) One condenser (0.5 microfarad) is connected in the radio
terminal box (on Carryall only).
209
TM 9-808
103
3/4 -TON 4x4 TRUCK (DODGE)
I RESISTOR-SUPPRESSORS
CONDENSER
FILTERS
SHIELDING
BONDING (GROUND STRAP)
L-i^^
INTERNAL-EXTERNAL TEETH LOCK WASHERS
RA PD 312569
Figure 1 I 7— Radio Interference Suppression Components
210
RADIO INTERFERENCE SUPPRESSION
TM 9-808
103
BONDING WASHERS
AT NO. 2, 3, AND 4
CLIP BOLTS-
'■■
1
o
/?— '
m
1
^
n
Z
n
m
\
nO
>
)
A VN-id
-i
o
TO
4 INTERNAL-EXTERNAL TEETH LOCK WASHERS
GROUND
STRAP
RA PD 312570
figure 1 1 3— Location of Radio Interference Suppression Bonds
211
TM 9-808
103
3/4 -TON 4x4 TRUCK (DODGE)
HOOD GROUND
SIDE PANEL PADS
SPLASH
SHIELD
GROUND STRAP
FRAME
(LEFT SIDE ONLY)
HOOD SECTIONS -
GROUND STRAP -
(FRONT OF HOOD)
■ HOOD SECTIONS
(REAR OF HOOD)
DASH
GROUND STRAP
ENGINE
CYLINDER HEAD
GROUND STRAP
(CLOSED CAB MODELS)
I INTERNAL-EXTERNAL TEETH LOCK WASHERS
RA PD 312571
Figure I I 4— Location of Radio Interference Suppression Bonds
212
TM 9-808
103
RADIO INTERFERENCE SUPPRESSION
GROUND
CLUTCH PEDAL
BRACKET
ENGINE
SUPPORT
REAR
(LEFT SIDE)
UNDERBODY
(OPEN CAB MODELS EXCEPT
COMMAND-IRIGHT SIDE)
FRONT FENDER
REAR SUPPORT
ENGINE
SUPPORT
REAR
CLUTCH
HOUSING
(RIGHT SIDE)
GENERATOR CABLES SHIELDING
BATTERY
TRAY
GROUND STRAPS
UNDERBODY ■# "^^
^ FRAME
CAB HOLD DOWnL
BRACKET — >^
(OPEN CAB MODELS EXCEPT
COMMAND— LEFT SIDE)
DASH
DASH
TIE STRAP IN "CLOVE HITCH"
AROUND CONTROL CABLES
GROMMET
GROUND STRAP
FIRST TYPE
•4 INTERNAL-EXTERNAL TEETH LOCK WASHERS
SECOND TYPE
RA PD 312572
Figure I 1 5— Location of Radio Interference Suppression Bonds
213
TM 9-808
103
3/4 -TON 4x4 TRUCK (DODGE)
CONDENSER
INSTRUMENT PANEL
HEADLIGHT BEAM INDICATOR
SPLASH SHIELD
BONDING
WASHER
BLACKOUT
DRIVING
LIGHT
BONDING
WASHER
FRONT
FENDER
'INTERNAL-EXTERNAL TEETH LOCK WASHERS
RA PD 312573
figure 1 1 6— Location of Radio Interference Suppression Bonds
214
TM 9 808
103
RADIO INTERFERENCE SUPPRESSION
FLOOR AND
TOE BOARDS
MOUNTING
BRACKET
(COMMAND)
BREATHER TUBE
ENGINE CYLINDER HEAD
DASH
STARTER
PEDAL ROD
BRACKET
FUEL PUMP TO
FUEL FILTER TUBE
ENGINE FRONT SUPPORT
ENGINE
CYLINDER
HEAD
IGNITION CABLES
TUBE AND BRACKET
■ INTERNAL-EXTERNAL TEETH LOCK WASHERS
RA PD 312574
Figure 1 I 7— Location of Radio Interference Suppression Bonds
215
TM 9-808
103
3/4 -TON 4x4 TRUCK (DODGE)
GUARD FOR TRUCKS
WITH WINCH
|fi25. GUARD FOR
TRUCKS WITH-
. OUT WINCH
DASH
MAP BOARD
CHANNEL
COWL
REAR VIEW
MIRROR
1^
(OPEN CAB MODELS)
DASH
COWL VENTILATOR
BRACE
(CLOSED CAB MODELS)
^ DASH
STEERING COLUMN
BRACKET
BODY SIDE PANEL
ANTENNA h
BRUSH
GUARD
yilB
rp ENGINE FRONT
-SUPPORT PLATE
CAB HOLD DOWN BRACKET
FRAME
(EXCEPT AMBULANCE)
-♦ INTERNAL-EXTERNAL TEETH LOCK WASHERS RA PD 312575
Figure I 1 8— Location of Radio Interference Suppression Bonds
216
TM 9-808
103
RADIO INTERFERENCE SUPPRESSION
GENERATOR
BATTERY
GROUND CABLE
GENERATOR BRACKET
ENGINE
BAT TERY HAIHGERS
^SPLASH
L SHIELD
(CARRYALL)
r
BATTERY SUPPORT
PLATE
A.
(CARRY
ALL)
BATTERY COVER
X -gJ^ REAR
FENDER
(CARRYALL)
BATTERY HOLD
DOWN CLAMP
BATTERY COVER
HOLD DOV^N
BRACKET
RUNNING
BOARD (COMMAND)
RUNNING BOARD
(COMMAND)
BATTERY
COVER.
RADIATOR
SIDE SHELL
FRONT HOOD
CATCH
RADIATOR GUARD
RADIATOR SIDE SHELL
RADIATOR CORE SUPPORT
radiator core support
radiator guard
support and
side shell
'front
FENDER
==31, FRONT
^^f'^sUPPORT
BRACE
FRONT
FENDER/
FRONT SUPPORT
BATTERY
COVER
HINGE
BAHERY
SUPPORT
PLATE
(CARRYALL)
BAFMATriD rr.Di: RADIATOR GUARD
RADIATOR CORE SUPPORT AND
SUPP.ORT n n SIDE
FRONT (r^Mf—^ \»^
FENDER
FRONT SUPPORT-
J^^
BATTERY
HOLD
DOWN
CLAMP
(COMMAND)
INTERNAL-EXTERNAL TEETH LOCK WASHERS
RADIATOR CORE
CORE
SUPPORT
RA PD 312576
figure I 1 9— Cocafion of Radio Interference Suppression Bonds
217
TM 9-808
103
3/4 -TON 4x4 TRUCK (DODGE)
(AMBULANCE)
HEATER
FRAME
FRONT FENDER
(REAR END)
RUNNING
%,-^ / BOARD
■^RUNNING BOARD
HANGER
SPLASH SHIELD
RUNNING BOARD
(OPEN CAB MODELS
EXCEPT COMMAND)
SPLASH SHIELD
(REAR END)
FRAME
COWL
SUPPORT
BRACKET
.ANTENNA BRACKET
ANTENNA
BRUSH
GUARD
(CARRYALL)
SIDE PANEL
ANTENNA BRACKET
TOGGLE
BRACKET
(OPEN CAB
MODELS)
(COMMAND)
■INTERNAL-EXTERNAL TEETH LOCK WASHERS
(OPEN CAB MODELS)
COWL
WINDSHIELD
PIVOT
BRACKET
RA PD 312577
Figure 120— location of Radio Interference Suppression Bonds
218
TM 9-808
103
RADIO INTERFERENCE SUPPRESSION
(3) Shielding (fig. 112). Shielding is accomplished by encasing
wires of the electrical system in a metal braid and grounding the
braid at both ends to keep the wires and braid from radiating inter-
ference.
(4) Bonding (fig. 112). Bonding is an electrical contact of ex-
tremely low resistance, between two or more metal parts. Various
points of the vehicle are bonded by means of tinned copper braid
ground straps. These straps are fastened to their respective points by
cSdmium plated bolts and nuts or screws and toothed lock washers.
Fenders, shields and other sheet metal parts are fastened together
by means of cadmium plated fastening bolts and toothed lock
washers; these lock washers when drawn up tight "bite" into the
metal surfaces which they contact and form a good ground.
b. Servicing and Replacing Bonded Parts (figs. 113 through
120). Before replacing bonded parts, clean off all paint and dirt from
the mounting surfaces, tops and bottoms of both ends of bonds and
their placement position on the vehicle. Replace any broken or
frayed bonds. Exercise special care when replacing bonded parts to
be sure they are installed in exactly the same manner as they were
assembled before removal. Install toothed lock washers in their
original sequence and draw up mounting bolts very tight to form a
good ground. All important points of bonding are illustrated in figures
113 through 120.
219
TM 9-808
104
3/4 -TON 4x4 TRUCK (DODGE)
Section XXIV
LIGHTING SYSTEM
Paragraph
General description 104
Headlights 105
Headlight beam indicator and switch 106
Blackout parking lights 107
Blackout driving light and switch 108
Tail and stop hghts 109
Instrument lights and switch 110
Dome lights Ill
Spotlight (Ambulance) 112
Main lighting and blackout switch 113
SEALED BEAM UNIT
-CABLE CONNECTOR
■SEALED BEAM UNIT
: DOOR rSHELL
r CABLE CONNECTOR
DOOR MOUNTING'
SCREW
RA PD 52954
MOUNTING BOLT
RETAINER
MOUNTING
BOLT, NUT
AND
LOCKWASHER
RA PD 52953
Figure 1 2 1 -Installing Right
Headlight Sealed Beam Unit
Figure 1 22-Headlight
Assembly
104. GENERAL DESCRIPTION.
a. All lights, except the Ambulance dome light, operate through
the main lighting and blackout switch (fig. 127). A circuit breaker
mounted on the switch protects the lighting system against damage
caused by short circuits. The circuit breaker automatically opens
the circuit if any light wire becomes grounded.
220
TM 9-808
105
LIGHTING SYSTEM
105. HEADLIGHTS.
a. Removal of Sealed Beam Lamp-unit (fig. 121). Remove the
headlight door. Lift out the sealed beam unit and pull the cable
connector straight off. When removing the sealed beam unit in the
right headlight, loosen the mounting bolt nut and turn the headlight
away from the radiator to make the mounting screw in the door
accessible.
b. Installation of Sealed Beam Lamp-unit (fig. 121). Hold the
sealed beam lamp-unit with the word "TOP" (on the lens) up and
push the cable connector over the prongs on the lamp-unit. Place
the unit in the headlight shell so that the long lug on the unit regis-
ters with the notch at the right side of the body. Install the headlight
door and the mounting screw at the bottom. If the sealed beam unit
has been replaced in the right headlight, turn it back into position,
aim the light (subpar. e below) and tighten mounting bolt nuts.
c. Removal and Disassembly of Headlight (fig. 122).
(1) Remove Headlight and Sealed Beam Unit. Remove nut
from headlight mounting bolt and lift headlight off the fender. Re-
move the door. Pull the cable connector straight off the three prongs
of the sealed beam unit.
(2) Disconnect and Remove Wire Assembly. Remove two
screws which attach wire grommet to the fender and open clip
which holds cable assembly to the radiator shell. Disconnect the
two wires from the terminal block on frarrte front cross member.
Pull cable assembly up through the fender and slip the grommet
off the wire. Disconnect ground wire and retainer from the head-
light body and pull the cable assembly out of the back of the
light body.
d. Assembly and Installation of Headlight (fig. 122).
(1) Install and Connect Wire Assembly. Put the two wires
and loom through hole in headlight body and connect the ground
wire and retainer to the headlight body. Slide the wire grommet
over the cable assembly. Then thread the wires down through the
fender and clip on the radiator shell and connect each wire to the
terminal block that carries the same color wire at the terminal block
on the frame. Install a standard lock washer under each nut and
tighten. Close wire clip and attach grommet to fender.
(2) Install Sealed Beam Unit and Headlight. Hold the
sealed beam unit with the word "TOP" (on the lens) up and push
the cable connector over the prongs on the unit. Place the unit in
the headlight so that the long lug on the unit registers with the
notch at the right side of the body. Install the headlight door and
mounting screw at bottom of the door. Place headlight mounting
bolt through plate and fender and install toothed lock washer and
nut.
(3) Aim Headlights (subpar. e below).
221
TM 9-808
105
3/4 -TON 4x4 TRUCK (DODGE)
HEADLIGHT ADJUSTMENT SCREEN
SIGHT LINE OVER THE TOP OF TWO 36-IN. LENGTH STICKS
TO THE 36-IN. MARK ON THE HEADLIGHT ADJUSTMENT SCREEN
25-FT. HEADLIGHTS TO SCREEN
-TWO 36-IN. LENGTH STICKS
MOVABLE CORD— SET AT THE INCH MARKS ON THE CHART THREE INCHES
BELOW THE MEASURED HEIGHT OF THE HEADLIGHT CENTERS
CENTER LINE OF CHART— LINE UP WITH CENTER OF
VEHICLE BY SIGHTING PAST THE CENTER BAR OF
WINDSHIELD AND THE RADIATOR FILLER CAP
MOVABLE MARKERS-SET AT THE INCH MARKS ON THE CHART CORRESPONDING
TO THE MEASURED DISTANCE BETWEEN THE HEADLIGHT CENTERS
RA PD 312539
Figure 1 23— Headlight Aiming
e. Headlight Aiming (fig. 123).
(1) Prepare Vehicle and Screen for Aiming. Inflate all tires
on vehicle to 40 pounds pressure. Mount the headlight screen on a
movable frame and draw the screen taut on the frame. Place the
vehicle on the most level floor or surface available.
(2) Locate and Center Screen. Hang or locate the screen at
right angles to the vehicle exactly 25 feet ahead of the headlights.
Move the screen so that the heavy vertical line on the screen is
directly in line with center line of the vehicle. Sight past the center
222
TM 9-808
105-106
LIGHTING SYSTEM
bar of the windshield and the radiator filler cap to establish
alinement.
(3) Level Screen. Stand two sticks, 36 inches long, at the front
and rear wheels on one side of the vehicle. Sight over the two sticks
and adjust the screen vertically so that the 36-inch mark on the
screen is on a line with the top of the two sticks. Repeat the oper-
ation on the other side of the vehicle.
(4) Locate Correct Headlight Position on Screen. Measure
the distance from the center of the headlights to the floor and hook
the cord to both ends of the screen at the inch marks three inches
below the measured height of the headlight centers. Do not measure
height from floor to cord. Measure the distance between the head-
light centers and slide the two vertical markers on the horizontal
cord to the inch marks on the screen corresponding to the measured
distance between the headlight centers.
(5) Aim Headlights. Loosen headlight mounting bolt nut and
turn on the headlight bright beam. Cover one light and aim the
other so that the center of zone of highest intensity falls on the
screen at the intersection of the horizontal cord and the vertical
marker directly in front of the light. Tighten the headlight mounting
bolt nut securely and aim the other light in the same manner.
106. HEADLIGHT BEAM INDICATOR AND SWITCH.
a. Replacement of Lamp. Pull the socket and lamp forward
and off the body. Turn lamp counterclockwise and pull it from
socket. To install, push lamp into the socket and turn in clockwise.
Push the socket into the body.
b. Removal of Headlight Beam- Indicator Assembly. Remove
lamp (subpar. a above). Push the socket, up the wire and pull the
small tip off the wire. Then slide fiber insulator, spring and socket
off the wire. Unscrew the body from light outlet in instrument panel.
c. Installation of Headlight Beam Indicator Assembly. Insert
light outlet through instrument panel. Install tapered washer over
light outlet with the thin side up. Screw the light body into place.
Slide socket, spring, and fiber insulator, over the end of the wire.
Round up the wire tip so the wire will enter the tip. Place tip on
end of wire, pinch the tip to the wire and solder the tip to the wire.
Install socket' and lamp (subpar. a above).
d. Replacement of Headlight Beam Control Switch. Raise left
upper corner of floor mat and remove the two screws which hold
the switch to the toeboard. Pull the switch down through toeboard
and disconnect the wires. To install, hold the switch in the position
it will be installed, with the wire terminals away from the center of
the vehicle. Connect the single black wire to the rear terminal of
the switch, the red wire and brown wire to center terminal, and the
223
TM 9-808
106-108
3/4 -TON 4x4 TRUCK (DODGE)
other two wires to the front terminal. Insert switch button up
through toeboard and install the two mounting screws in the toe-
board with a toothed lock washer under the head of each screw.
107. BLACKOUT PARKING LIGHTS.
a. Replacement of Lamp. Loosen nut on mounting stud and
turn front of light away from radiator guard. Remove light door.
Remove lamp and install a new lamp, hang door in place, and
install mounting screw at bottom of the door. Turn light so that
it faces directly forward and tighten the mounting stud nut.
b. Removal of Parking Light Assembly. Slide rubber insulator
along wire and disconnect wire at connector near terminal block on
frame front cross member. Open wire clip on radiator shell and pull
wire and loom out under light. Screw the loom off the light mounting
bolt, then slide it off the wire. Remove nut from light mounting stud
and lift light off fender.
c. Installation of Parking Light Assembly. Insert mounting
stud through fender and install toothed lock washer and nut. Slide
loom over wire and screw end of . loom over mounting stud. Thread
wire and loom over fender bracket and through clip on radiator
shell and close the clip. Push wire terminal into connector and slide
the rubber insulator over the connector.
108. BLACKOUT DRIVING LIGHT AND SWITCH.
a. Removal of Sealed Beam Unit (fig. 124). Remove screw at
bottom of door and lift off door. Disconnect cable from center of
sealed beam unit and release three wire clips which hold the retain-
ing ring and sealed beam unit to'door.
b. Installation of Sealed Beam Unit (fig. 124). Place sealed
beam unit, then retaining ring in door, and spring the three retain-
ing ring clips into place. Connect cable to the sealed beam unit, hang
the door in place, and install the mounting screw at bottom of the
door.
c. Removal of Blackout Driving Light Switch. Loosen set
screw in switch button and unscrew knob from switch shaft. Remove
nut which holds switch to instrument panel. Disconnect wires from
switch.
d. Installation of Blackout Driving Light Switch. Connect wires
to switch. Put switch shaft through instrument panel and install
toothed lock washer and nut which holds switch to panel. Screw
switch knob onto switch shaft and tighten set screw.
e. Removal of Blackout Driving Light Assembly (fig. 125).
Remove mounting screw at bottom of door and lift out the door
and sealed beam unit. Then disconnect cable from the center of the
224
TM 9-808
108
LIGHTING SYSTEM
sealed beam unit. Close the clip on the end of wire loom to allow
the cable to be pulled out of the light. Remove the nut from the
light mounting bolt and lift the body off the fender.
f. Installation of Blackout Driving Light Assembly (fig. 125).
Insert light mounting bolt through fender and install a lock washer
and nut on mounting bolt. Push loom end of cable through hole in
rear of light body and spread clip so that the loom cannot slide out
of light. Connect the cable to center of sealed beam unit, hang the
door in place, and install mounting screw at bottom of the door.
Aim lamp (subpar. g below).
SEALED BEAM
UNIT RETAINING
RING CUPS
DOOR
SEALED BEAM
UNIT
RETAINING RINGi
^GROUND WIRE— REMOVED FROM
RETAINING RING TERMINAL
.CABLE (BLACK AND WHITE) REMOVED
FROM SEALED BEAM UNIT TERMINAL
RA PD 52960
figure 124— Installing Blackout
Driving Light Sealed Beam Unit
BODY
GROUND WIRE
■TERMINAL CAB;E
GROMMET
SEALED BEAM
UNIT RETAINER
RING AND CLIP
DOOR RETAINER
SCREW
FRONT FENDER
MOUNTING NUT, SPACER
AND LOCKWASHER
RA PD 52959
figure 125— Blackout Driving
Light
g. Aiming of Blackout Driving Light.
(1) Prepare Vehicle and Screen for Aiming (par. 105 e (1)).
(2) Locate and Center Screen (par. 105 e (2)).
(3) Level Screen (par. 105 e (3)).
(4) Locate Correct Light Position on Screen. Measure the
distance from the top of the opening in the light to the floor. Hook
the cord to the screen at the inch marks five inches below measured
height of the light. Do not measure height of the cord from floor.
Measure the distance from, the center of the light to the center of
the vehicle. Measure the same distance to the left of the heavy
225
TM 9-808
108-110
3/4 -TON 4x4 TRUCK (DODGE)
vertical center line on the screen and slide one of the vertical markers
along the horizontal cord to that point.
(5) Aim BLACKpuT Driving Light. Loosen blackout driving light
mounting bolt nut and turn on the light. Aim the light so that the
center of zone of highest intensity falls on the screen at the inter-
section of the horizontal cord and the vertical marker. Tighten the
light mounting bolt nut securely.
109. TAIL AND STOP LIGHTS.
a. Replacement of Sealed Beam Unit. Remove two long mount-
ing screws which hold light door in place and pull the door off the
body. Pull the sealed beam unit out to remove and push it in to
install. Place door on light body and install the attaching screws.
b. Replacement of Tail and Stop Light Assembly. The wires
are connected to the light by two bayonet-type connectors. Push
connector toward lamp, turn clockwise, then pull out. Remove two
nuts from light mounting bolts and remove the light. To install,
insert mounting bolts through light bracket and install toothed lock
washers and nuts. Push connectors into sockets and turn counter-
clockwise.
c. Replacement of Stop Light Switch. The stop light switch is
automatically operated by hydraulic pressure when the brake pedal
is depressed. The switch is mounted on the brake line tee which is
located on the inside of the frame side member just forward of the
steering gear housing. To remove, pull the two wire connections
straight up off the posts of the switch and unscrew the switch from
the brake line tee. To' install, start the threads on the switch into
the brake line tee. Then slowly depress the brake pedal a short dis-
tance to force a little brake fluid out around the threads of the
switch. While fluid is escaping, tighten the switch into place. Push
the wire connectors straight down on posts of the switch.
110. INSTRUMENT LIGHTS AND SWITCH.
a. Replacement of Lamp. Pull the assembly sharply to one
side to release its mounting prongs from the instrument panel. Pull
the socket from the light body. Then turn the lamp counterclockwise
and pull it from the socket. To install, push the lamp into the socket
and turn it clockwise. Puslj the socket into the light body. Then
push the assembly into the instrument panel' with the slot straight
down.
b. Replacement of Instrument Light Switch. Loosen set screw
in switch knob and screw knob off switch shaft. Remove nut which
holds switch to instrument panel. Then disconnect wires from switch.
To install, connect wires to switch. Insert switch shaft through the
instrument panel and install toothed lock washer and nut. Screw
knob on switch shaft and tighten the set screw.
226
TM 9-808
110-112
LIGHTING SYSTEM
c. Replacement of Instrument Light Socket. Remove lamp
(subpar. a above). Slide the socket up the wire and pull small tip
from end of wire. Then slide the fiber insulator, spring and socket
off the wire. To install, slide the socket, spring and fiber ins.ulator
over the wire. Round up the wire tip so the wire will enter the tip.
Place tip on end of wire and pinch tip to wire. Solder the tip to the
wire. Install lamp (subpar. a above).
111. DOME LIGHTS.
a. Replacement of Lamp. Remove two screws which hold glass
and bezel to the light body. Turn lamp counterclockwise and pull
out of socket. To install, push lamp into socket and turn it clock-
wise. Install cork gasket, glass and bezel.
b. Replacement of Dome Light Switch. Remove two screws
which hold switch to the instrument panel. Remove switch from
back of instrument panel and disconnect wires. To install, connect
wires to the switch. Hold the switch against instrument panel and
install the two mounting screws with the toothed lock washer under
the head of each screw.
c. Replacement of Dome Light Assembly (Ambulance). Re-
move the two screws which hold the glass and bezel to the light
body. Then remove four screws which hold the light body to the
roof. Remove lamp from socket and push body and socket up the
wire. Then cut wire off close to fiber washer and pull wire out of
light. To install, clear old wire out of hole in fiber washer. Peel
about ]/g inch insulation off the wire. Then insert the wire through .
the socket and spring. Stick the bare end of the wire through the
fiber washer and place a small drop of solder on the end of the wire.
Pull socket down over fiber washer and install the lamp. Place light
body in place in roof and install four screws. Install cork gasket,
glass and bezel on light body and install two screws.
d. Replacement of Dome Light Assembly (Carryall). Remove
screws which hold glass and bezel to light body and pull bezel
straight down off body. Then remove screws which hold body to
roof. Disconnect wire from light socket. To install, connect wire to
lamp socket. Install two screws which hold light body to roof, then
install two screws which hold glass and bezel to light body.
112. SPOTLIGHT (AMBULANCE).
a. Replacement of Lamp (fig. 126). Remove the door, lens,
bulb, and reflector, as a unit. Unhook the three springs which hold
the reflector to the door and lift the reflector and lamp away from
the door and lens. Then remove the lamp from the socket by turning
it counterclockwise. To install, place the flange of the lamp over the
three prongs of the socket and turn the lamp clockwise. Place the
227
TM 9-808
112
%
■TON 4x4 TRUCK (DODGE)
lens and reflector with gasket into the door and connect the three
retaining springs. Assemble the door, lens, lamp, and reflector, to
the body as a unit and install the door.
b. Removal of Spotlight Assembly.
(1) Remove Control Body and Grip. Remove flat head screw
directly over control grip and pull the grip down and out of control
body. Then remove the small clamp which holds the wire to the
shaft. Disconnect the wire from the main lighting and blackout
switch. Remove the terminal from the wire and pull the wire through
the instrument panel. Remove the nut and clamp bolt which holds the
control body to the shaft and pull the control body off end of shaft.
REFLECTOR SPRINGS
DOOR, LENS, BULB AND REFLECTOR
figure 1 26— Installing Spotlight Lamp (Ambulance)
(2) Remove Spotlight and Shaft. Remove screw which holds
bracket to instrument panel. Loosen clamp bolt and pull the bracket
off end of shaft. Unscrew large nut from bracket at outside of body
post and pull spotlight and shaft away from body.
c. Installation of Spotljght Assembly. If spotlight is assembled,
remove control body and grip from shaft (subpar. b (1) above).
(1) Install Spotlight and Shaft. Insert the shaft through the
body post and screw large nut into bracket on body post. If there is
misalinement, loosen the bracket from the body post. Slide inner
bracket over the shaft and install screw in instrument panel and
tighten the screws in the outer bracket if loosened. Then tighten the
228
TM 9-808
112-113
LIGHTING SYSTEM
cl-amp bolt in the inner bracket enough to hold the spotlight in any
position but still let the shaft be turned by the control grip.
(2) Install Control Body and Grip. Turn the face of the
spotlight at right angle to the shaft so that the gear racks on the
inner ends of the small control shafts are even at the ends. Slide the
control grip body over the shafts and into place so that the clamp
bolt will slide through the notch in the shaft. Push the control grip
into the control body and between the gear racks on the small control
shafts. Install tension spring and screw in top of the control grip.
Install and tighten nut on clamp bolt in the control body.
(3) Connect Wire and Wire Clamp. Insert wire through instru-
ment panel, install terminal on wire and connect wire to headlights
and taillight post of the main lighting and blackout switch (HT,
fig. 127). Install clamp which holds wire to spotlight shaft.
KNOB SET SCREWy JSl^fc,.— LOCK
CNOB — "MBm ^^^^W' C"*^
LOCK MOUNTING SCREW
SWITCH MOUNTING NUT
AND LOCK WASHER
"B" TERMINAL
"A" TERMINAL
CIRCUIT BREAKER
S- SERVICE STOP LIGHT TERMINAL— RED WITH TWO BLACK TRACERS
BS-BLACKOUT STOP LIGHT TERMINAL— YELLOW WITH TWO BLACK TRACERS
TT-TRAILER TAILLIGHTS TERMINAL- BLUE
HT— HEAD AND TAILLIGHTS TERMINAL— YELLOW OR GREEN — INSTRUMENT
LIGHT SWITCH FEED CABLE— RED- AMBULANCE SPOTLIGHT FEED
CABLE— RED
BHT— BLACKOUT HEAD AND. TAILLIGHTS TERMINAL— BLACK WITH TWO WHITE
SS— STOP LIGHT SWITCH TERMINAL— BLACK AND RED TRACERS
SW— STOP LIGHT SWITCH FEED TERMINAL— BLACK AND YELLOW
A— AUXILIARY FEED TERMINAL— AMBULANCE DOME LAMP— GREEN
B— BATTERY TERMINAL— SWITCH FEED CABLE— BROWN
RA PD 312561
¥igure 127 -Main Lighting and B/ackouf Switeli Wire Connections
113. MAIN LIGHTING AND BLACKOUT SWITCH.
a. Removal of Switch Assembly. Disconnect cable from bat-
tery to avoid damage from short circuit. Loosen set screw in switch
knob and screw knob off switch shaft. Loosen mounting screw in lock
assembly. Push lock assembly in to remove it. Unscrew mounting nut
which holds switch to panel. Disconnect all wires from switch.
Identify or tag wires as they are removed to insure proper assembly
on terminals.
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113
3/4 -TON 4x4 TRUCK (DODGE)
b. Installation of Switch (fig. 127). Connect wires to proper
terminals. Insert switch shaft through instrument panel and install
toothed lock washer and mounting nut that holds switch in place.
Push lock assembly in and install it over switch shaft with the lock
button to the left. Hold lock assembly against instrument panel and-
tighten mounting screw. Screw knob onto switch shaft and tighten set
screw. Connect battery cable to battery.
c. Removal of Circuit Breaker (fig. 127). Disconnect cable
from- battery to avoid damage from short circuit. Remove main light-
ing and blackout switch (subpar. a above). Disconnect wire from
circuit breaker. Then remove two screws which hold circuit breaker
to switch body.
d. Installation of Circuit Breaker (fig. 127). Install two screws
which hold circuit breaker to switch, placing standard lock washer
under head of each screw. Connect wire which runs from ammeter to
upper post on circuit breaker. On Ambulance model only, connect
dome light wire to lower post on circuit breaker. Install main lighting
and blackout switch (subpar. b above). Connect cable to battery.
230
TM 9-808
114-115
Section XXV
INSTRUMENTS, GAGES, AND MISCELLANEOUS
ELECTRICAL EQUIPMENT
Paragraph
General description 114
Ammeter 115
Voltmeter (Command and Carryall) 116
Oil gage 117
Thermometer 118
Speedometer 119
Horn 120
Heater (Ambulance) 121
Roof ventilator (Ambulance) 122
Trailer connector . : 123
114, GENERAL DESCRIPTION.
a. Instruments and Gages. Replacement of all instruments and
gages, mounted on the instrument panel, is described in this section,
except the fuel gage which is covered in paragraph 72. The purpose
and use of instruments and gages are explained in paragraph 5.
b. Horn. The horn circuit consists of a feed wire running from
the generator regulator to the horn, a wire from the horn to a con-
nector at the bottom of the steering gear, and up through the
steering tube and worm to the horn button on the steering wheel.
The horn circuit is completed by pressing the button, which grounds
the circuit.
c. Heater, The Ambulance is equipped with a heater, defroster,
and roof ventilator, which are operated by switches mounted on the
left side of the instrument panel. The wiring diagram (fig. 137).
shows the electrical connections for these units.
d. Trailer Connector. A trailer connector is mounted on the
rear frame cross member of some models. Provision is made in the
wiring of all models, except the Ambulance, for installation of a
trailer connector.
115, AMMETER,
a. Removal, Disconnect cable from battery to avoid damage
from short circuit. Disconnect wires from back of ammeter. Remove
two nuts which hold mounting bracket against rear of instrument
panel, and remove ammeter.
b. Installation.
(1) Install Ammeter. Place ammeter in instrument panel from
driver's side, and install the mounting bracket and round fiber disk
over the two wire posts with the legs of the bracket against the instru-
ment panel. Install a nut on each post and tighten.
231
TM 9-808
115-116
3/4 -TON 4x4 TRUCK (DODGE)
(2) Connect Wires to Ammeter (fig. 128).
(a) Six-volt System. Connect single red wire to left post of
ammeter. Connect two brown wires and one black wire to right post
of ammeter.
(b) Twelve-volt System. Connect one large red wire and one
small red wire to left post of atpmeter. Connect large black wire and
two brown wires to right post of ammeter. Put standard lock washer
under each terminal nut.
(3) Connect Cable to Battery (par. 88).
; RIGHT TERMINAL POST
- AMMETER
vLEFT TERMINAL POST
rRED WIRE-
TWO RED WIRES
ON 12-VOLT
SYSTEMS
VOLTMETER SWITCH
SWITCH TO
VOLTMETER CABLE
WIRING ASSEMBLY (BODY SECTION) ^
RA PD S2980
VOLTMETER
-MOUNTING CLAMP
VOLTMETER SWITCH FEED CABLE'
TO LEFT TERMINAL POST-
ON AMMETER
RA PD 52981
figure 128— Ammeter Terminals Figure 1 29— Voltmeter and
Switch Wiring
116. VOLTMETER (COMMAND AND CARRYALL).
a. Later production Command and Carryall vehicles are not
equipped with a voltmeter.
b. Removal of Voltmeter. Turn* voltmeter switch to "OFF"
position and disconnect single wire from meter. Remove two nuts
which hold the mounting bracket to back of the instrument panel and
remove the voltmeter from the driver's side of instrument panel.
c. Installation of Voltmeter (fig. 129). Place the voltmeter in
the instrument panel from the driver's side and install the mounting
bracket over the two studs on the meter with the legs of the bracket
against the instrument panel. Install the two attaching nuts with a
standard lock washer under each nut. Connect the wire from the
voltmeter switch.
232
TM 9-808
116-118
INSTRUMENTS, GAGES, AND MISCELLANEOUS
ELECTRICAL EQUIPMENT
d. Replacement of Voltmeter Switch (fig. 129). Remove two
screws which hold switch to the instrument panel. Remove switch
-from back of instrument panel and disconnect the two wires. To
install, connect wires to the switch. Hold the switch against instru-
ment panel and install the two mounting screws with a toothed lock
washer under the head of each screw.
117. OIL GAGE.
a. RemiGvaL Disconnect oil tube from gage. Remove two nuts
which hold mounting bracket to instrument panel and remove gage
from driver's side of instrument panel.
INSTRUMENT
'CONTROL TUBE DASH GROMMET
-COVER TYPE .r-CLAMP TYPE
BRACKET
THERMOMETER GLAND NUT
RA PD 52978
Figure 1 30— Dash Control Tube
Covers
BULB'
DO NOT DISASSEMBLE THE BULB
OR TUBE FROM THE INSTRUMENT
RA PD 52979
Figure 131 —Thermometer
h. InstaUation. Place gage in the instrument panel from driver's
side, and install the mounting bracket on the two studs on the gage
with the legs of the bracket against the instrument panel. Install the
two attaching nuts with a standard lock washer under each nut.
Connect the oil tube to the gage.
118. THERMOMETER,
a. Removal.
(1) Drain Cooling System (par. 81).
(2) Disconnect Cable from Battery (par. 88).
233
TM 9-808
118-119
3/4 -TON 4x4 TRUCK (DODGE)
(3) Remove Thermometer Bulb (fig. 131). Unscrew nut and
pull thermometer bulb from left side of cylinder head. Open the clip
which holds the tube to the cylinder head rear stud.
(4) Remove Thermometer Tube and Bracket.
(a) Vehicles Equipped with Ground Strap and Bracket (fig. 130).
Remove the two cap screws which hold the bracket to the dash and
untie the ground strap. Remove the bracket and r,ubber grommet.
(b) Vehicles Equipped with Clamp Bracket (fig. 130). Remove
the two screws which hold the upper part of the bracket to the lower
part. Remove one and loosen the other cap screw which holds the
bracket to dash and swing the lower part of bracket down.
(5) Remove Assembly. Remove two nuts which hold the mount-
ing bracket to the instrument panel. Remove assembly from the
driver's side of instrument panel.
b. Installation.
(1) Install Thermometer. Insert the bulb end of the assembly
through the instrument panel and dash from the driver's side of the
panel. Install the mounting bracket over the two studs on the ther-
mometer head with the legs of the bracket against the instrument
panel. Place a standard lock washer and nut on each stud.
(2) Install Thermometer Tube and Bracket.
(a) Vehicles Equipped with Ground Strap at Bracket (fig. 130).
Install rubber grommet over thermometer tube and control cables
and the bracket over the grommet. Tie a new bond strap to the
thermometer tube and control cables. Install the bracket to the
dash with a toothed lock washer between each end of the bracket
and the dash. Place another toothed lock washer and one end of the
bond strap over each cap screw which holds the bracket to the dash.
Install the screws and tighten securely.
(b) Vehicles Equipped with Bond Clamp (fig. 130). Swing
lower part of the bracket up into place and install cap screw with
a toothed lock washer under head of cap screw, tightening both cap
screws securely. Place upper part of bracket over thermometer tube
and control cables and install two screws with a toothed lock washer
under head of each screw.
(3) Install Thermometer Bulb. Make a loop approximately
two inches in diameter in the tube and place the looped tube in the
clip at the cylinder head rear stud and close the clip. Install the bulb
in the cylinder head and tighten the nut.
(4) Connect Cable to Battery (par. 88).
(5) Fill Cooling System (par. 81).
119. SPEEDOMETER.
a. Removal of Head. Disconnect speedometer drive cable from
speedometer. Open wire clip and move wiring assembly away from
upper wing nut on mounting bracket. Remove the two wing nuts
which hold mounting bracket to back of instrument panel and
234
TM 9-808
119
INSTRUMENTS, GAGES, AND MISCELLANEOUS
ELECTRICAL EQUIPMENT
remove the speedometer from the driver's side of the instrument
panel.
b. Installation of Head. Place the speedometer in the instru-
ment panel from the driver's side and install the mounting bracket
with the *vire clip and a plain washer on the upper stud and a
standard lock washer under each wing nut. Put the wiring assembly
in the wire clip and close the clip. Insert the squared speedometer
drive shaft into the speedometer head so that the flange on the
cable housing is against the speedometer. Then screw the connecting
nut into place.
c. Removal of Cable.
(1) Disconnect Cable from Battery (par. 88).
(2) Remove Floor Plates (par. 133 a (1) through (3)).
(3) Disconnect and Remove Cable.
(a) Early Models. Disconnect cable from transmission. Remove
clip which holds cable to underside of toeboard riser. Remove clip
which holds cable to engine side of dash and remove control cable
bracket at dash (fig. 131). Disconnect cable assembly from speed-
ometer head and remove cable assembly.
(b) Late Models. Disconnect cable from transmission. Remove
spare parts kit box under map board. Remove clips which hold
cable to driver's side of dash and frame side member. Disconnect
cable from speedometer head and remove cable assembly.
d. Installation of Cable.
(1) Connect Cable to Speedometer Head.
(a) Early Models. String cable assembly through dash, with
smaller connecting nut to driver's side. Insert square end of speeds
ometer drive shaft into speedometer head so that flange on the
cable housing is against the speedometer, then screw the connecting
nut into place. Install control cable bracket (par. 118 b (2)).
(b) Late Models. String cable assembly along driver's side of
dash and insert square end of drive shaft into speedometer head so
that flange on cable is against the speedometer, then screw connect-
ing nut into place.
(2) Connect Cable to Transmission.
(a) Early Models. Make loop in cable housing, between control
cable bracket and clip on dash, as large as possible to prevent break-
age of drive cable. Install clip which holds cable to engine side of
dash, and clip which holds cable to underside of toeboard riser.
Connect speedometer cable to transmission.
(b) Late Models. Install clips which hold cable in position on
driver's side of dash and frame cross member and connect cable to
transmission. Position cable so that it lies along top of frame side
member.
(3) Install Floor Plates (par. 133 b (8) through (10)).
(4) Connect Cable to Battery (par. 88).
235
TM 9-808
120
120.
3/4 -TON 4x4 TRUCK (DODGE)
HORN.
a. Removal of Horn. Remove cable from battery to avoid
damage from short circuit. Remove two nuts which hold wires to
terminal posts on horn. Remove two nuts which hold horn to bracket
and remove horn.
b. Installation of Horn. Insert horn mounting studs through
bracket and install a toothed lock washer and nut on each stud.
Connect horn button wire to lower post and wire from regulator to
upper post of horn. Connect cable to battery.
c. Horn Adjustment (fig. 132). Loosen the lock nut and turn the
adjusting screw counterclockwise until the motor is actuated but the
horn does not vibrate. Then turn the screw approximately J/^ turn
clockwise and tighten the lock nut.
; HORN ADJUSTING SCREW
AND LOCK NUT
rSTRING rHORN BUTTON CABLE
-RED WITH THREE
WHITE TRACERS
GREEN WIRE WRAPPED
IN BLACK TAPE
RA PD 52969
figure 1 32— Adjusting Horn
HORN BUTTON
RA PD 52970
Figure 133—lnstailing Horn
Button Cable
d. Removal of Horn Button and Wire (fig. 133). Disconnect
horn wire at the connector near bottom of steering housing, slide the
rubber insulator along the wire and pull the connector apart. Tie a
string securely to the lower end of the wire so it will be pulled into
the steering column as the wire is pulled out. The string can be used
to pull the new wire down through the column. Press down on the
horn button and turn it clockwise, release the pressure and the button
will pop out. Pull the horn wire out the top of the column and untie
the string.
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TM 9-808
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INSTRUMENTS, GAGES, AND MISCELLANEOUS
ELECTRICAL EQUIPMENT
e. Installation of Horn Button and Wire (fig. 133). If a pilot
string has been left in the steering column, run the string through the
horn button spring and tie the string securely to the end of the horn
wire and pull the wire down through the column. Place the horn
button over the spring in the steering wheel and press it down, then
turn it counterclockwise and release the pressure. Remove the string
from the lower end of the wire, push the wire connector together, and
slide the rubber insulator over the connector.
121. HEATER (AMBULANCE).
a. Removal of Heater Switch. Pull switch knob straight down
and off switch. Remove nut which holds switch to instrument panel.
Then disconnect wires from switch.
b. Installation of Heater Switch. Connect the two single wires
to the left post of the switch and the double wire connection to the
right post. (Right and left posts viewed from front of switch when
installed in vehicle.) Insert shank of switch through instrument panel
and install nut. Place the switch knob over the end of the switch
shaft so that the small boss in the hub of the knob registers with slot
in the switch shaft. Then push the knob into place.
c. Removal of Defroster Assembly. Disconnect the feed wire
from the defroster switch and disconnect the inlet and output tubes
from the defroster blower. Remove two mounting stud nuts from
engine side of dash, and remove the defroster from driver's side of
the dash.
d. Installation of Defroster Assembly. Insert the mounting studs
through the dash. Place dash ground strap over lower mounting stud,
a toothed lock washer over each stud, and install the nuts. Connect
the inlet and two output tubes to the defroster. Then connect the feed
wire to the defroster switch.
e. Removal of Defroster Switch. Pull switch knob straight down
and off switch. Remove nut which holds switch to the instrument
panel. Pull switch out of instrument panel and disconnect wires.
f. Installation of Defroster Switch. Connect the larger wire to
the left post of the switch and the smaller wire to the right post.
Insert the shank of the switch through the instrument panel and
install the nut which holds the switch in place. Place the knob over
the end of the switch shaft so that the small boss in hub of the knob
registers with the slot in the shaft, and push the knob into place.
g. Removal of Heater Assembly. Drain the radiator (par. 81).
Disconnect the feed wire from the starting switch and disconnect the
two hose from heater at engine side of dash. Remove four nuts and
bolts which hold the heater to the dash and remove the heater.
h. Installation of Heater Assembly. Insert the heater water tubes
through the dash and install the five mounting bolts with a toothed
lock washer under each nut. Connect the water hose which runs from
237
TM 9-808
121-122
3/4 -TON 4x4 TRUCK (DODGE)
front of engine to the upper tube of heater and the hose which runs
from rear of the engine to the lower tube of heater. Connect the feed
wire to the heater switch. Fill the radiator (par. 81). If water does
not circulate through heater radiator when engine is warmed up and
running, loosen hose connection at upper heater tube and allow air
to bleed out of heater radiator.
122. ROOF VENTILATOR (AMBULANCE).
a. Replacement of Switch. Remove two screws which hold
switch to the instrument panel. Remove switch from back of instru-
ment panel and disconnect wires. To install, connect wires to the
switch. Hold the switch against instrument panel and install the two
mounting screws with a toothed lock washer under the head of each
screw.
-WIRING ASSEMBLY -LOWER
TERMINAL MARKED
TERMINAL MARKED _.. . _ _
TERMINAL MARKED "GR" GREEN WIRE
TERMINAL MARKED "IL" BLUE WIRE-
RA PD 312562
figure 1 34— Trailer Connector Wiring
b. Removal of Roof Ventilator Assembly. Remove three screws
which hold the ventilator deflector to the top of the roof. Remove
eight screws which hold the ventilator assembly to the roof and lift
the ventilator out through the top of roof. After lifting the ventilator
assembly out of the roof, disconnect the feed wire from the ventilator.
c. Installation of Roof Ventilator Assembly. Connect the feed
wire to the terminal on the ventilator. Lower the ventilator into
238
TM 9-808
122-123
INSTRUMENTS, GAGES, AND MISCELLANEOUS
ELECTRICAL EQUIPMENT
opening in the roof and install the eight screws which hold the
assembly in place. Place a toothed lock washer under the head of
each screw. Install the ventilator deflector over the assembly with the
high portion of the deflector forward. Install the three attaching
screws with a toothed lock washer under the head of each screw.
123. TRAILER CONNECTOR.
a. Removal. Remove nut which holds cap to connector body.
Disconnect wire from connector. Remove four bolts and nuts which
hold connector body and cover to mounting bracket.
b. Installation.
(1) Install Connector. Place connector body through mounting
bracket with groove and drain hold down. Place cover assembly over
the top two bolt holes and install the mounting bolts, standard lock
washers, and nuts.
(2) Connect Wires (fig. 134). Connect blue wire to the upper
left post; longer green wire to the lower left post; and the short green
and black wire to the lower right post. Attach wires as follows: Place
toothed lock washer and small plain washer on the post of the
connector. Then place wire terminal and terminal shield on post and
install standard lock washer and nut. Arrange the wires so that the
terminal cap will go into place, and install toothed lock washer and
nut which hold cap to the connector body.
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124
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■TON 4x4 TRUCK (DODGE)
V
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Section XXVI
WIRING
Paragraph
Description 124
Lower wiring assembly (junction block to lights) 125
Upper wiring assembly (junction block to instrument panel) . 126
Body wiring assembly (filter to instrument panel) 127
Generator to regulator wiring assembly 128
124. DESCRIPTION,
a. General.
(1) All electrically operated units on the vehicle, except the
ignition coil and the horn, are constantly grounded to the vehicle
chassis through their mounting. The coil is intermittently grounded
to the chassis when the breaker points in the distributor are closed.
The horn is grounded when the horn button is depressed. The nega-
tive post of the battery is also constantly grounded to the chassis.
(2) A single cable, connected to the positive post of the battery,
runs directly to the feed post on the cranking motor switch. When the
switch is closed, current flows from the battery through the cranking
motor to ground. No other wiring is involved in the starting circuit.
(3) From the feed post on the cranking motor switch and the
generator regulator, single feed wires run through the radio inter-
ference filter to the ammeter. From the ammeter, single feed wires,
which are built into assemblies, run indirectly through switches to all
electrically operated units, except the cranking motor. When the
switch which controls any unit, except the cranking motor, is closed,
current flows from the battery through the ammeter, through the
switch and single wire in the wiring assemblies, then through the
unit to ground.
b. Wiring Assemblies (figs. 135, 136, 137 and 138).
(1) Upper Wiring Assembly (figs. 136 and 137). This assembly
contains a group of single-feed wires which run from the main
lighting and blackout switch, blackout driving light switch, headlight
beam indicator, and fuel gage on the instrument panel to the driver's
side of the junction block on the dash. The road lights or fuel gage
only can be affected by this wiring assembly.
(2) Lower Wiring Assembly (fig. 135). This assembly contains
a group of single-feed wires which run from the engine side of the
junction block on the dash to all road lights, headlight beam control
switch and fuel gage tank unit. The road lights or fuel gage only can
be affected by this wiring assembly.
(3) Body Wiring Assembly (figs. 136 and 137). This assembly
contains two feed wires which run from the radio interference filter
to the ammeter; also feed wires which run from the ammeter to the
241
TM 9-808
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A— NO. 14— BLACK
B— NO. U^BLUE
C— NO. 14— YELLOW
D— NO. 14— RED— BLACK TRACER
E— NO. 14— GREEN OR
NO. 12— YELLOW
F— NO. 14— BLACK AND RED
G— NO. 18— BLUE
H— NO. 14— BLACK AND YELLOW
I — NO. 16— BLUE
J — NO. 16— BLACK
K— NO. 16— RED
L— NO. 18— RED
M— NO. 16— GREEN
N-NO. 18- YELLOW
O— NO. 12— BROWN
P— NO. 10— BLACK (6 VOLT)
p_NO. 8— BLACK (12 VOLT)
Q— NO. 10-RED (6 VOLT)
Q— NO. 8— RED (12 VOLT)
R_NO. 14— BLACK
S-NO. 16— BLACK
T— NO. 12— BLUE OR
NO. 12— GREEN
U— NO. 12— BROWN
V— NO. 14— BLACK
W— NO. 16— RED
X— NO. 16— RED
Y— NO. 12 — RED
Z— NO. 12 — RED
AA— NO. 12— RED
BB— NO. 18— RED
CC— NO. 18— BLACK
DD— NO. 12— RED
RA PD 312543B
Legend for Figure 1 37— Instrument Panel Wiring
(Closed Bodies)
main lighting and blackout switch, instrument light switch, ignition
switch, fuel gage; and a wire which runs from the ignition switch to
the radio interference filter. Any electrical unit on the vehicle, except
the cranking motor, can be affected by this wiring assembly.
(4) Generator to Regulator Wiring Assembly (fig. 138).
This assembly contains two wires which run from the generator to
the generator regulator. Only the charging rate of the generator will
be affected by this assembly.
c. Words "Right" and "Left." Use of these words in this section
to designate location of wires and terminals is defined in the following
steps :
(1) "Right." The side of the vehicle opposite the driver's side
where the steering gear is mounted. For example, the use of the
words "right post of ignition switch" (par. 127 c (2) (a)) means the
post on the side of the ignition switch opposite the steering gear side
of the vehicle when the switch is installed in its normal position on
the vehicle. The word "right" is not used in this manual to refer to
positions or locations in relation to the body of the mechanic doing
the work.
(2) "Left." The driver's side of the vehicle where the steering
gear is mounted. The side opposite the right side. For example, the
use of the words "left light upper socket" (par. 125 e (2)) means the
upper socket of the taillight oh the driver's side (steering gear side)
of the vehicle when the taillight is installed in its normal position on
the vehicle. The word "left" is not used in this manual to refer to
positions or locations in relation to the body of the mechanic doing
the work.
245
TM 9-808
124
3/4 -TON 4x4 TRUCK (DODGE)
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TM 9-808
125
WIRING
125. LOWER WIRING ASSEMBLY (JUNCTION BLOCK TO
LIGHTS).
a. Description (fig. 135). The lower wiring assembly contains
only lighting system wires and a wire to the fuel gage tank unit. Feed
wires from the junction block to all road lights are built into the
assembly.
b. Removal (fig. 135).
(1) Disconnect Wires. Disconnect all wires from engine side
of the junction block. Then open wire clips on dash and steering gear
housing. Remove headlight beam control switch and disconnect wires
(par. 106). Pull wire connector straight up and off post on stop light
switch.
(2) Remove Rear Section of Wiring Assembly. Open seven
clips which hold wire assembly to frame side member. Remove fuel
tank to get to clip opposite the end of the fuel tank (par. 71). Re-
move two clips which hold right taillight wires, and two clips which
hold fuel gage wire to frame cross member. On all vehicles (except
Ambulance) open clip which holds left taillight wires to end of
frame cross member. Turn taillight wire connectors clockwise and
pull them out of lights. Disconnect ground wire from frame (all
models except Ambulance). If vehicle is equipped with a trailer con-
nector, remove cap from connector and disconnect wires.
(3) Remove Front Section of Wiring Assembly. Open clip
which holds wiring assembly to frame side member just forward of
stop light switch, and three clips which hold wiring assembly to the
frame front cross member. Disconnect wires from headlight terminal
blocks one at a time, and out wire from light back on post to facilitate
installation. Disconnect blackout parking light wires by separating
the connectors in the wires. Then remove the wiring assembly.
c. Installation (fig. 135).
(1) Install Front Section of Wiring Assembly. String the
shorter section of the assembly forward through the clip on the frame
side member and the three clips on the frame cross member and close
the clips. Connect the wires to the blackout parking lights. Connect
the headlight and blackout driving light wires to the terminal blocks
so that the color of each wire matches the color of the feed wire which
runs to the light.
(2) Install Rear Section of Wiring Assembly. String the
rear section of the wiring assembly through the eight clips on the
channel of the frame side member and close the clips. Install the two
clips which hold the right taillight wires, and two clips which hold
the fuel gage wires to the frame cross members and (all models
except Ambulance) put the left taillight wires through clip on the
end of frame side member and close the clip. Connect taillight wires.
Connect the yellow wire to right light upper socket and the black
wire to the lower socket. Connect the two red wires to the left light
upper socket and the black wire to the lower socket. If vehicle is
equipped with trailer connector, connect three wires which are taped
247
TM 9-808
125-126
%-TON 4x4 TRUCK (DODGE)
together to trailer connector and install cap. Refer to paragraph 123
for position of wires. If vehicle (except Ambulance) is not equipped
with trailer connector, tape ends of trailer connector wires separately,
then together, and place them in frame rear cross member. On all
models (except Ambulance) connect single taped ground wire to the
rear end of frame side member.
(3) Install Fuel Tank (par. 71).
(4) Connect Wires and Install Headlight Beam Control
Switch (par. 106).
(5) Connect Wires to Stop Light Switch and Junction
Block. Push connector straight down on stop lamp switch post.
CONNECT WIRES TO THE JUNCTION BLOCK TERMINAL POSTS SO THAT THE
WIRE COLORS CORRESPOND ON EACH SIDE OF THE JUNCTION BLOCK.
•WIRING ASSEMBLY— UPPER rWIRING ASSEMBLY— LOWER /"GASKET
'-JUNCTION BLOCK— DRIVER'S SIDE ^JUNCTION BLOCK— ENGINE SIDE
RA PD S2976
Figure 139— Wiring Junction B/ock
Remove two screws which hold the junction block in place and pull
the block forward a few inches. Connect the wires to the junction
block so that the color of each wire matches the color of the wire on
the other end of the block terminal (fig. 139). Install junction block
in dash. Put wire assembly in clips on dash and steering gear housing
and close the clips.
126. UPPER WIRING ASSEMBLY (JUNCTION BLOCK TO
INSTRUMENT PANEL),
a. Description (figs. 136 and 137), The upper wiring assembly
contains only light wires and the . fuel gage instrument panel unit
248
TM 9-808
126-127
WIRING
wire. No difficulty other than with road lights or the fuel gage can
occur in this assembly.
b. Removal (figs. 136 and 137).
(1) Remove Main Light Switch (par. 113 a).
(2) Disconnect Wires. Disconnect the wires of the assembly
from the main lighting and blackout switch. Disconnect wire from
fuel gage instrument panel unit. Pull socket and bulb from headlight
beam indicator and remove the bulb. Remove blackout driving light
switch (par. 108) and disconnect two wires from it. Disconnect nine
wires from junction block at driver's side of dash and remove wire
assembly.
c. Installation (figs. 136 and 137).
(1) Connect Wires to Junction Block (fig. 139). Remove two
screws which hold junction block to engine side of dash and pull
block away from dash. Insert end of wire assembly through dash and
connect nine wires to the junction block so that the color of each wire
matches the color of the wire on the other end of the terminal, then
install the junction block in the dash.
(2) Connect Wires to Switches, Headlight Beam Indicator,
AND Fuel Gage. String wiring assembly over the steering column
brace and the two longer wires, which are taped together, onto the
blackout driving light switch. Connect the two wires to the blackout
driving light switch and install the switch in the instrument panel
(par. 108). Install the' bulb in socket on the longest wire and push the
socket into the headlight beam indicator. Connect the next longest
wire to the fuel gage instrument panel unit. Connect the remaining
wires of approximately the same length to the main lighting and
blackout switch. Refer to figure 136 or 137 for proper position of
wires.
(3) Install Main Lighting and Blackout Switch (par. 113).
127. BODY WIRING ASSEMBLY (FILTER TO INSTRUMENT
PANEL).
a. Description (figs. 136 and 137). The body wiring assembly
carries current from the battery and generator through the ammeter
to the switches which control all electrical units on the vehicle, except
the cranking motor. Current furnished by the generator in excess of
the immediate demand passes back from the ammeter through this
wiring assembly and is stored in the battery.
b. Removal (figs. 136 and 137).
(1) Disconnect Battery Cable (par. 88).
(2) Disconnect Wires.
(a) All Models. Disconnect three wires from radio interference
filter on driver's side of dash and one wire from main lighting and
blackout switch. Disconnect one wire from the circuit breaker (all
models except Ambulance; two wires on Ambulance). Disconnect
single wire from fuel gage (all models except Ambulance; two wires
on Ambulance). Disconnect single wire from left side and double
249
TM 9-808
127
3/4 -TON 4x4 TRUCK (DODGE)
wire from right side of ignition switch. Disconnect single wire from
right side and group of wires from left side of instrument light switch.
Remove all instrument light lamps. Disconnect three-wire group from
right side, and single wire from left side of ammeter on all 6-volt
systems. Disconnect single wire and two groups of two wires each
from right side, and two single wires from left side of ammeter on all
12-volt systems.
- (b) Ambulance Only. Disconnect single wire from upper terminal
of roof ventilator switch and group of two wires from upper terminal
of dome light switch. Also disconnect group of two wires from heater
switch, and one wire from defroster switch.
-LARGE BLACK AND WHITE WIRE
■SMALL BLACK AND WHITE WIRE
RED AND WHITE WIRE-^ WIRING ASSEMBLY (BODY SECTION) i
-RADIO INTERFERENCE FILTER— TERMINALS ON DRIVER'S SIDE.
RA PD 52977
figure 140— Radio Interference Filter— Driver's Side
(3) Remove Wiring Assembly. Open two clips that hold wiring
assembly to steering column brace, one clip which holds assembly to
lower flange of instrument panel, and one clip at speedometer mount-
ing bracket. Then remove assembly.
c. Installation (figs. 136 and 137).
(1) Install Wiring Assembly. String wiring assembly through
two clips on steering column brace ; one clip on lower flange of instru-
ment panel and clip at speedometer mounting bracket String the
branch which runs to the right of the panel through hole in cowl
ventilator handle bracket. When assembly is in place, close all clips.
250
TM 9-808
127-128
WIRING
(2) Connect Wires.
(a) All Models. Connect large black and white wire to left post
of radio interference filter (fig. 140), small black and white wire to
center post of filter and large red and white wire to right post of
filter. Connect brown wire on upper post of circuit breaker. On
Ambulance only, connect green wire to lower post of circuit breaker.
On all models except Ambulance, connect green and white wire to
fuel gage. On Ambulance only, connect green and white, and red
and white wires to same terminal on fuel gage. Connect red wire to
main lighting and blackout switch terminal marked "HT". Connect
single brown wire to left post of ignition switch; connect black and
white, and green and white wires to right post of ignition switch.
Connect single red wire to right side, and group of black wires to left
side of instrument light switch. Install all instrument light bulbs.
(b) Six-volt System. Connect single red wire to left post of
ammeter, and connect two brown, and one black and white wires to
right post of ammeter.
(c) Twelve-volt System. Connect one large red wire, and one
small red wire to left post of ammeter; and connect large black wire,
and two brown wires to right post of ammeter. .
(d) Ambulance Only. Connect single wire to upper terminal of
roof ventilator switch. Connect wire to upper terminal of dome light
switch, pair of red wires to heater switch, and single red wire to the
defroster switch.
(3) Connect Cable to Battery (par. 88).
128, GENERATOR TO REGULATOR WIRING ASSEMBLY.
a. Removal (fig. 138). Disconnect twb wires from generator
regulator. Disconnect two wires from generator. Remove wire clips
which hold wire assembly to generator and regulator and open clip at
dash. Then remove three clips which hold the assembly to the fender.
On vehicles with 6-volt electrical systems, remove clip from battery
hold-down bolt.
b. Installation (fig. 138). String wiring assembly into place with
longer terminal on small wire to the regulator. Install three clips and
special washers which hold the assembly to the fender. Attach wire
clips to generator and regulator with toothed lock washer below and
above each clip, and close the clip at the dash. On vehicles with 6-volt
electrical system, install wire clip on battery hold-down bolt with
toothed lock washer below and above clip. Connect large wire to
center terminal strap with a standard lock washer under head of
screw. Connect small wire to lower post of regulator with a toothed
lock washer under head of screw. Connect wires to generator terminal
post with a standard lock washer under each nut.
251
TM 9-808
129-130
3/4 -TON 4x4 TRUCK (DODGE)
Section XXVII
CLUTCH
Paragraph
General description 129
Clutch pedal 130
Clutch disk and release bearing 131
129. GENERAL DESCRIPTION.
a. The clutch is the single dry plate type. A steel cover bolted to
the flywheel encloses the clutch disk, the pressure plate, the pressure
springs, and fingers. A composition facing is riveted to each side of
the clutch disk. Coiled springs assembled around the hub of the disk
absorb power shocks and torsional vibration.
OPERATING SHAFT LEVER
CLUTCH HOUSING
rRELEASE FORK
rOPERATING ROD PIN
OPERATING ROD ADJUSTING YOKE
OPERATING LEVER CLAMP SCREW
ADJUSTING YOKE LOCK NUT
OPERATING ROD
OPERATING ROD PIN
PEDAL SHAFT LEVER
PEDAL BRACKET BUSHING
PEDAL SHAFT
LUBRICANT NIPPLE
CLUTCH PEDAL BRACKET
PEDAL PULL-BACK SPRING
PEDAL CLAMP BOLT
- PEDAL STOP SCREW
CLUTCH PEDAL
PEDAL PULL-BACK SPRING BRACKET
PEDAL FREE PLAY
RA PD 52904
Figure 141— Clutch Pedal Adjustments
130. CLUTCH PEDAL.
a. Description (fig. 141). The backward travel of the clutch
pedal is limited by a stop screw so that the pedal has % inch clear-
ance between the pedal and the bottom of the floor plate. Clutch
pedal free play should be adjusted when the clutch pedal pad has
less than 1^ inch free movement from the released position to the
point where the clutch starts to release.
252
TM 9-808
130
CLUTCH
b. Adjustment.
(1) Disconnect Clutch Operating Rod (fig. 141). Remove
cotter pin and rod pin to disconnect clutch operating rod from the
clutch operating shaft lever.
(2) Adjust Location of Pedal. Loosen the lock nut on the
stop screw which is screwed into a pad on the pedal and contacts
the clutch pedal bracket. Adjust the stop screw so that the pedal
(when in the released position) has y^ inch clearance with the
bottom of the floor plate. Tighten the adjusting screw lock nut.
COAT crankshaft BUSHING WITH GREASE, GENERAL PURPOSE
CONTACT SURFACES OF FLYWHEEL AND PRESSURE PLATE CLEAN •
RA PD 52906
figure 1 42— Cleaning Clutch friction Surfaces and Lubricating
Pilot Bushing
(3) Adjust Pedal Free Play (fig. 141). Loosen the lock nut on
the clutch operating rod. Push the clutch shaft lever forward to take
up its free movement and adjust the yoke on the rod so that the pin
will slide through the clutch operating shaft lever when the clutch
pedal pad is held down lYs inches from its released position. (This
operation can be facilitated if the pedal is held down lyg inches with
a pedal jack.) Install the pin and cotter pin and tighten the yoke
lock nut. The clutch pedal pad will then have 1^ inch free move-
ment from the released position to the point where the clutch starts
to release.
253
TM 9-808
131
3/4 -TON 4x4 TRUCK (DODGE)
131. CLUTCH DISK AND RELEASE BEARING.
a. Removal.
(1) Remove Transmission (par. 133).
(2) Remove Clutch Release Bearing. Remove the six cap
screws which hold the clutch housing pin. Disconnect the spring from
the pull-back screw in the clutch housing and remove the clutch
release bearing and sleeve.
(3) Remove Clutch Disk. Remove the clutch cover to flywheel
cap screws. Loosen the screws a turn or two at a time to avoid dis-
torting the cover. Remove the clutch cover and pressure plate
assembly and clutch disk from the clutch housing.
ENGINE
FLYV/HEEL
CLUTCH COVER
ASSEMBLY
CLUTCH DISK AUNING TOOL RA PD 312563
figure 1 43— Installation of Clutch Disk
b. Cleaning of Parts (fig. 142). The clutch release bearing is
packed with lubricant and sealed when manufactured and no further
lubrication is required. CAUTION: Never wash clutch release bear-
ing in kerosene, gasoline, or other dry-cleaning solvent which would
dissolve the lubricant in the bearing. Keep oil and grease off friction
surfaces of clutch parts to avoid chattering and grabbing of clutch.
c. Installation.
(1) Install Clutch Disk. Coat the bushing in the end of the
crankshaft with general purpose grease No. 2 (fig. 142). Wipe the
contact surfaces of the flywheel and pressure plate thoroughly with
254
TM 9-808
131
CLUTCH
a clean dry cloth, to make certain that the surfaces are clean and
free from oil. Hold the clutch cover and disk in place and install the
cover attaching cap screws with lock washers, but do not tighten.
(2) Aline Clutch Disk (fig. 143). Center the clutch disk with
the clutch alining tool. Tighten the clutch cover cap screws, a turn
or two at a time to avoid distorting the cover. Finally tighten the
screws to 15 to 20 foot-pounds. Remove the clutch alining tool.
(3) Install Clutch Release Bearing. Install the clutch release
bearing and sleeve and connect the spring to the pull-back spring
screw in the clutch housing. Install the cap screws with Ipck washers
for the clutch housing pan.
(4) Install Transmission (par. 133).
(5) Adjust Clutch Pedal Free Play (par. 130).
255
TM 9-808
132-133
3/4 -TON 4x4 TRUCK (DODGE)
Section XXVIII
TRANSMISSION AND POWER TAKE-OFF
Paragraph
General description 132
Transmission ° 133
Power take-off control linkage 134
132. GENERAL DESCRIPTION.
a. The transmission is known as a four-speed, selective sliding
gear type. Its purpose is to provide different gear ratios for forward
motion of the vehicle and a means of reversing the motion of the
vehicle. A power take-off assembly is mounted on the side of the
transmission case and provides a means of taking power from the
engine to operate the winch on the Weapon Carrier (model WC-52)
and Command (model WC-57).
133. TRANSMISSION.
a. Removal of Transmission Assembly (fig. 144).
(1) Remove Floor Mat (Ambulance Only). Tilt the attend-
ant's seat forward and remove the four cap screws from the seat
support brackets. Raise the driver's seat to its highest position and
tilt forward. Remove the seat adjusting mechanism to floor cap
screws. Remove the cotter pin and pin from the accelerator pedal
at the accelerator pedal rod. Remove the floor mat front section.
Remove the center and two end linoleum retainer angles, remove the
screws from the floor mat and lift out the mat.
(2) Remove Left Floor Plate. Remove the clutch and brake
pedal draft pads and retainers. Remove the left floor plate screws and
lift out the floor plate.
(3) Remove Right Floor Plate. Disconnect the throttle control
spring from the clip on the accelerator shaft to throttle bell crank
rod, located under the hood at the right rear side. Remove the right
floor plate screws and lift out the floor plate.
(4) Remove Center Floor Panel. Remove the cotter pin and
yoke pin from the shifter lever end plate, also the cotter pin from
the shifter shaft eyebolt pin where it is attached at the power take-
off control lever. Lower the control lever down through the opening
in the floor panel. Remove the cotter pin and pin from the accelerator
pedal rod at the pedal. Remove the center floor panel cap screws.
Move the hand brake lever and transfer case control lever into posi-
tion so that the center panel can be lifted out.
(5) Disconnect Winch Drive Shaft. Remove the lock wire and
loosen the set screw which holds the drive shaft collar on the drive
shaft just ahead of the splined yoke at power take-off. Remove the
lock wire and loosen the set screw which holds the rear universal
joint assembly on the power take-off drive shaft. Slide the collar and
256
TM 9-808
133
TRANSMISSION AND POWER TAKE-OFF
I — POWER TAKE-OFF ASSEMBLY WITH CONTROL LEVER REMOVED
TRANSMISSION TO CLUTCH HOUSING SCREWS— UPPER
CONTROL ROD TO LEVER CLEVIS PIN^ i — MUFFLER
PROPELLER SHAFT ASSEMBLY ' SPEEDOMETER CABLE
TRANSMISSION TO CLUTCH HOUSING SCREWS— LOWER
FRAME INTERMEDIATE CROSSMEMBER
WINCH DRIVE SHAFT REMOVED FROM POWER TAKE-OFF ASSEMBLY
RA PD 312564
Figure 1 44— Removal of Transmission
257
TM 9-808
133
3/4 -TON 4x4 TRUCK (DODGE)
the universal joint assembly forward on the drive shaft. This will
disengage the joint assembly from the power take-off drive shaft.
Lower the shaft until it rests on the front axle housing.
(6) Disconnect Transfer Case Control Rod and Speedom-
eter Cable. Remove the cotter pin from the transfer case control
rod clevis pin at the transmission end and remove the clevis pin. Let
the rod drop down out of the way. Disconnect the speedometer cable
and housing assembly from the transmission.
(7) Loosen Frame Cross Member (Except Ambulance). Re-
move the four bolts and nuts that attach the rear gusset to the inter-
mediate frame cross member and left frame side rail. Also remove
the two cross member to front gusset bolts and nuts. Remove the two
bolts and nuts that attach the cross member to the upper flange of
the left frame side rail. Remove the two bolts and nuts that attach
the cross member to the upper flange of the right frame side rail.
Remove the two large bolts and nuts from cross member to right
frame side rail. Move the cross member toward the rear axle as far
as possible.
(8) Disconnect Propeller Shaft. Open the universal joint
clamp bolt nut locks. Remove the nuts from the universal joint clamp
bolts. Remove the bolts and locks, then the universal joint clamps.
Slide the splined yoke on the shaft as far as it will go to disengage
from transmission.
(9) Remove Transmission. Remove the two upper transmission
to clutch housing cap screws. Insert pilot studs in the two upper
holes and screw studs in place. (Pilot studs can be made by sawing
the heads from two %<; inch— 12 x 13/^ inch— cap screv/s and slotting
the ends with a hack saw so that a screwdriver can be used to screw
the studs in place.) Remove the two lower cap screws which hold the
transmission to the clutch housing. Place a jack under the transmis-
sion to support it and move the transmission rearward sufficiently to
pull the transmission main drive pinion out of the clutch disk. Lower
transmission to the floor. Care must be exercised to prevent trans-
mission dropping down and springing the clutch assembly.
b. Installation of Transmission Assembly (hg. 144).
(1) Install Transmission. Use the pilot studs installed when the
transmission was removed to help guide the main drive pinion
straight through the clutch disk hub splines and into the pilot bush-
ing in the end of the crankshaft. Support the transmission with a
jack to prevent damaging the clutch assembly. Install the lower
transmission to clutch housing cap screws with lock washers and
tighten. Remove the two pilot studs from the upper holes. Install the
cap screws with lock washers and tighten.
(2) Connect Propeller Shaft. Place the universal joint clamos
in position, install the clamp bolt locks on the bolts and install the
bolts in the universal joint. Place new clamp bolt nut locks on the
bolts, then install the nuts and tighten to 20 to 25 foot-pounds. Bend
over the lugs of all the clamp bolt locks and nut locks.
258
TM 9-808
133
TRANSMISSION AND POWER TAKE-OFF
(3) Attach Frame Cross Member (Except Ambulance). Move
the cross member into position and insert the four small bolts which
attach the cross member to the upper flanges of the frarrie side rails.
Jnstall lock washers and nuts but do not tighten the nuts. Assemble
the rear cross member to frame gusset to the cross member with two
of the large bolts and nuts with lock washers, also the two large
bolts and nuts with lock washers, to attach the cross member to the
front gusset. Install the two rear gussets to frame side rail bolts and
nuts with lock washers, also the two large bolts and nuts with lock
washers, attaching the cross member to the right frame side rail.
Tighten all bolts and nuts securely.
(4) Connect Speedometer Cable and Transfer Case Con-
trol Rod. Insert the speedometer cable drive shaft in the transmis-
sion main shaft rear bearing retainer. Make sure the cable engages
with the drive pinion before the retaining nut is screwed into place.
Tighten the cable housing nut. Attach the transfer case control rod
to the control lever on the transmission and insert the clevis pin.
Lock the clevis pin with a cotter pin.
(5) Connect Winch Drive Shaft. Make sure the power take-
off drive shaft key is in place. Slide the drive shaft joint assembly
onto the power take-off drive shaft. Tighten set screw which holds
the universal joint assembly on the power take-off drive shaft. Place
a new wire through the head of the set screw and lock it around the
joint. Set the drive shaft collar from ^ to ^ inch ahead of the splined
yoke. Tighten the set screw. Place a new wire through the head of the
set screw and lock it around the collar.
(6) Fill Transmission with Lubricant. Remove the transmis-
sion filler plug and fill the transmission to I/2 inch below the level
of filler hole with universal gear lubricant (par. 24). Use seven pints
if vehicle is equipped with power take-off and 5^4 pints if not
equipped with power take-off. Install filler plug.
(7) Install Center Floor Panel. Lower the center floor panel
into position over gearshaft lever, hand brake, and transfer case
levers. Install the cap screws with toothed lock washers and tighten.
Slide the end of the power take-off control lever up through the open-
ing in the center floor panel and hold it in position. Install the yoke
pin and cotter pin at the shifter lever end plate, also the cotter pin
with plain washer in the shifter shaft eyebolt pin. Install the pin and
cotter pin which attach the accelerator pedal to the accelerator pedal
rod.
(8) Install Right Floor Plate. Lay the right floor plate in
place and install the screws with toothed lock washers. Connect the
throttle control spring to the clip on the accelerator shaft to throttle
bell crank rod.
(9) Install Left Floor Plate. Lay the left floor plate in place
and install the screws with toothed loCk washers. Install the clutch
and brake pedal draft pads and pad retainers. Tighten the screws
with toothed lock washers.
259
TM 9-808
133-134
3/4 -TON 4x4 TRUCK (DODGE)
(10) Install Floor Mat (Ambulance Only). Place the rear
section of the floor mat in position and install the screws with plain
washers. Install the center and two end linoleum retainer angles.
Work the front section of the floor mat into place so that the open-,
ings in the mat will slide down over the gearshift, hand brake, trans-
fer case levers, and accelerator pedal. Attach the accelerator pedal
to the accelerator pedal rod. Install floor mat screws. Position the
driver's seat so that it is raised to its highest position and install the
cap screws with lock washers. Install the one short cap screw in the
right rear screw hole of the seat adjusting mechanism. Place the
attendant's seat in position in the cab and tilt it forward. Install the
seat support bracket cap screws with lock washers.
•POWER TAKE-OFF ASSEMBLY
ONTROL LEVER
EVER TO
SHIFTER SHAFT
CLEVIS PIN
SHIFTER SHAFT EYE BOLT
LOCK NUT
RA PD 52985
Figure 1 45— Power Take-off Control Lever and Linkage
134. POWER TAKE-OFF CONTROL LINKAGE.
a. Removal of Control Lever (fig. 145). Remove the cotter pin
and clevis pin from the control lever end plate, also the cotter pin
from the shifter shaft clevis pin where it is attached at the power
take-off control lever. Pull the control lever down through the open-
ing in the floor panel.
b. Installation of Control Lever (fig. 145). Slide the end of the
power take-off control lever up through the opening in the center
floor panel and hold it in position. Install the clevis pin and cotter
pin at the control lever end plate, also the cotter pin with plain
washer in the shifter shaft clevis pin.
260
TM 9-808
134
TRANSMISSION AND POWER TAKE-OFF
f. Adjustment of Control Lever Linkage (fig. 145).
(1) Whenever the control lever is replaced, adjust the location of
the neutral position control lever lock on the center floor panel or the
eyebolt in the end of the shifter shaft so that the power take-off will
be in neutral, and the shifter shaft poppet ball indexed with the
indent in the shifter shaft when the control lever is locked in the
neutral position.
(2) If the control lever lock cannot be locked without moving the
control lever out of the neutral position, loosen the control lever lock
cap screws, and move the lock forward or to the rear on the elongated
holes. Adjustment can also be made at the shifter shaft eyebolt.
Remove control lever. Loosen eyebolt lock nut. Turn eyebolt clock-
wise to adjust control lever rearward and counterclockwise to adjust
control lever forward. Tighten lock nut and install control lever.
261
TM 9-808
135-136
3/4 -TON 4x4 TRUCK (DODGE)
Section XXIX
TRANSFER CASE
Paragraph
General description 135
Control lever and linkage 136
Transfer case assembly 137
135. GENERAL DESCRIPTION.
a. The transfer case is located back of the trsnsmission. It is con-
nected with the transmission by means of a short propeller shaft
through which power is transmitted from the engine. The transfer
case transmits the engine power to the front and rear axles by means
r TRANSFER CASE CONTROL ROD
CONTROL HAND LEVER
Z^S^LEVIS Pl^
CONTROL ROD
YOKE
'■ TRANSFER CASE SHIFT RAIL /CONTROL HAND LEVER SHAFT AND BRACKET
RA PD 52987
Figure 1 46— Transfer Case Control Lever and Linkage
of the propeller shafts. It is in constant mesh for transmitting power
to the rear axle and a means is provided whereby the drive to thq
front axle can be engaged or disengaged by a control lever in the
driver's compartment (par. 5).
136. CONTROL LEVER AND LINKAGE.
a. Removal (fig. 146). Remove the cotter piri and clevis pin
from the front end of the control rod yoke at the control rod hand
262
TM 9-808
136-137
TRANSFER CASE
lever and the cotter pin from the transfer case control rod at the
transfer case. Remove the cotter pin from the control lever bracket
shaft. Remove three cap screws that hold the control lever bracket
to the transmission. Lower lever and bracket and slide lever off
bracket. Loosen the control rod yoke lock nut and unscrew the yoke
from the rod.
b. Installation (fig. 146). Insert the control rod end in the shift
rail at the transfer case and install the cotter pin. Screw the yoke on
the control rod up to the lock nut. Slide the control lever onto the
control lever bracket shaft. Install the three cap screws and lock
washers that hold control lever bracket to transmission. Place the
plain washer on the shaft and install the cotter pin. Position the
control lever with the control rod yoke and install the clevis pin.
c. Adjustment of Linkage.
(1) When the control hand lever is shifted to the engaged or dis-
engaged positions, the shift rail poppet ball must index with the
indent on the shift rail to prevent disengagement of the front axle
drive. If the control lever can be shifted to the engaged or disengaged
positions without the control lever striking the ends of the lever
opening in the floor panel, the adjustment is satisfactory.
(2) To adjust, loosen the lock nut, remove the cotter pin and
clevis pin from the yoke at the control lever. Then turn the yoke on
the control rod clockwise to shorten the rod, or counterclockwise to
lengthen the rod for correct adjustment of control lever. Install clevis
pin and cotter pin and tighten lock nut.
137. TRANSFER CASE ASSEMBLY.
a. Transfer Case Misalinement. The transfer case may become
misalined due to severe shock, contact with stumps, stones, banks of
streams, or other obstructions. Transfer case misalinement often
causes the propeller shaft spline to be partially withdrawn from the
propeller shaft companion yoke spline, causing propeller shaft whip
and /or destructive wear of the propeller shaft splines and propeller
shaft compound yoke splines.
(1) Checking Misalinement. Transfer case misalinement may
be determined by measuring the front propeller shaft from the center
of the rear universal joint cross bearing to the center of the front
universal joint cross bearing. The correct measurement is 34 inches.
If the dimension varies more than plus ^ inch or minus % inch,
check the front axle for alinement (par. 141). If the front axle aline-
ment is correct, the transfer case is misalined. Notify higher authority.
b. Removal.
(1) Disconnect Propeller Shafts. Open the universal joint
clamp bolt nut locks. Remove the nuts from the universal joint clamp
bolts. Remove the bolts and locks, then the universal joint clamps.
(2) Disconnect Control Rod. Remove cotter pin from the
transfer' case control rod at the transfer case, and the cotter pin and
clevis pin from the control lever end of the control rod.
263
TM 9-808
137
3/^ .TON 4x4 TRUCK (DODGE)
(3) Remove Transfer Case. Remove the lock wires from the
four cap screws which attach the transfer case .to the mounting
brackets. Support the transfer case with jack to prevent personal
injury. Remove the four transfer case to mounting bracket cap screws.
c. Installation.
(1) Install Transfer Case. Place the transfer case under the
vehicle and raise it into position with jack. Install the transfer case
to frame bracket cap screws and lock washers. Lock the screws in
place with a piece of wire.
■ (2) Connect Propeller Shafts to Transfer Case. Place the
universal joint clamps in position, then install the clamp bolt locks on
the bolts, and install the bolts in the universal joint. Place new clamp
bolt nut locks, then install the nuts and tighten to 20 to 25 foot-
pounds. Bend over the lugs of all the clamp bolt and nut locks.
(3) Connect Control Rod. Insert the control rod end in the
shift rail and install the cotter pin. If it is necessary to adjust the
control rod, refer to paragraph 134 for procedure.
(4) Fill Transfer Case with Lubricant. Remove the transfer
case filler plug and fill with lubricant to y^ inch below filler opening,
with transfer case and lubricant at room temperature (70°F) (par.
24). Do not overfill, as this will cause overheating and leakage of
lubricant.
264
TM 9-808
138-139
Section XXX
PROPELLER SHAFTS
Paragraph
General description • 138
Propeller shafts 139
138. GENERAL DESCRIPTION.
a. Three propeller shafts are used in each vehicle: One extends
from the transmission to the transfer case; one from the transfer case
to the rear axle; one from the transfer case to the front axle. Each
propeller shaft has one universal joint that slides on the splined end
of the shaft, and one that is welded to the other end of the shaft (fig.
147).
TRAN.SMISSION ASSEMBLY
SPLINE YOKE
■ INTERMEDIATE PROPELLER SHAFT ASSEMBLY
UNIVERSAL JOINT ^re^R AXLE ASSEMBLY
■ TRANSFER CASE ASSEMBLY
SPLINE YOKE
SPLINE YOKE
■ FRONT PROPELLER SHAFT ASSEMBLY
UNIVERSAL JOINT
'FRONT AXLE ASSEMBLY
UNIVERSAL JOINT
RA PD 52990
Figure 1 47— Propeller Shafts and Universal Joints
139. PROPELLER SHAFTS.
a. Removal (fig. 148). Open the universal clamp bolt nut locks.
Remove the nuts from the universal joint clamp bolts. Remove the
bolts and locks, then the universal joint clamps. Open the universal
clamp bolt nut locks on the universal joint at the other end of the
shaft. Remove the nuts from the universal joint clamp bolts. Remove
the bolts and locks, then the universal joint clamps. Remove the
assembly from the vehicle.
265
TM 9-808
139
3/4 -TON 4x4 TRUCK (DODGE)
PROPELLER SHAFT
COMPANION FLANGE
PROPELLER SHAFT ASSEMBLY
UNIVERSAL JOINT BUSHING CLAMP BOLTS, NUTS AND LOCKS
RA PD 52989
Figure 1 48— Disconnecting Propeller Shaft
aunement arrows— -
stamped on spline- yoke
and propeller shaft
RA PD 312565
figure 1 49— Propeller Shaft Alinement Arrows
266
TM 9-808
139
PROPELLER SHAFTS
b. Installation.
(1) Install Spline Yoke (fig. 149). Coat the splines of the
propeller shaft with general purpose grease and slide the universal
joint and spline yoke assembly onto the propeller shaft. Make sure
that the two arrows, one on the splined yoke and the other on the
propeller shaft, point directly toward each other so that the yokes
at the ends of the propeller shaft are in alinement. If the yokes are
not alined with each other,' failure of the joints or shaft will result.
(2) Install Universal Joint Clamps (fig. 148). Lift the pro-
peller shaft assembly in place. Place the universal joint clamps in
position. Install the clamp bolt locks on the bolts and install the
bolts in the universal joint. Place the clamp bolt nut locks on the
bolts, then install the nuts and tighten to 20 to 25 foot-pounds. Bend
over the lugs of all the clamp bolt locks and nut locks.
267
TM 9-808
140-141
3/4 -TON 4x4 TRUCK (DODGE)
Section XXXI
FRONT AXLE
Paragraph
General description 140
Front wheel alinement 141
Front wheel bearings 142
Universal drive shaft bushings and oil seals 143
Steering arm and tie rod .^ 144
Front axle assembly 145
140. GENERAL DESCRIPTION.
a. The front axle as well as the rear axle is a driving unit. The
front axle drive shafts have universal joints at the steering knuckles
through which power is transmitted to the wheels. It is of the full-
floating type so that only the torque or driving power is carried by
the axle drive shafts. The differential and carrier assembly in the
front axle is identical with that used in the rear axle.
b. The differential lubricant is confined to the differential and
drive pinion sections of the axle housing by the drive pinion bearing
oil slinger, the drive pinion oil seal, and the universal drive shaft oil
seal. The universal drive shaft joint lubricant is retained in the uni-
versal joint and steering knuckle housings by the trunnion socket
bushing and the steering knuckle bushing. Wheel bearing lubricant
is retained by the front wheel bearing oil seal.
141. FRONT WHEEL ALINEMENT.
a. General. Front wheel alinement is governed by four factors
commonly known as camber, king pin angle, caster, and wheel toe-in.
(1) Camber and King Pin Angles. The correct camber and king
pin angles are built into the front axle and will change only if the
axle housing or steering knuckles are distorted by accidental damage.
Therefore, no adjustments are provided.
(2) Caster. Caster is governed by the chassis springs and the
mounting of "the front axle to the front springs. Correct caster is
established by design and will be changed only by shifting of the
front axle on the springs or by distortion of the chassis frame or
springs or by the use of caster shims. No adjustment of caster is
provided."
(3) Toe-in. Front wheel toe-in is the most important factor in
front wheel alinement. It is governed by the angle of the steering
knuckle arms and the length of the steering tie rod. Inasmuch as
wheel toe-in can be accidentally altered without serious damage to
the vehicle, an adjustment is provided so that the tie rod may be
lengthened or shortened to maintain correct front wheel toe-in of
to i/^ inch (i/ie in. preferred).
268
TM 9-808
141
FRONT AXLE
b. Checking and Adjusting Toe-in.
(1) Check Toe-in (fig. 150). With the front wheels in a straight
forward position, move the vehicle at least three feet forward to get
the tires in free rolling condition. Place the wheel alinement gage
between the tires forward of the axle with both pendant chains barely
touching the floor. Set the scale so that the pointer registers with
zero. Move the vehicle forward until the gage is back of the axle with
the pendant chains barely touching the floor, and read the gage. The
amount the scale has moved in relation to the pointer will indicate the
amount of wheel toe-in or toe-out. Since toe-out is never deisirable,
the gage is calibrated in inches for toe-in only.
PONTER aT "C i-WHEEL ALINEMENT GAGE \
ENDS OF PENDENT CHAINS JUST TOUCHING THE FLOOR -i
RA PD 52992
figure 1 50— Front Wheel Toe-in Adjustment
(2) Adjust Toe-in (fig. 151). Remove cotter pin and nut which
hold the left tie rod end to the steering knuckle arm. Insert a pinch
bar between the tie rod end and the arm and strike the arm with a
hammer. Loosen tie rod end clamp bolt. Turn tie rod end clockwise
to shorten tie rod and decrease toe-in, or counterclockwise to lengthen
tie rod and increase toe-in. After each adjustment of tie rod length,
install tie rod end to the steering knuckle arm, and recheck the wheel
toe-in. When correct toe-in adjustment has been made, tighten the
tie rod clamp bolt. Install nut and cotter pin which hold the tie rod
end to the steering knuckle arm, and tighten securely.
269
TM 9-808
141-142
3/4 -TON 4x4 TRUCK (DODGE)
c. Front Wheel Turning Radius.
(1) General. Ability to maneuver the vehicle in close quarters
and the life of the front axle universal drive assemblies depend upon
correct turning radius being maintained. It is desirable that a vehicle
turn in as small a circle as is practicable ; however, if the inside wheel
(when on a turn) is turned more than 28 degrees from a straight for-
ward position, the front axle universal drive assemblies may be
damaged. Turning radius is governed by stop screws which are ad-
justed, then tack-welded, to the steering knuckle arms. If inspection
shows the screw to be loose or missing, notify higher authority.
s^ACK OFF NUT BUT DO NOT REMOVE UNTIL TIE ROD END HAS BEEN PRIED LOOSE
\P BOLT, NUT AND LOCKWASHER
tSTEERING KNUCKLE TIE ROD
END ASSEMBLY— LEFT
RA PD 52993
Figure 15 1 — Removing Steering fCnuck/e Tie Rod End
142. FRONT WHEEL BEARINGS.
a. Adjustment of Front Wheel Bearings.
(1) Remove Drive Flange from Wheel Hub (fig. 152). Place
a jack under the axle housing and raise wheel until tire clears the
ground. Remove the six stud nuts which hold the drive flange to the
wheel hub. Remove two flange puller screws from a rear axle shaft
flange, remove the lock nuts from the screws, and use the screws to
pull the drive flange off the hub.
(2) Adjust Bearings (fig. 153). Remove the wheel bearing outer
adjusting nut and the adjusting nut lock. Turn the inner adjusting
nut tight to seat the bearings and then back it off about one-sixth of
a turn. Wheel should rotate freely with no end play. Install the
270
TM 9-808
142
FRONT AXLE
adjusting nut lock, making sure that the dowel pin in the inner ad-
justing nut enters a hole in the lock. It may be necessary to turn the
lock over or even turn the inner adjusting nut slightly to permit the
dowel pin to enter one of the holes in the lock. With the lock over
the dowel pin, install the outer adjusting nut and tighten it securely.
(3) Install Drive Flange. Remove flange puller screws from
flange and install the screws and lock nuts in rear axle drive shaft
flange. Place the drive flange over the splines of the drive shaft and
over the studs in the wheel hub. Install the flange attaching nuts
with a standard lock washer back of each nut and tighten the nuts
securely. Remove the jack from under axle housing.
•PULLER SCREWS- REMOVED FROM
REAR AXLE DRIVE SHAFT FLANGE.
-WHEEL BEARING ADJUSTING
NUT WRENCH
-LOCK
-NUT-OUTER
■ FLANGE GASKET
-DRIVE SHAFT FLANGE
Figure 1 52— Removing Drive
Flange
Figure 1 53— Adjusting Front
Wheel Bearing
b. Removal of Front Wheel Bearings and Oil Seal. Before
removing the wheel bearings or oil seals, put a new wheel bearing
oil seal in thin oil and allow it to soak while the following operations
are being performed.
(1) Jack Up Wheel. Raise wheel with jack and place stand
under axle housing.
(2) Remove Axle Drive Flange (subpar. a (1) above).
(3) Remove Wheel and Tire Assembly (par. 163).
(4) Remove Wheel Hub and Bearings (fig. 154). Turn the
brake shoe adjusting cams to increase the clearance between the
brake shoes and the drums (par. 151). Remove wheel bearing outer
271
TM 9-808
142
3/4 -TON 4x4 TRUCK (DODGE)
adjusting nut, adjusting nut lock, and inner adjusting nut with wheel
bearing adjusting nut wrench. Remove the wheel outer bearing and
pull drum, hub, and wheel inner bearing from steering knuckle.
(5) Remove Oil Seal, Cone and Cups (fig. 154). Remove wheel
bearing oil seal snap ring from inner end of hub. Remove wheel bear-
ing inner cone and oil seal from hub by driving against the hub of
the bearing cone. Drive inner and outer bearing cups from hub.
c. Installation of Front Wheel Bearings and Oil Seals.
(1) Install Wheel Bearings and Oil Seal (figs. 155 and 156).
Install inner and outer bearing cups in hub, thick edge first. Pack
DRIVE flange AND GASKET
FRONT V/HEEL BEARING
CONE-OUTER
FRONT WHEEL BEARING ADJUST
ING NUT AND PIN— INNER
FRONT V^'HEEL BEARING ADJUST
ING NUT LOCK
FRONT V^HEEL BEARING ADJUST
ING NUT- OUTER
HUB AND BRAKE DRUM
ASSEMBLY
FRONT WHEEL BEARING
OIL SEAL
FRONT WHEEL BEARING
CONE— INNER
FRONT WHEEL BEARING
OIL SEAL SNAP RING
Figure 1 54— Removing Front Wheel Inner Bearing and Oil Seal
the wheel inner bearing cone with wheel bearing grease and place the
bearing cone in the bearing cup. Work the oil seal, after soaking in
thin oil, by rolling with pressure applied by a smooth bar. Drive the
seal in the hub with oil seal drift just far enough so that the oil seal
snap ring can be installed, to prevent interference with the bearing.
(2) Install Hub and Drum and Adjust Brake Shoes. Clean
the steering knuckle and inspect the oil seal bearing surface. Remove
any roughness that may exist on that surface. Slide the hub and drum
straight onto the steering knuckle. Exercise care to prevent damage
to oil seal. Pack the outer bearing cone with wheel bearing grease and
install the bearing and inner bearing adjusting nut on the steering
knuckle. Adjust the wheel bearings (subpar. a (2) above). Turn brake
272
TM 9-808
142-143
FRONT AXLE
shoe adjusting cams until brake drags and then back off just enough
to free the drum.
(3) Install Wheel and Tire Assembly (par. 163).
(4) Install Axle Drive Flange (subpar. a (3) above).
143. UNIVERSAL DRIVE SHAFT, BUSHINGS, AND OIL
SEALS.
a. Removal.
(1) Remove Wheel and Tire Assembly (par. 163).
(2) Remove Hub and Drum; Check End Play in Universal
Drive. Turn the tops of the brake shoe adjusting cams toward each
• LEATHER TYPE OIL SEAL- DO NOT
DISASSEMBLE THE SEAL
DRIFT
ROLL LEATHER WITH A SMOOTH
AFTER SOAKING SEAL IN THIN OIL
RA PD 530M
:. WHEEL BEARING OIL SEAL \- HUB
RA PD 53001
Figure 155— Conditioning Oii
Seal
Figure 1 56— Installing Wheel
Bearing Oil Seal with
Drift 41 -D-l 535-50
other to increase the clearance between the shoes and drums. Remove
the nuts which hold the drive flanges to the hubs and install puller
screws. Pull the flanges from the hubs and remove the wheel bearing
outer adjusting nuts and adjusting nut locks. Remove the inner ad-
justing nuts and outer bearings and pull the hubs from the steering
knuckles. Check end play in universal drive assembly. If the end
play exceeds 0.059 inch, replace the housing bushing and the steer-
ing knuckle bushing.
273
TM 9-808
143
3/4 .TON 4x4 TRUCK (DODGE)
(3) Remove Universal Drive Assembly (fig. 157). Remove
five cap screws which hold the brake support and steering knuckle
to the steering knuckle flange. Lay the brake support to rear of axle
without damaging the brake hose. Tap the steering knuckle with
hammer and pull it off. Pull the universal drive assembly, keeping
it as straight as possible. // the joint is allowed to Hex excessively,
it may fall apart. If the inner drive shaft is broken between the oil
seal and four inches from the differential, fish the inner piece out
with a wire snare. If breakage is within four inches of differential,
remove differential carrier assembly and remove broken piece.
(4) Remove Oil Seals and Bushings. Pull the trunnion socket
bushing and drive shaft oil seal located in the housing assembly with
DO NOT FLEX JOINT
WHEN REMOVING
DO NOT DAMAGE OIL SEAL
V^HEN INSTALLING SHAFT
/ RA PD 312566
figure 157— Removing Universal Drive Assembly
a slide hammer type puller (41-P-2957). Drive the bushing out of
the steering knuckle with a drift and hammer.
(5) Remove Steering Knuckle Flange Oil Seal (fig. 158).
Remove cap screws which hold the oil seal retainer to the steering
knuckle flange and pull the felt seal and pressure spring out of the
retainer. Twist the retainer open at the joint and remove it from the
axle housing.
b. Cleaning and Inspection of Universal Drive Assembly. Clean
the joint thoroughly in dry-cleaning solvent to remove all traces of
274
FRONT AXLE
TM 9-808
143
STEERING KNUCKLE FLANGE
OIL SEAL RETAINER
STEERING KNUCKLE FLANGE
OIL SEAL FELT
STEERING KNUCKLE FLANGE
OIL SEAL FELT PRESSURE
SPRING
STEERING KNUCKLE FLANGE
JOINT OIL SEAL FELT
AND RETAINER
STEERING KNUCKLE FLANGE
OIL SEAL GASKET
Figure 158— Removing Steering Knuclile flange Oil Seal Retainer
STEERING KNUCKLE
FLANGE BEARING
ADJUSTING SHIMS
ADJUST BEARINGS BY
REMOVING OR ADDING
SHIMS— CORRECT
PRE-LOAD IS 25 TO
27% FT. LBS. WITH
THE FLANGE IN
MOTION
RA PD 312579
Figure 1 59— Adjusting Steering Knuckle Flange Bearing
275
TM 9-808
143
3/4 -TON 4x4 TRUCK (DODGE)
old lubricant. Clamp one end of the assembly in a vise. Push the two
sections of the joint together and twist the section not clamped in
the vise to determine if any play exists between the races and drive
balls. If any play is evident, notify higher authority.
c. Adjustment of Steering Knuckle Flange Bearings (fig. 159).
With all parts removed as outlined in subparagraph a above, remove
steering tie rod (par. 144 c) and disconnect steering drag link (par.
169 b). Make sure that bearing caps and bearings are seated by
tapping with a hammer. Check the preload of the bearings with a
foot-pound torque wrench attached to one of the cap screws of the
HOUSING ASSEMBLY
HOUSING BUSHING
DRIVE SHAFT OIL SEAL
STEERING KNUCKLE
M95
1.502 ^
RA PD 312578
Figure 1 60— Installation of Oil Seal and Bushing with
Drift 4 1 -D- 1 535-25
steering knuckle flange bearing cap. The torque wrench reading should
be from 25 to 27^/2 foot-pounds while the flange is in motion. If the
preload is not within specifications, remove or add shims between the
top bearing cap and the steering knuckle flange. Remove shims to
tighten or add shims to loosen the bearings. When the adjustment
is completed, connect steering drag link (par. 169 d), and install
steering tie rod (par. 144 d).
d. Installation.
(1) Install Oil Seals and Bushings (fig. 160). Drift the oil
seal and bushing into the front axle housing with special drift
276
TM 9-808
143
FRONT AXLE
(41-D-1535-25). Use same drift to install bushing in steering knuckle.
(2) Install Steering Knuckle Flange Oil Seal (fig. 158).
Clean the sealing surfaces and the seal retainer. Install the pressure
spring in the retainer so that the ends of the spring are even with the
ends of the retainer. Soak the felt seal in light oil and install it in the
retainer with the ends even with the ends of the retainer. Twist the
retainer open at the joint and put it over the axle housing. Place a
new felt on the joint seal retainer and a new gasket on the steering
knuckle flange. Install the seal asserhbly with the joint seal retainer
at the top. Tighten the cap screws evenly to avoid distorting the
retainer.
BEARING CAP SHIMS
DUST COVER WASHERS
SPRING
■STEERING ARM
RA PD 53004
-STEERING TIE ROD DUST COVER
RA PD S300S
figure 1 61— Removing Steering Figure 1 62— Installing Tie Rod
Arm Dust Cover
(3) Install Universal Drive Assembly (fig. 157). Pack the
universal joint with lubricant and install the assembly with the long
shaft first, being careful to insert the shaft through the drive shaft
oil seal without damaging the oil seal. Install the steering knuckle,
then the brake support assembly and lubricate the steering knuckle
flange through the lubricant fitting (par. 24).
(4) Install Hub and Drum Assembly (par. 142 c (2)).
(5) Install Wheel and Tire Assembly (par. 163).
(6) Install Axle Drive Shaft Flange (par. 142 a (3)).
277
TM 9-808
144-145
3/4 -TON 4x4 TRUCK (DODGE)
144. STEERING ARM AND TIE ROD.
a. Removal of Steering Arm.
(1) Disconnect Drag Link from Steering Arm (par. 169).
(2) Remove Steering Arm (fig. 161). Remove four cap screws
which hold the steering arm to the flange and raise arm off the flange.
Be sure to leave all the adjusting shims pn the steering knuckle
flange.
b. Installation of Steering Arm.
(1) Install Steering Arm (fig. 161-). Place the arm over the
steering knuckle flange bearing shims, making sure all original shims
are in place. Install the four attaching cap screws with toothed lock
washer under head of each cap screw.
(2) Connect Drag Link to Steering Arm (par. 169).
c. Removal of Steering Tie Rod (fig. 151). Remove cotter pins
and two nuts which hold tie rod ends to the steering knuckle arms.
Insert pinch bar between tie rod end and steering knuckle and strike
the steering knuckle arm with hammer. Loosen clamp bolt nut and
screw tie rod ends off tie rod.
d. Installation of Steering Tie Rod (fig. 162). Screw the tie rod
ends onto tie rod, leavin_g about six threads exposed at the left end
of the tie rod, and about 10 threads exposed at the right end of the
tie rod. Place the dust washers, '.covers; and springs over the ball
studs. Insert tie rod end ball studs up through steering knuckle arms
and install nuts. Tighten right-hand nut securely and install cotter
pin. Tighten the left-hand nut sufficiently to draw the ball stud into
place, but do not tighten securely. Turn tie rod so that the offset
is down. Tighten clamp bolt at right-hand tie rod end. Check and
adjust front wheel toe-in (par. 141). When toe-in has been adjusted,
tighten left tie rod end ball stud nut securely.
145. FRONT AXLE ASSEMBLY.
a. Cleaning Front Axle Housing Vent (fig. 163). Remove the
vent assembly and wash in dry-cleaning solvent. Blow through vent
with compressed air to make sure it is not plugged, and install vent
assembly.
b. Removal of Differential and Carrier Assembly.
(1) Remove Wheel and Tire Assemblies (par. 163).
(2) Remove Drive Flange from Wheel Hub (par. 142 a (1)).
(3) Remove Hub and Drum Assemblies (par. 142 a (3)).
(4) Remove Universal Drive Assemblies (par. 143 a (3)).
(5) Disconnect Steering Tie Rod at One End (par. 144 c).
(6) Disconnect Propeller Shaft (par. 139).
(7) Remove Differential and Carrier Assembly. Remove
drain plug and drain lubricant. Remove the attaching stud nuts and'
lower the assembly from the axle housing.
278
TM 9-808
145
FRONT AXLE
c. Installation of Differential and Carrier Assembly.
(1) Install Differential and Carrier Assembly. If the
differential side bearing caps are attached with cap screws, place one
new gasket over the housing studs. If the differential side bearing
caps are attached with studs and nuts use three new gaskets. Install
the ciarrier in the housing and securely tighten all attaching nuts.
(2) Install Universal Drive Assemblies (par. 143 d (3)).
(3) Install Hub and Drum Assemblies (par. 142 c (2)).
(4) Adjust Front Wheel Bearings and Install Drive
Flange (par. 142 a).
(5)
(6)
(7)
(8)
d.
(1)
(2)
(3)
RA PD 52996
Figure 1 63— Front Axle Housing Vent
Install Wheel and Tire Assemblies (par. 163).
Connect Propeller Shaft (par. 139).
Coni^ect Steering Tie Rod (par. 144 d).
Adjust Brakes (par. 151).
Removal of Front Axle Assembly.
Remove Wheel and Tire Assemblies (par. 163).
Disconnect Propeller Shaft (par. 139).
Disconnect Brake Tube. Disconnect the brake tube from
the front of the tee at the top of the axle housing.
(4) Disconnect Front End of Drag Link (par. 169).
279
TM 9-808
145
3/4 -TON 4x4 TRUCK (DODGE)
(5) Disconnect Shock Absorber Link Eyebolts. Remove nut
from lower end of shock absorber link eyebolts and raise eyebolts out
of the spring clip plates.
(6) Remove Axle Assembly. Remove nut from each end of four
spring clips (U-bolts) and raise the clips out of spring clip plates.
Then lower axle assembly and remove it from under vehicle.
e. Installation of Front Axle Assembly.
(1) Install Axle and Connect Shock Absorber Links. Move
axle assembly under vehicle and jack it into place. Install the spring
clips and nuts with a standard lock washer above each nut. Connect
the shock absorber link eyebolts to the spring clip plates.
(2) Connect Drag Link to Steering Arm (par. 169).
(3) Connect Brake Tube. Connect the brake tube to the front
of the tee on the top of the axle housing.
(4) Connect Propeller Shaft (par. 139).
(5) Bleed Air from Brake System (par. 152).
(6) Install Wheel and Tire Assemblies (par. 163).
(7) Check Lubricant Level in Differential (par. 24).
280
TM 9-808
146-147
Section XXXII
REAR AXLE
Paragraph
General description 146
Rear wheel bearings 147
Rear axle drive shafts 148
Rear axle assembly 149
146. GENERAL DESCRIPTION.
a. The rear axle is of the full-floating type with a hypoid ring
gear and drive pinion. With this type axle it is possible to remove or
replace the axle drive shaft without removing the wheels. The differ-
ential carrier assembly in the rear axle is identical with that used in
the front axle.
WHEEL BEARING
ADJUSTING
NUT WRENCH
ADJUSTING
NUT LOCK
ADJUSTING NUT-OUTER
OIL SEAL RETAINER GASKET
OIL SEAL AND RETAINER
REAR AXLE SHAFT GASKET
RA PD 53010
figure 1 64~Adjusting Rear Wheel Bearing
147. REAR WHEEL BEARINGS.
a. Adjustment of Rear Wheel Bearings.
(1) Jack Up Wheel. Place a jack under the axle housing and
raise the vehicle until the tire clears the ground.
(2) Remove Axle Drive Shaft (par. 148).
(3) Remove Wheel Bearing Outer Oil Seal (subpar. b below).
(4) Adjust Bearings (fig. 164). Remove the wheel bearing outer
adjusting nut, with wheel bearing adjusting nut wrench, and the
281
TM 9-808
147
3/4 -TON 4x4 TRUCK (DODGE)
adjusting nut lock. Turn the inner adjusting nut tight and then back
it off about 1/6 of a turn. Install the adjusting nut lock, making sure
that the dowel pin in the inner adjusting nut enters a hole in the
lock. It may be necessary to turn the lock over or even turn the inner
adjusting nut slightly to permit the dowel pin to enter one of the holes
in the lock. With the lock over the dowel pin, install the outer adjust-
ing nut and tighten it securely.
(5) Install Wheel Bearing Outer Oil Seal (subpar. c below).
(6) Install Axle Drive Shaft (par. 148).
b. Removal of Outer Oil Seal (fig. 164). Remove axle drive
shaft (par. 148). Slide the wheel bearing outer oil seal retainer off the
axle shaft drive studs.
REAR WHEEL BEARING
CONE-OUTER
REAR WHEEL BEARING ADJUST-
ING NUT AND PIN— INNER
REAR WHEEL BEARING ADJUST-
ING NUT LOCK
REAR WHEEL BEARING ADJUST-
ING NUT— OUTER
REAR WHEEL BEARING OIL SEAL
AND RETAINER— OUTER
REAR WHEEL BEARING
CONE— INNER
REAR WHEEL BEARING OIL
SEAL -INNER
REAR WHEEL BEARING OIL
SEAL SNAP RING
RA PD 53011
figure 165— Removing Rear Wheel Bearing and Oil Seal
c. Installation of Outer Oil Seal (fig. 164). Soak the oil seal in
light engine oil to make it pliable. Clean the outer end of the wheel
hub and drive shaft studs. Install a good paper gasket over the drive
studs. Inspect the wheel bearing outer adjusting nut. If the oil seal
bearing surface is rough or grooved, replace the nut. Install the oil
seal over the adjusting nut and the axle shaft drive studs. Install the
axle drive shaft (par. 148).
d. Removal of Inner Oil Seal and Bearings (fig. 165). Before
removing the wheel bearings or oil seals, put a new wheel bearing oil
seal in thin oil and allow it to soak while the following operations are
being performed.
282
TM 9-808
147-148
REAR AXLE
(1) Jack Up Wheel. Raise vehicle with jack and place stand
under axle housing.
(2) Remove Axle Drive Shaft (par. 148).
(3) Remove Wheel and Tire Assembly (par. 163).
(4) Remove Wheel Bearing Outer Oil Seal (subpar. b
above).
(5) Remove Brake Drum and Hub (fig. 165). Turn the brake
shoe adjusting cams to increase the clearance between the brake shoes
arid the drum. Remove the outer wheel bearing adjusting nut, adjust-
ing nut lock, and inner adjusting nut with wheel bearing adjusting nut
wrench. Remove the outer wheel bearing and pull the drum, hub, and
inner wheel bearing, from the axle housing.
(6) Remove Oil Seal, Cone and Cups (fig. 165). Remove the
rear wheel bearing oil seal snap ring from the inner end of the hub.
Remove wheel inner bearing cone and oil seal from the hub by driv-
,ing against the hub of the bearing cone with a large drift. Drift inner
and outer bearing cups out of hub.
e. Installation of Inner Oil Seal and Bearings.
(1) Install Wheel Bearings and Oil Seal (figs. 155 and 156).
Install inner and outer bearing cups in hub, thick edge first. Pack the
wheel inner bearing cone with wheel bearing grease and place the
bearing cone in the bearing cup. Work the oil seal, after soaking in
thin oil, by rolling with pressure applied by a smooth bar. Install the
seal in the hub with oil seal drift (41-D-1535-50) and install the oil
seal snap ring.
(2) Install Hub and Drum and Adjust Brake Shoes. Inspect
the oil seal bearing surface and remove any roughness that may exist.
Slide the hub and drum straight onto the axle housing. Exercise care
to prevent damaging the oil seal. Pack the outer wheel bearing cone
with wheel bearing grease and install the bearing and inner bearing
adjusting nut on the housing. Adjust the wheel bearings (subpar. a
(4) above). Turn brake shoe adjusting cams until brake drags and
then back off just enough to free the drum.
(3) Install Wheel Bearing Outer Oil Seal (subpar. c above).
(4) Install Rear Axle Drive Shaft (par. 148).
(5) Install Wheel and Tire Assembly (par. 163).
148. REAR AXLE DRIVE SHAFTS.
a. Removal (fig. 152). Remove the six rear axle drive shaft flange
retaining stud nuts. Remove the two flange puller screws from the
axle shaft flange; remove the lock nuts from the screws and use the
screws to pull the drive flange off the hub. Pull the drive shaft out of
the housing. If the rear axle drive "shaft is broken, and the break is
less than four inches from the inner end of the shaft, it will be neces-
sary to remove the differential carrier assembly; and the condition
should be referred to ordnance personnel. If the break in the shaft is
more than four inches from the inner end of the shaft, it will be
283
TM 9-808
148-149
3/4 -TON 4x4 TRUCK (DODGE)
necessary to snare the inner end of the shaft, pulling it through the-
housing with a wire loop.
b. Installation.
(1) Inspect Drive Shaft Contacting Surfaces. Make sure all
contacting surfaces are clean and free of foreign matter which would
prevent the shaft flange, the oil seal retainer and the wheel hub seat-
ing properly against the gasket when tightened ddwn with the retain-
ing nuts.
(2) Install Puller Screws and Lock Nuts. Remove the puller
screws from the drive shaft flange and install the lock nuts. Reinstall
the screws in the flange so that the ends of the screws do not protrude
through the flange, and tighten the lock nuts.
-VENT- REMOVE AND WASH IN DRY CLEANING
1 SOLVENT. BLOW THROUGH VENT WITH
\C0MPRESSED AIR. DO NOT REMOVE CAP
\FROM THE VENT BODY.
■REAR AXLE HOUSING
Figure 166— Rear Axle Housing Vent
(3) Install Drive Shaft. Place a new gasket on the drive studs
and install the drive shaft in the housing. Engage the splines on the
inner end of the shaft with the differential side gear and push the
shaft into place. Install standard lock washers and flange attaching
nuts on the drive studs and tighten evenly.
149. REAR AXLE ASSEMBLY.
a. Cleaning Rear Axle Housing Vent. Remove the vent assembly
and wash in dry-cleaning solvent. Blow through vent with com-
pressed air to make sure it is not plugged and install vent assembly
(fig. 166).
284
TM 9-808
149
REAR AXLE
b. Removal of Differential and Carrier Assembly.
(1) Remove Axle Drive Shafts (par. 148 a).
(2) Disconnect Propeller Shaft (par. 139).
(3) Remove Differential and Carrier Assembly. Remove
drain plug and drain lubricant. Rerhove the attaching stud nuts and
lower the assembly from the axle housing.
c. Installation of Differential and Carrier Assembly.
(1) Install Differential and Carrier Assembly. If the differ-
ential side bearing caps are attached with cap screws, place one new
gasket over the housing studs. If the differential side bearing caps are
attached with studs and nuts, use three new gaskets. Install the
carrier in the housing and securely tighten all attaching nuts.
(2) Install Axle Drive Shafts (par. 148 b).
(3) Connect Propeller Shaft (par. 139).
d. Removal of Rear Axle Assembly.
(1) Disconnect Brake Tube. Disconnect the brake tube from
the brake hose at the brake tube to hose bracket located on the frame
cross member. Disconnect the hose from the brake tube to hose
bracket by removing the attaching nut.
(2) Disconnect Propeller Shaft, at Drive Pinion Flange
(par. 139).
(3) Remove Wheel and Tire Assembly (par. 163).
(4) Remove Rear Axle Assembly. Remove the spring clip nuts.
Remove the spring clips and clip plates. Lower the axle from the
vehicle with the jack.
e. Installation of Rear Axle Assembly.
(1) Install Rear Axle Assembly. Place the rear axle on the
jack and roll it into position under the vehicle. Jack up the axle until
it contacts the rear springs. Make certain that the center bolts line up
properly in the holes provided in the pads that are a part of the rear
axle housing. Install the spring clips down through the plates. In-
stall standard lock washers and nuts and tighten the nuts securely.
(2) Install Wheel and Tire Assemblies (par. 163).
(3) Connect Propeller Shaft (par. 139).
(4) Connect Brake Hose. Connect the brake hose to the hose
bracket located on the frame cross member and tighten the attaching
nut. Attach the frame brake tube to the brake hose and tighten the
connection.
(5) Bleed Brake System (par. 152).
285
TM 9-808
150
3/4 -TON 4x4 TRUCK (DODGE)
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286
TM 9-808
150-151
Section XXXIII
FOOT BRAKES
Paragraph
General description 150
Brake adjustments 151
Bleeding brake system 152
Brake shoes, linings, and drums 153
Wheel* cylinders 154
Master cylinder 155
150. GENERAL DESCRIPTION.
a. The foot brakes (fig. 167) are of the hydraulic expanding type
and operate on all four wheels. The brake pedal is connected to a
piston which operates within a master cylinder. When the brake pedal
is depressed, the master cylinder piston forces fluid under equal pres-
sure to all four wheel cylinders. The fluid enters the wheel cylinders
between two pistons, causing the pistons to move in opposite direc-
tions and push the brake shoes against the brake drums. Adjustments
are provided to compensate for wear of the brake shoe linings. How-
ever, because the hydraulic pressure is always equal to all four wheels,
no adjustment is provided or required to equalize the brake shoe
pressure.
151. BRAKE ADJUSTMENTS.
a. Minor Brake Adjustment. A minor brake adjustment consists
of adjusting the brake shoe cams which control only the released
position of the brake shoes. The minor adjustment will reduce brake
pedal travel caused by brake lining or drum wear, or will relieve
brake drag caused by lack of clearance between the brake shoes and
drum. Before attempting to adjust the brakes, make certain the
master cylinder piston rod is properly adjusted (subpar. c (3) below)
and that wheel bearings have no play. Do not adjust brake shoes
when brake drums are hot, because the drums will contract when they
cool off and cause the brakes to drag.
(1) Adjust Brake Shoe Cams (fig. 168). Jack up wheel until
the tire is clear of the ground. Revolve the wheel and turn one brake
shoe cam pin until the brake shoe contacts the drum and causes the
brake to drag. Then turn the cam pin in the opposite direction just
enough to eliminate the brake drag. Adjust the other shoe in the
.same manner and repeat the operation on the other three wheels.
(2) Check Fluid Level in Master Cylinder (fig. 169). Re-
move the filler plug from top of the master cylinder. If fluid level is
more than ^ inch below top of opening, add fluid to proper level
and install filler plug.
b. Major Brake Adjustment. A major brake adjustment consists
of adjusting the brake shoe anchor bolts so that the full area of the
shoe lining will contact the brake drum when the brakes are applied.
287
TM 9-808
151
3/4 -TON 4x4 TRUCK (DODGE)
A major brake adjustment may be required when the brake shoe
and- lining assemblies are replaced or when the brake drums are re-
surfaced or replaced. Before attempting to make a major adjustment,
make certain the master cylinder piston rod is properly adjusted
(subpar. c (3) below) and that the wheel bearings have no play.
CAUTION: While making a brake adjustment, do not apply the
brakes as the resulting distortion ot the various parts will make it
impossible to accomplish an accurate adjustment.
(1) Remove Wheel and Tire Assembly (par. 163). Install two
of the wheel stud nuts and tighten with wheel wrench so that brake
drums will be held in proper alinement.
BRAKE SHOE ADJUSTING PINS
TO INCREASE CLEARANCE
TO DECREASE CLEARANCE
BRAKE CAM ADJUSTING WRENCH^
RA PD 53013
Figure 1 68— Adjusting Brake
Shoe Cam
REMOVE THE FILLER PLUG. IF THE
FLUID LEVEL IS MORE THAN 3/4-IN.
BELOW TOP OF OPENING, ADD BRAKE
FLUID UP TO THE %-IN. LEVEL .
AND INSTALL FILLER PLUG
RA PD 53012
Figure 1 69— Master Cylinder
Fluid Level
(2) Position Anchor Bolts (fig. 170). Loosen anchor bolt lock
nuts. Turn anchor bolts to the fully released position so that the dots
on any pair of anchor bolts face toward each other and the flats of
the anchor bolts are in the same horizontal plane. This can best be
determined by placing a straightedge across the flats of the anchor
bolts.
(3) Adjust Brake Shoe Cams (fig. 170). Turn the brake shoe
adjusting cams so that a 0.006-inch feeler gage will be a snug fit
between the toe of the brake shoe lining and drum.
(4) Adjust Anchor Bolts (fig. 170). Turn the anchor bolts in
the direction indicated by the arrows in figure 170, to decrease the
288
TM 9-808
151
FOOT BRAKES
BRAKLPRUM INSPECTION HOLE COVER
SCREW " '^ ^^H fWHEEL
BRAKE
DRUM
: TOE OF REAR SHOE
INSPECTION OPENING WITH
THE COVER REMOVED
DRUM INSPECTION HOLE
TOE CLEARANCE 0.01 2-IN.
TOE ADJUSTMENT
HEEL CLEARANCE 0.006-IN.
• HEEL OF REAR SHOE
HEEL OF FRONT SHOE — '
HEEL ADJUSTMENT
TURN THE BRAKE SHOE ANCHOR
BOLTS IN THE DIRECTION OF ARROWS
TO DECREASE CLEARANCE BETWEEN
THE HEEL OF THE SHOE AND THE
BRAKE DRUM— TURN IN THE
OPPOSITE DIRECTION TO INCREASE
CLEARANCE.
ANCHOR BOLT ADJUSTMENT
.RA PD 58366
Figure 170— Brake Shoe Adjustments
289
TM 9-808
151
3/4 -TON 4x4 TRUCK (DODGE)
clearance between the heel of the brake shoe lining and drum to
0.006 inch. This will cause the brake shoe to move down and out, in-
creasing the clearance at the toe of the brake shoe lining to approxi-
mately 0.012 inch, resulting in proper centralization of the brake shoes.
When "the shoes have been adjusted, hold the anchor bolt from turn-
ing and tighten the lock nuts securely. If the pedal travel is too great
after the adjustments have been completed, decrease the clearance
between the toe of the shoe lining and the drum. Make certain the
brakes do not drag.
(5) Install Cover over Inspection Hole. Place the cover over
the inspection hole in the drum and install the attaching screw with
a standard lock washer under the head of the screw
PEDAL FREE TRAVEL-
PEDAL STOP SCREW NUT
EDAL STOP SCREW
rPULL-BACK SPRING
EXTENSION
fBRAKE PEDAL
PULL-BACK SPRING
BRAKE /
MASTER
CYLINDER
ASSEMBLY
PULL-BACK SPRING BRACKET
■ BRAKE PEDAL BRACKET
MASTER CYLINDER PISTON ROD END PIN
. MASTER CYLINDER PISTON ROD
. MASTER CYLINDER PISTON ROD NUT
■MASTER CYLINDER PISTON PUSH ROD
RA PD
53018
Figure 171— Brake Pedal Adjustments
(6) Install. Wheel and Tire Assembly (par. 163). .
(7) Check the Fluid Level in the Master Cylinder (fig.
169). Remove the filler plug from the top of the master cylinder. If
the fluid level is more than ^^■'"'^h below the top of the opening,
add brake fluid to proper level and install filler plug.
c. Adjustment of Brake Pedal Free Travel.
(1) Description (fig. 171). The backward travel of the brake
pedal is limited by a stop screw so that the pedal will not strike the
engine rear support when released. The pedal free travel is the amount
of movement 'of the pedal from its fully released position to the point
where noticeable resistance is felt in the downward movement of the
2 90
TM 9-808
151-152
FOOT BRAKES
pedal. This free travel is controlled by the length of the master cylin-
der piston rod.
(2) Check Pedal Stop Screw Adjustment (fig. 171). Depress
and release the brake pedal and note whether it contacts the engine
rear sujiport. If so, loosen the lock nut on the pedal stop screw and
turn the stop screw in the bracket so that the pedal does not contact
the engine support when the pedal is released.
(3) Adjust Master Cylinder Piston Rod (fig. 171). Loosen the
lock nut at the front end of the rod between the pedal and the master
cylinder and turn the master cylinder piston rod until the pedal has
^1 (J -inch free travel.
HEEL CYLINDER BLEEDER SCREW
TO OPEN VALVE /"TO CLOSE VALVE
BRAKE FLUID
RA PD 65956
Figure 1 72-Bleeding Brake At Wheel Cylinder
152. BLEEDING BRAKE SYSTEM.
a. Bleeding Brake System with Hydraulic Brake Filler.
(1) Attach Hydraulic Brake Filler. Partially fill the brake
filler with hydraulic brake fluid. Attach air hose to connection at top
of the filler and apply 25 pounds air pressure to the filler tank. Remove
the plug from the top of the master cylinder. Place end of filler hose
in master cylinder, open the shut-off valve in the filler hose slightly
and fill the master cylinder to top of the opening. Install tapped fitting
in master cylinder " filler opening. Install threaded nipple into the
tapped fitting and connect the filler hose to the nipple. Before tight-
291
TM 9-808
152
3/4 -TON 4x4 TRUCK (DODGE)
ening the hose to nipple connection, open the shut-off valve slightly
and when fluid; free of air, is forced out of the loose connection,
tighten the connection and open the shut-off valve fully.
(2) Bleed Brake System (fig. 172). Remove the cap screw from
the wheel cylinder bleeder screw and attach the bleeder tube. Sub-
merge the free end of the bleeder tube in brake fluid in a receptacle.
Open the bleeder screw and allow fluid to flow into the receptacle until
fluid coming from the brake system is clear and free of air bubbles.
Then close the bleeder screw securely, remove the bleeder tube and
install cap screw. Follow this procedure at all four wheel cylinders.
PULLER SCREWS— THE REAR AXLE
DRIVE SHAFT. PULLER SCREWS
\CAN BE USED HERE
WHEEL BRAKE DRUM
8RAKE SHOE RETURN SPRING
BRAKE SHOE AND LINING
BRAKE DRUM TO HUB SCREW
REMOVED
PULLER SCREWS IN PLACE
ANCHOR BOLT "C" WASHERS
PRAKE DRUM REMO VED
RA PD 65955
Figure 173— Removing Brafce Drum
(3) Lower Fluid Level in Master Cylinder. When the last of
the four wheel cylinders has been completely bled and while the
bleeder screwis still open and the bleeder tube is still in the receptacle
of fluid, close the shut-off valve in the filler hose and disconnect the
hose from the master cylinder. Push the brake pedal all the way
down and hold it down while the bleeder screw at the wheel cylinder
is being closed. Then release the brake pedal. This will lower the fluid
in the master cylinder to approximately 54 i^ich below the top of the
filler opening. Remove fittings and install filler plug in master cylinder.
292
TM 9-808
152-153
FOOT BRAKES
b. Bleeding Brake System without Use of Hydraulic Filler
Tank.
. (1) Fill Master Cylinder. Remove the filler plug from the top
of the master cylinder and fill the cylinder with clean fresh brake
fluid.
(2) Bleed Each of the Four Wheel Cylinders (fig. 172).
Remove the cap screw from the wheel cylinder bleeder screw and
attach the bleeder tube. Submerge the free end of the bleeder tube in
brake fluid in a receptacle and open the bleeder screw. Push the
brake pedal down slowly about half way, then allow the pedal to
return to its released position. Keep refilling the master cylinder and
repeat the brake pedal operation until clear fluid, free of air bubbles,
flows from the bleeder tube when the pedal is pushed down. Close
the bleeder screw securely; remove the bleeder tube and install the
cap screw.
(3) Check Fluid Level in Master Cylinder. Measure the
fluid level in the master cylinder and add fluid if necessary to bring
fluid to 3/^ inch from top of the filler opening. Install filler plug. .
153. BRAKE SHOES, LININGS, AND DRUMS.
a. Cleaning and Inspection of Brakes.
(1) Remove Wheel and Tire Assembly (par. 163).
(2) Remove Brake Drum (fig. 173). Turn brake shoe cams to
increase clearance between shoes and drum (fig. 168). Remove three
countersunk screws which hold brake drum to hub. Remove puller
screws from rear axle drive shaft flange, remove lock nuts and use
the screws in holes provided in drum to pull the drum from the hub.
(3) Clean and Inspect Brakes. Brush dust or dirt from the
brake shoes and interior of the brake drum. Inspect brake return
spring and brake anchor "C" washers for being intact. Inspect brake
shoe lining. If linings are worn down to rivets, loose on shoe, or greasy,
replace shoe and lining assemblies (subpars. b and c below). Inspect
brake drum. If badly scored or cracked, notify ordnance personnel.
(4) Install Brake Drum. Remove puller screws from drum and
install the screws and lock nuts in the rear axle drive shaft flange.
Lubricate hub with water pump lubricant to facilitate future removal
of the drum. Place drum over the hub so that the attaching screw
holes line up with the tapped holes in the hub. Install the attaching
screws and draw the drum into place. Make sure the drum is tight
against the flange of the hub by tapping with a hammer, and tighten
the screws securely.
(5) Check Brake Anchor Bolt Adjustment (par. 151).
(6) Check Fluid Level in Master Cylinder (fig. 169). Mea-
sure fluid level in master cylinder and add fluid if necessary to bring
fluid to 5^ inch from top of filler opening.
(7) Install Wheel and Tire Assembly (fig. 163).
293
TM 9-808
153
3/4 .TON 4x4 TRUCK (DODGE)
h. Removal of Brake Shoes.
(1) Remove Wheel and Tire Assembly (par. 163).
(2) Remove Brake Drum (subpar. a (2) above).
(3) Remove Brake Shoes (figs. 174 and 175). Place clamp over
brake cylinder to hold pistons in brake cylinder and remove brake
shoe return spring. Remove shoe anchor bolt nuts and washers and
tap out anchor bolts. Swing brake shoes out of brake cylinder and
remove from brake support.
BRAKE SHOE AND LINING
brake spring pliers j
lbrake shoe return spring
RA PD 53026
RA PD 312567
figure 174— Removing Brake
Shoe Return Spring
Figure 175— Removing Bralce
Shoe and Lining
(4) Inspect Brake Drum. If the brake drum is excessively
scored or cracked, notify higher authority.
c. Installation of Brake Shoes.
(1) Install Brake Shoes. Place the brake shoes in position on
the support assembly, forcing them into the guide springs on each
side. Lubricate anchor bolts with a thin coating of chassis grease and
install them complete with oil washers, retainers, and "C" washers.
Install the anchor bolt lock washers and nuts. Attach the brake shoe
return spring and remove the brake cylinder clamp.
(2) Install Brake Drum v(subpar. a (4) above). Turn the
anchor bolts so that the prick punch marks on the inner end of the
294
TM 9-808
153-154
FOOT BRAKES
bolts are toward each other (fig. 170). The drum can then be in-
stalled. Make major brake adjustment (par. 151).
(3) Install Wheel and Tire Assembly (par. 163).
154. WHEEL CYLINDERS,
a. Removal.
(1) Remove Wheel and Tire Assembly from Hub (par. 163).
(2) Remove Brake Drum from Hub (par. 153).
(3) Remove Cylinder (fig. 178). Disconnect brake hose from
brake cylinder. Remove two cap screws which hold brake cylinder to
brake support. Remove brake shoe return spring. Swing brake shoes
out of brake cylinder.
BRAKE WHEEL CYLINDER ASSEMBLY
-WHEEL CYLINDER TO BRAKE SUPPORT MOUNTING SCREWS
RA PD 53028
Figure 1 76— Removing Wheef Cylinder
h. InstaHation.
(1) Install Brake Cylinder (fig. 176). Place brake cyHnder on
brake support and install two cap screws. Then connect brake hose
with washers on both sides of inlet connection. Swing brake shoes
into position and attach brake shoe return spring.
(2) Install Brake Drum ON Hub (par. 153).
(3) Bleed Air from Brake System (par. 152).
(4) Install Wheel and Tire Assembly (par. 163).
295
TM 9-808
155
3/4 -TON 4x4 TRUCK (DODGE)
155. MASTER CYLINDER.
a. Removal (fig. 177).
(1) Remove Left Engine Dustpan. Disconnect the chassis wir-
ing cable from the engine dustpan and remove the clip, bolt and nut.
Remove the front spring torque arrester assembly. Remove the cap
screws that hold the dustpan to the frame side member and the front
cap screw that holds the dustpan to rear of front frame cross member.
(2) Remove Master Cylinder. Disconnect hydraulic brake
tube from the master cylinder. Remove the three cap screws which
hold the master cylinder to the mounting bracket. Pull the cylinder
forward and disconnect the push rod from the brake pedal.
• BRAKE MASTER CYLINDER ASSEMBLY
BRAKE TUBE
'-BRAKE PEDAL TO MASTER CYLINDER ROD
figure I 77— Master Cylinder
h. Installation (fig. 177).
(1) Install Master Cylinder. Insert the push rod through
the brake cylinder mounting bracket and install the clevis pin and
cotter pin in the brake pedal. Install the three cap screws which hold
the cylinder to the bracket with a toothed lock washer under the head
of each cap "screw. Connect the brake tube to the master cylinder.
(2) Install Left Engine Dustpan. Place the dustpan in posi-
tion and insert battery box drain hose in hole provided for it on
vehicle with 6-volt electrical systems. Install the toothed lock washers
on the two dustpan cap screws and tighten the screws. Tighten the
fraia* tee bracket bolt. Place torque arrester in position on the frame
296
TM 9-808
155
FOOT BRAKES
side member and attach it with the bolts, toothed lock washers and
nuts. Attach the chassis wiring cable with the wiring clip to the dust-
pan. Install the screw that attaches the dustpan to the frame front
cross member. Insert the screw by reaching down between the radiator
and engine. Place the wiring and fuel line clip and lock washer on the
screw and tighten.
(3) Bleed the Brake System (par. 152).
297
TM 9-808
156-157
3/4 -TON 4x4 TRUCK (DODGE)
Section XXXIV
HAND BRAKE
Parograph
General description 156
Hand brake adjustment 157
Band and lining 158
Hand brake lever and linkage 159
Hand brake drum 160
156. GENERAL DESCRIPTION.
a. The hand brake consists of a drum mounted at the rear of the
transmission with a contracting band. The hand brake operates in-
dependently of the foot brakes and applies equal braking force to
the wheels through the differentials.
157. HAND BRAKE ADJUSTMENT.
a. Procedure.
(1) Adjust Hand Brake Rod. Set hand brake lever in the fully
released position. Remove the cotter pin and clevis pin from the rear
end of the hand brake rod. Loosen the lock nut and adjust the rod
so that with the hand lever in the fully released position, the cam
levers bear squarely against the brake band. Install the clevis and
cotter pin and tighten the lock nuts with 5^ inch open-end wrench
(41-W-3579).
(2) Adjust Anchor Clip Screw (fig. 178). Remove the anchor
clip screw lock wire. Adjust the anchor clip screw so there is 0.010
inch to 0.012 inch clearance between the drum and the lining at the
anchor. Install a lock wire through the anchor clip and screw.
. (3) Adjust Bracket Adjusting Screw (fig. 178). Back off the
adjusting bolt lock nuts until free with 54-inch box wrench (41 -W-
635). Adjust the bracket adjusting screw so there is 0.010 inch to
0.012 inch clearance between the drum and the bottom of the band
and lock the nuts together.
*
(4) Adjust Adjusting Bolt Nuts (fig. 178). Turn adjusting
bolt nuts down until the bracket adjusting screw is just .relieved of
tension with f4 inch box wrench (41-W-635). If a new band and
lining assembly does not form a true circle, it may be necessary to
alter the adjustment slightly to establish clearance all the way around
the drum. In that case readjust the band after the lining has worn to
a true circle.
(5) Lock Adjusting Bolt Nuts (fig. 178). Place a s/g inch
open-end wrench (41-W-3579) between the hand brake and transfer
case levers and on the lower nut to hold it from turning. With a short
Ya inch box wrench (41 -W-635) reach between the frame cross mem-
ber and the floor plate and tighten the lock nut.
298
HAND BRAKE
r HAND BRAKE BAND ANCHOR CUP SCREW
/THAND BRAKE BAND ASSEMBLY
LOCK WIRE
0.010-lN. TO 0.01 2-IN,
LOCK NUT.
HAND BRAKE ROD-
TM 9-808
157
HAND BRAKE
ADJUSTING BOLT
LOCK NUTS
OCK NUB
BRACKET
ADJUSTING
SCREW
CAM LEVERS
CLEVIS PIN
RA PD 53031
Figure 1 78— Hand Brake Adjustments
■ HAND BRAKE BAND AND LINING ASSEMBLY
HAND BRAKE LEVER
HAND BRAKE
SPACER LINK
TRANSFER CASE CONTROL HAND LEVER BRACKET ■
RA PD 53032
Figure 1 79— Removing Hand Brake Band
299
TM 9-808
158
3/4 -TON 4x4 TRUCK (DODGE)
158. BAND AND LINING,
a. Removal.
(1) Loosen Frame Cross Member (Except Ambulance) (par.
133 a (7)).
(2) Remove Band and Lining Assembly (fig. 179). Remove
cotter pin and yoke pin from the hand brake rod and remove cotter
pin from spacer link. Remove lock nuts, plain washer, and operating
spring, from top of the adjusting bolt. Pull the adjustment bolt down
out of the band and remove the two adjusting bolt springs. Remove
the bracket adjusting screw. Remove the band anchor clip screw
lock wire and screw. Remove the small coiled spring from between
the anchor and the anchor bracket and slide the band and lining
a.ssembly off the brake drum.
r frame intermediate crossmember
\ \-hand brake operating spring
\ x^and brake adjusting bolt
I
RACKET ADJUSTING SCREW
AND BRAKE LEVER
HAND BRAKE ADJUSTING BOLT SPRINCr-HAND BRAKE ROD
CLEVIS PIN
RA PD 53033
Figure 1 80— Hand Brake Linkage
h. Installation.
(1) Install Band and Lining Assembly (fig. 179). Slide the
hand brake band over drum and anchor. Install small coiled spring
between the anchor and outer edge of anchor bracket. Install anchor
clip screw through anchor bracket and small coiled spring. Install
bracket adjusting screw, nut and lock nut. Install adjusting bolt up
through the band and bracket, with coiled springs above and below
the bracket. Install operating spring, plain washer, and adjusting bolt
lock nuts on upper end of the adjusting bolt. Place spacer link over
300
TM 9-808
158-160
HAND BRAKE
link stud and install cotter pin. Install yoke pin and cotter pin in end
of hand brake rod.
(2) Adjust Brake Band (par. 157).
(3) Install Frame Cross Member (par. 133 b (3)).
159. HAND BRAKE LEVER AND LINKAGE.
a. Removal of Lever (fig. 180). Remove the cotter pin and clevis
pin from the front end of the hand brake rod. Remove the three cap
screws which hold the brake sector and the transfer case lever bracket
to the transmission case. Remove the nut which holds the brake sector
to the brake band spacer link. Lift the lower end of the lever over
the front axle propeller shaft and pull the lever down through. the
floor pan.
b. Installation of Lever (fig. 180).
(1) Install Lever and Lever Bracket. Raise lever up between
the exhaust pipe and the front axle propeller shaft and through the
slot in the floor plate. Place the lever sector over the stud in the
spacer link and install toothed lock washer and nut.
(2) Assemble Lever Bracket to Transmission Case. Insert
three cap screws which hold the brake lever sector and the transfer
case lever bracket to the transmission through the transfer case lever
bracket. Place the short spacer tubes over each of the two lower cap
screws. Insert the two cap screws through the bracket and sector and
start them into the transmission case. Place the longer spacer tube
over the upper cap screw and tighten the three cap screws.
(3) Connect Hand Brake Rod. Install clevis pin through hand
brake rod clevis and brake lever. Install cotter pin through clevis pin.
c. Removal of Hand Brake Rod. Remove cotter pins from
clevis pins at each end of the hand brake rod and remove the rod. ■
d. Installation,' and Adjustment of Hand Brake Rod.
(1) Install Rod. Install clevis pin through the hand brake rod
yoke and the hand lever and install cotter pin.
(2) Adjust Pull Rod. Loosen lock nut on the hand brake rod
and adjust the rod so that when the hand lever is in the fully released
position, the brake cam levers squarely contact the brake band. Install
clevis pin through the brake cam levers and the eye at the rear end of
the hand brake rod and install cotter pin through the clevis pin.
160. HAND BRAKE DRUM,
a. Removal.
(1) Loosen Frame Cross Member (Except Ambulance) (par.
133 a (7)).
(2) Remove Band and Lining Assembly (par. 158 a (2)).
(3) Disconnect Propeller Shaft (par. 139).
(4) Remove Brake Drum. Remove cotter pin from nut which
holds universal joint companion flange to transmission ■ main shaft.
301
TM 9-808
160
3/4 -TON 4x4 TRUCK (DODGE)
Remove the nut. Drive the brake drum off transmission main shaft.
(5) Remove Universal Joint Companion Flange. Remove four
bolts and nuts which hold flange and drum together. Tap drum from
the flange.
b. Installation.
(1) Connect Universal Joint Companion Flange. Place com-
panion flange through brake drum and install four bolts and nuts with
a toothed lock washer under each nut.
(2) Install Brake Drum. Place brake drum over splines on
transmission main shaft. Install attaching nut. Install cotter pin
through nut and shaft.
(3) Connect Propeller Shaft (par. 139).
(4) Install and Adjust Brake Band (pars. 158 b (1) and 157).
(5) Install Frame Cross Member (par. 133 b (3)).
302
TM 9-808
161-162
Section XXXV
WHEELS AND TIRES
Paragraph
General description 161
Tire inflation and care 162
Wheel and tire assembly 163
Spare wheel and tire assembly 164
Tire casing and tube 165
161. GENERAL DESCRIPTION.
a. Wheel and tire assemblies are interchangeable, front and rear.
The tires are retained on the wheels by a side ring which is attached
to the wheel by studs and nuts. A bead lock ring (fig. 181) is as-
sembled between the beads of the tire to prevent the tire from coming
off the wheel when deflated.
-TIRE CASING
■TIRE TUBE
■;-:?%'>
m
■ WHEEL SIDE RING /.BEAD LOCK RING
.WHEEL
RA PD S3036
figure 181 —Cross-Section of Tire Mounted on Wheel
162. TIRE INFLATION AND CARE.
a. Tire Inflation. The life of the tire depends largely upon load
and inflation. Inflate all tires to 40 pounds pressure. This is particu-
larly important so as to maintain the same rolling radius of all
four tires when in four-wheel drive.
(1) Keep Tires Inflated. An under-inflated tire causes the cords
to pull loose from the position in which they were originally vulean-
303
TM 9-808
162-163
3/4 -TON 4x4 TRUCK (DODGE)
ized, as well as irregular tread wear. When a tire is over-inflated, only
the center of the tread comes in contact with the road. Wear is then
more rapid because it is concentrated on a small section of the tread.
The wheels will also bouijce and spin causing the rubber to scuff off.
Tire cords are easily broken when an over-inflated tire runs over a
sharp cornered chuckhole or other obstacle.
(2) Install Valve Caps. After tire pressures are checked, see
that all valve caps are securely in place. The tire valve is actually
a check valve and although its sealing efficiency is high, the valve
cap is the sealing unit. The valve cap contains an inside rubber washer
and plate to insure positive sealing. Be sure to keep valve caps in
place at all times.
|llEFTFR0Nr\/4l6HT
'UtFTREARy^VRIGHT
SPARE
FRONT
REAR
?^.
CHANGE THE SPARE TO THE
RIGHT REAR. .
CHANGE THE RIGHT REAR TO
LEFT FRONT.
CHANGE THE LEFT FRONT TO
LEFT REAR.
CHANGE THE LEFT REAR TO
RIGHT FRONT.
CHANGE THE RIGHT FRONT
TO THE SPARE.
TIRE ROTATION WITH SPARE
I lEFT \ / RIGHT *.
I FRONT \/ FRONT |
I LEFT /\ RIGHT I
\ REAR / \ REAR /
CHANGE THE RIGHT FRONT TO
RIGHT REAR.
CHANGE THE RIGHT REAR TO
LEFT FRONT.
CHANGE THE LEFT FRONT TO
LEFT REAR.
CHANGE THE LEFT REAR TO
RIGHT FRONT.
TIRE ROTATION WITH NO SPARE
RA PD 58367
Figure 1 82— Tire Rotation
h. Care of Tires. Change the position of the tire and wheel
assemblies as shown in figure 182. Changing the direction of rotation
increases tire life. Repair any damage to tires as soon as possible
after damage is discovered. Prompt repairs of small damage will save
tires that might otherwise be ruined in a short distance. Do not allow
oil or grease to contact tires unnecessarily.
163. WHEEL AND TIRE ASSEMBLY.
a. Removal. Jack up wheel and remove the five large nuts which
hold the wheel to the hub. Turn the nuts on the left wheel clockwise
and the nuts on the right wheel counterclockwise to remove.
304
TM 9-808
163
WHEELS AND TIRES
FIRST POSITION
SECOND POSITION
THIRD POSITION
RA PD 58369
figure 1 83— Installing Spare Wheel on Carrier
305
TM 9-808
163-165
3/4 -TON 4x4 TRUCK (DODGE)
b. Installation. Install wheel and tire assembly on mounting'
studs. Turn nqts clockwise to install on right wheel and' counter-
clockwise to install on left wheel. Tighten nuts, then remove jack and
tighten each nut securely.
164. SPARE WHEEL AND TIRE ASSEMBLY.
a. RemovaL Insert key in lock, turn key clockwise and pull lock
off the mounting stud. Remove the large retaining nut, plain washer,
and plate which hold the wheel to the carrier bracket. CAUTION:
Lower wheel and tire assembly carefully to avoid possible personal
injury.
b. Installation (fig. 183). Roll the wheel and tire assembly
against the running board with the outside of the wheel out. To make
mounting the wheel to the carrier bracket easier and avoid possible
personal injury, lift the bottom of the tire out, and up until the tire
rests on the running board with the inside of the wheel out. Then lift
the wheel and tire assembly to the carrier bracket. On the Ambulance,
hook the center opening in the wheel disk over the clip on the carrier
bracket. Place the retaining plate and. plain washer over the carrier
jracket stud. Install the large stud nut and push the lock into place.
165. TIRE CASING AND TUBE.
a. Removal (fig. 184).
(1) Remove Tire from Wheel. Deflate inner tube if not
already deflated. Remove the 10 nuts which hold the side ring to the
wheel. Pry the side ring away from the tire and off the studs. Drive
the tire away from the inner flange and off the wheel.
(2) Remove Tube from Casing. Pry open the bead lock ring
hinge, thus reducing the diameter of the ring. Turn the bead lock ring
at right angles to the tire and slide jt off the valve stem. Remove the
tube from the casing.
b. Inspection. Inspect the inner and outer surfaces of the casing
for cuts, breaks, or any foreign material that would damage the tube.
If possible, repair any damage to casing before installing the tire.
Inspect the tube and valve for leaks by inflating the tube and holding
a portion of the tube at a time under water. A leak will be indicated
by air bubbles rising to the surface of the water.
c. Installation.
(1) Coat Tire Beads with Soapy Water. Installation of the
bead lock ring in the casing and assembly of tire on the wheel is made
easier by coating the base of the tire beads with soapy water. Do
not use oil or grease.
(2) Install Tube and Bead Lock Ring in Casing (fig. 185).
(a) Install the inner tube in the tire with valve stem opposite
balance dot on tire to maintain balance of the tire and wheel assembly.
Inflate the tube sufficiently to just round it out to prevent the tube
falling out of the tire or being pinched, during the mounting oper-
306
TM 9-808
165
WHEELS AND TIRES
DEFLATE INNER TUBE BEFORE
REMOVING SIDE RING ,
WHEEL SIDE RING BOLT NUTS
PRYING WHEEL SIDE RING
DRIVING WHE EL fROM TIRE
SLIDING TIRE BEAD LOCK RING OFF
VALVE STEM RA PD 301080
Figure 1 84— Removing Tire from Wheel
307
TM 9-808
165
3/4 -TON 4x4 TRUCK (DODGE)
COLLAPSING TIRE BEAD
LOCK RING
SLIDING TIRE BEAD LOCK
RING ON VALVE STEM
EXPANDING TIRE BEAD
LOCK RING IN TIRE
TIRE BEAD LOCK RING
INSTALLED
RA PD 65948
figure 1 85— Installing Tire Bead Lock Ring
308
TM 9-808
165
WHEELS AND TIRES
ation. This will also facilitate installation of the bead lock ring. With
a quick pressure on the bead lock ring about eight inches from the
hinge, collapse it to the limit which the hinge will allow.
(b) Hold the tire with the tube installed, upright with valve stem
at point nearest the ground, and insert the valve stem through- the
driving lug of the bead lock ring with ring at right angle to the tire.
Pull the stem up through the bead lock ring so that the valve stem
rests on top of the lug. Then apply pressure to the bead lock ring
until the point opposite the valve opening is centered between the
beads of the tire.
(c) Apply air pressure to the tube to spread the beads of tire
apart for a distance approximately equal to the width of the bead lock
ring. Then swing the ring, using the valve opening as an axis, until it
slips into place between the beads of the tire. With the bead lock
ring in this position, release enough air from the tube to permit the
ends of the bead lock ring to be returned to their normal position. To
do this, hold the extended end of the lock ring in place with one foot
and give the depressed end a quick upward pull with both hands.
(d) Inspect the complete assembly to make sure that the bead
lock ring is properly centered with its edges below the base of the tire
bead.
(3) Install Tire on Wheel. Place the wheel on blocks high
enough to prevent the tire sidewalls touching the ground when the
tire is in place on the wheel. Drop the tire down over the wheel, care-
fully centering the valve stem in the slot in the wheel. Be sure neither
the tire nor the valve stem is cocked as this would cause difficulty in
mounting the tire. Install the tire side ring so that the valve stem is
centered in one of the valve slots in the side ring. Tap the side ring
down and start the side ring nuts on the studs. Proper installation
of the tire side ring nuts will avoid distortion of the side ring. Begin
by drawing down at least three side ring nuts on each side of ring.
Do not draw down the nuts at the cut-outs first, as this would cause
distortion of the side ring at these points. Draw down all nuts evenly
and alternately until they are all tight and inflate the tire to 40
pounds pressure.
309
TM 9-808
166-167
3/4 -TON 4x4 TRUCK (DODGE)
Section XXXVI
STEERING
Paragraph
General description 166
Steering gear 167
Steering gear (Pitman) arm 168
Drag link : 169
166. GENERAL DESCRIPTION.
a. The steering gear is the worm and sector type. Adjustments
for proper mesh and elimination of end play can be made without
removing the assembly from the vehicle.
167. STEERING GEAR.
a. Adjustment of Steering Gear in Vehicle.
(1) Preliminary Checks.
(a) Check for Backlash. Turn the steering wheel all the way to
right or left, then ^ turn in the oposite direction. With the wheel
in that position there will be backlash in the steering gear. If • the
steering wheel can be moved back and forth through the backlash
without noticeable resistance, the steering post is in alinement.
(b) Check for Bend in Steering Post. If the steering wheel does
not move freely through the backlash, there is excessive friction in
the steering post, caused by misalinement of the post,, excessive end
thrust on the steering gear, worn bearings or a tight stetring column
jacket bushing. Remove the bracket which holds the steering post
to the instrument panel. If the post shifts when the bracket is re-
moved and the excessive friction is relieved or if the post bears up
against the instrument panel, realine the post (step (2) below).
(c) Check Worm Adjustment. If the excessive friction is not
relieved by removing the clamp from the instrument panel and the
post does not bear agaiinst the panel, loosen the four cap screws
which hold the steering gear housing cap to the steering gear housing
(fig. 186). If the friction is then relieved, adjust the steering gear
worm bearings (step (3) below). If friction still exists, with the
post bracket damp -removed, post not bearing against the instrument
panel and the steering gear housing cap loose, the steering column
jacket bushing is binding. Notify higher authority. Install post
bracket clamp and tighten the steering gear housing cap screws.
(2) Steering Post Alinement.
(a) Adjust Bracket. If the steering post moves down or bears
against the instrument panel when the bracket is removed, loosen
the bolts which hold the steering gear housing to the frame. Move
the steering post into position and install bracket. Tighten the steer-
ing housing to the frame. If the steering post moves sidewise when
310
TM 9-808
167
STEERING
the bracket is removed, shift the clamp on the instrument panel to
meet the post by elongating the bolt holes in the clamp and the
instrument panel.
(b) Install Bracket. Install the steering post bracket. Place a
toothed lock washer on each of the two attaching bolts. Insert the
right bolt through the clamp and instrument panel, install another
toothed lock washer over the bolt, and install the nut. Install the
left bolt through the ground strap, place another toothed lock washer
over the bolt, then insert the bolt through the clamp and instrument
panel. Install a third toothed lock washer over the bolt and install
the nut.
STEERING GEAR HOUSING
BRACKET ADJUSTING STUD NUT
■ ECCENTRIC ADJUSTING SLEEVE
.STEERING
GEAR SHAFT
ADJUSTING SCREW '
HOUSING CAP SHIMS .
RA PD 53058
[STEERING GEAR HOUSING BRACKET
. HOUSING BRACKET STUD NUTS
RA PD 53057
Figure 1 86— Worm and Shaft
End Play Adjustments
Figure 1 87— Worm and Sector
Mesh Adjustment
(3) Worm Bearing Adjustment (fig. 186).
(a) Check Adjustment. Turn the steering wheel all the way to
right or left,' then y^ turn in the opposite direction. With the wheel
in that position, side thrust on the worm bearings will be relieved
and there will be some backlash in the steering gear. Separate the
connector in the horn wire between the steering gear and the horn.
Remove the four cap screws which hold the cap to the lower end of
the steering gear housing and remove the cap. Shims of three differ-
ent thicknesses (0.010 in., 0.005 in., and 0.003 in.) are used at this
point.
311
TM 9-808
167
3/4 -TON 4x4 TRUCK (DODGE)
(b) Remove or Install Shims as Required. When the cap is
tightened into place there should be slight resistance to the backlash
in the wheel and no end play in the worm. Use a knife to separate
top shims, passing the blade all the way around between the shims,
taking care not to mutilate the remaining shims. Check end play by
lifting up and pushing down on the steering wheel while holding a
finger against the joint between the bottom of the steering wheel hub
and the steering column jacket. Any end play in the worm can be
felt at that point. When adjustment is completed, connect the horn
wire and make sure the insulator is over the connector.
(4) Steering Gear Shaft Adjustment (fig. 186). Loosen lock
nut on steering gear shaft adjusting screw. Loosen the screw so that
RA PD 312568
Figure 1 88— Removing Sfeering Wheel
end play can be felt in the shaft by pushing in and pulling out on
the steering gear arm. Turn the adjusting screw in just enough to
eliminate the end play and tighten the lock nut.
(5) Worm and Sector Adjustment (fig. 189).
(a) Locate Steering Gear Mid-Position. Remove rear end of
drag link from steering gear arm (par. 169). With drag link discon-
nected, turn the steering wheel to the extreme right or left. Then
turn it all the way in the opposite direction, counting the number
of turns required to make the turn from one extreme to the other.
Then turn the steering wheel back % that number of turns. At this
position, the spoke with the trade mark (composition type wheels)
312
TM 9-808
167
STEERING
should point directly down. On later model vehicles having a steel
spoke wheel, the spoke adjacent to the two square openings in the
lower edge of the wheel hub should point straight down. If the spoke
does not point straight down, rotate the' steering wheel the 'nearest
way to bring the spoke straight down. The steering gear will then
be in mid-position.
(b) Adjust Worm and Sector. Loosen the housing bracket to
frame bolts. Loosen the four housing bracket stud nuts Yn turn and
the bracket adjusting stud nut 54 turn. Turn the eccentric adjusting
sleeve clockwise very slowly, checking at each movement the amount
RA PD 53065
Figure 189— Removing Steering Gear Arm
of lost motion still existing at the steering gear arm. Adjust to a
point where a slight resistance is felt in mid-position as the wheel
is moved back and forth. With this adjustment correctly made,
tighten the housing bracket stud nuts and the bracket adjusting stud
nut. Turn the steering wheel throughout full travel and test for free
operation. Backlash will be noticeable when the wheel is turned from
the mid-position. Tighten the housing bracket to frame bolts. Install
drag link to the steering gear arm (par. 169).
b. Removal of Steering Wheel (fig. 188). Remove horn button
and cable assembly (par. 120 d). Remove nut which holds the steer-
ing wheel on the tube. Pull steering wheel off the tube.
* 313
TM 9-808
167-169
%
-TON 4x4 TRUCK (DODGE)
c. Installation of Steering Wheel. Install the steering wheel key
in the steering gear tube and install the steering wheel on the tube.
Install the horn button lower retainer plate, steering wheel nut, and
tighten the nut. Place the horn button retainer plate spring on the
lower retainer plate and install horn button and cable assembly (par.
120 e).
168. STEERING GEAR (PITMAN) ARM.
a. Removal (fig. 189). Disconnect drag link at steering gear arm
(par. 169). Remove the steering gear arm nut. Install the steering
gear arm puller and pull the arm from the steering gear shaft.
[LOCK WIRE REMOVED
DRAG LINK REMOVED FROM
STEERING ARM
. DRAG LINK END ADJUSTING TOOL
RA PD 53061
■ STEERING ARM BALL
. DRAG LINK DUST COVER
RA PD 53062
figure 1 90— Adjusting Drag
Link End
Figure 1 9 1 —Removing Drag
Link from Steering Arm
b. Installation. Turn the front wheels by hand so they are set
in the straight ahead position. Locate the mid-position of the steer-
ing gear (par. 167 a (5) (a)). Connect drag link to steering gear arm
(par. 169). Install the steering gear arm on the steering gear shaft
and drive the arm on the shaft. Install the steering gear arm lock
washer and nut and tighten securely.
169. DRAG LINK.
a. Adjustment (fig.. 190). Remove lubricating fitting. Remove
lock wire. Screw end plug in tight, then back it off to the nearest
lock wire hole. Install lock wire and lubricating fitting.
314
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169
STEERING
b. Removal and Disassembly (fig. 191). Remove lubricating
fitting. Remove lock wire. Unscrew and remove the end plug. Remove
the metal dust cover. Turn the steering wheel back and forth to
loosen the ball socket and allow the drag link to be lifted off the-
ball of the steering arm.
c. Inspection. Inspect the ball on the steering arm and the steer-
ing gear arm. If either ball is damaged or worn excessively out of
round, replace the arm.
d. Assembly and Installation. Place drag link end over ball on
the steering arm and install the metal dust cover. Install the ball
socket, spring, and end bumper in order. Install end plug and screw
the plug in tight, then back it off to the nearest lock wire hole. Install
wire lock and lubricating fitting. Lubricate through lubricating
fitting.
315
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170-171
3/4 -TON 4x4 TRUCK (DODGE)
Section XXXVII
FRAME
Paragraph
General description 170
Bumpers 171
170. GENERAL DESCRIPTION.
a. The frame (fig. 192) is constructed of pressed steel channel
section side rails reinforced by cross members. A pintle hook is
mounted on the rear cross member of the frame and a tow hook is
attached to each of the frame front horns.
TRANSFER CASE FRAME CROSSMEMBER -
REAR SPRING FRONT BRACKET FRAME CROSSMEMBER .
FRAME SIDEMEMBER-LEFT FRAME REAR CROSSMEMBER -■>
U FRONT BUMPER — LEFT REAR BUMPER — LEFT
RA PD 53068
figure 192— Frame
171. BUMPERS.
a. Removal of Front Bumper (Vehicles without Winch). Re-
move the two tow hook to frame bolts and nuts. Loosen the two
tow hook to frame rear bolts and nuts and swing the tow hook to one
side. Remove the two upper bumper to frame bolts and nuts and the
four upper bumper to bumper reinforcement bracket bolts and nuts.
Remove the four lower bumper to bumper support bracket bolts and
nuts.
316
TM 9-808
171
FRAME
b. Installation of Front Bumper (Vehicles without Winch).
Install the two upper bumper to frame bolts and nuts with lock
washers. Install the four upper bumper to reinforcement bracket bolts
and nuts with lock washers. Install the two tow hook to frame front
bolts and nuts with lock washers. Tighten the two tow hook to frame
rear bolts and nuts.
c. Removal of Front Bumper (Vehicles with Winch). Remove
the two upper front bumper to frame bolts and huts. Remove the two
upper winch cable guide to bumper bolts. Remove the four upper
bumper to reinforcement bracket bolts and nuts and the eight lower
support bracket to bumper bolts and nuts. Pull right and left bumpers
from frame.
d. Installation of Front Bumper (Vehicles with Winch). Insert
upper flange of right and left bumpers between winch cable guide
and frame. Install the two bolts and nuts with lock washers through
the winch cable guide, the bumper and frame. Install the two winch
cable guide to bumper bolts. Install the four upper bumper to rein-
forcement bracket bolts and nuts with lock washers and the eight
lower support bracket bolts and nuts with lock washers.
e. Removal of Rear Bumper (Except Carryall). Remove the
four bolts and nuts which attach the tail and signal lamp brackets
to the frame. Remove the two remaining bolts and nuts which attach
the bumper to the rear of the frame side member. Remove the
four bumper to cross member bolts and nuts. Disconnect the ground
strap (if so equipped) at the bumper.
f. Installation of Rear Bumper (Except Carryall).
(1) Install Bumper. Install the plain washers on the two upper
bolts or eyebolts and the two lower bolts and attach the bumper to
the frame rear cross member. Install the lock washers and nuts.
Install the two bolts and nuts with lock washers, attaching the bumper
to the frame side member. Attach the tail and signal lamp bracket
with the four bolts and nuts through the bracket, the bumper and
frairie.
(2) Install Ground Strap (If So Equipped). Install a toothed
lock washer on the bolt that attaches the ground strap to the bumper
and insert, the bolt through the bumper bar. Install another toothed
lock washer over the end of the bolt and place the ground strap over
the bolt. Then install the remaining toothed lock washer over the bolt
and install the nut.
g. Removal of Rear Bumper (Carryall). Remove the four cap
screws that attach the tail and signal lamp brackets to the frame.
Remove the two bolts and nuts attaching the bumper to the side
member and remove the four bumper to rear cross member bolts and
nuts. Disconnect the ground strap at the bumper.
317
TM 9-808
171
3/4 -TON 4x4 TRUCK (DODGE)
h. Installation of Rear Bumper (Carryall). Install the plain
washers on the two upper and two lower bolts and attach the bumper
to the frame rear cross member. Install the lock washers and nuts.
Install the two bolts and nuts with lock washers to attach the bumper
to the frame side member. Attach the tail and signal lamp bracket
with the four cap screws through the bracket, the bumper and into
the frame. Attach ground strap (subpar. f (2) above).
318
TM 9-808
172-173
Section XXXVIII
SPRINGS AND SHOCK ABSORBERS
Paragraph
General description 172
Shackle bolts 173
Spring bolts 174
Spring assemblies 175
Shock absorbers 176
172. GENERAL DESCRIPTION.
a. Springs. The chassis springs (fig. 193) are all of the semi-
elliptical type. The front end of the front springs and the rear end
of the rear springs pivot in shackles to allow for variant lengths of the
springs as they are flexed by load or rebound. The rear end of the
front springs and the front end of the rear springs are mounted on
pivot bolts in rigid brackets on the frame. The driving and braking
forces are transmitted from the axles to the frame through this end
of the springs.
b. Types of Springs Used. Trucks (other than Ambulance)
bearing serial number 81623727 or a lower serial number, excepting
serial numbers 81607816 through 81619000 were originally equipped
with eight-leaf front springs. Trucks (other than Ambulance) bearing
serial number 81623728 or a higher serial number and trucks with
serial numbers 81607816 through 81689000 were originally equipped
with nine-leaf front springs. The spring clips used with the eight-leaf
springs are 8^^ inches long. The clips used with most of the nine-leaf
springs are 8i%6 inches long. When a front spring is replaced, use
springs with the same number of leaves on both sides of the truck. If
81 %g inch clips are not available, when installing a nine-leaf spring,
use thin toothed lock washers instead of the heavy-duty lock washers
used with the 85^ inch clips.
c. Shock Absorbers. The hydraulic double-acting shock ab-
sorbers control the movement of the frame and body of the vehicle
in relation to the wheels and axles. By restricting rapid action of the
chassis springs, shock absorbers improve the riding qualities and
steering stability of the vehicle.
d. Data.
Springs, front:
Length 39 in.
Width 134 in.
Springs, rear:
Length 52 in.
Width If^ in.
173. SHACKLE BOLTS.
a. Removal of Front Spring Shackle Bolts (fig. 194). Place a
jack under the bumper and raise the front of the frame enough to
319
TM 9-808
173
3/4 -TON 4x4 TRUCK (DODGE)
-FRONT SPRING SHACKLE BOLTS
-FRONT SHOCK ABSORBER LINK ROD AND EYE BOLT
rFRONT SHOCK ABSORBER ASSEMBLY
' FRONT SPRING AXLE BUMPER
-FRONT SPRING CLIPS FRONT SPRING CLIP PLATE-
FRONT SPRING TORQUE ARRESTER^
CFRONT SPRING ASSEMBLY FRONT SPRING REAR BOLTJ
FRONT SPRING
REAR SPRING FRONT BOLT
. REAR SHOCK ABSORBER ASSEMBLY
■REAR SHOCK ABSORBER LINK ROD AND EYE
-REAR SPRING CENTER BOLT
-REAR SPRING CLIP PLATE
■ REAR SPRING ASSEMBLY
E / ^REAR SPR
i — DCAD QDDIM^ AYI
SPRING CLIPS
• REAR SPRING AXLE BUMPER
REAR SPRING SHACKLE BOLTS-'
RA PD 65950
J
Figure 1 93— front and Rear Spring Assemblies
320
TM 9-808
173
SPRINGS AND SHOCK ABSORBERS
take the load off the shackle bolts. Remove the cotter pins from the
slotted nuts at the outer end of the shackle bolts. Remove the slotted
nuts and drift out the bolts.
b. Installation of Front Spring Shackle Bolts (fig. 194).
(1) Install Shackle. Place the offset shackle to the inside of
the spring and frame with the long offset up. Install the bolts through
the shackle, spring and frame, raising or lowering the jack to aline
the holes. Place the straight shackle over the ends of the bolts and
install the nuts.
(2) Adjust Shackle Bolts. Tighten the shackle bolt nuts up
tight, using a 12 -inch wrench, then back each nut off one slot and
SHACKLE— INNER
r BOLT— UPPER
-SHACKLE AND BUSHING ASSEMBLY
BOLTS
-FRONT SPRING ASSE.MBLY
RA PD 53071
Figure 1 94— Front Spring
Shackle
■ REAR SPRING ASSE.MBLY
RA PD 53072
Figure 1 95— Rear Spring
Shackle
install the cotter pins. Do not adjust the bolts tighter than specified.
Too tight an adjustment will cause hard riding and spring breakage.
c. Removal of Rear Spring Shackle Bolt (figs. 195 and 199).
Remove lubrication fitting from end of bolt. Remove lock bolt from
bracket. Insert puller screw through puller barrel from closed end
and screw large nut back to head of puller screw. Screw the threaded
end of the puller screw tightly into the hole in the spring bolt from
which the lubrication fitting was removed. Center the open end of the
puller barrel around the end of the spring bolt. Hold the puller screw
from turning and screw the large nut against the closed end of the
puller barrel to pull the bolt.
321
TM 9-808
173-174
3/4 -TON 4x4 TRUCK (DODGE)
d. Installation of Rear Spring Shackle Bolt (fig. 195). Install
the spring bolt so that the lock bolt can be installed through the
groove in the bolt. Install the lock bolt with standard lock washer and
nut. Tighten nut securely. Remove jack from under frame.
174. SPRING BOLTS.
a. Removal of Front Spring Bolt (fig. 196). Place jack under
front bumper or frame and raise front of frame enough to take load
off spring bolt. Remove cotter pin and niit from outer end of spring
bolt. Remove the bolt from the bracket and spring eye.
FRONT SPRING REAR BOLT
• REAR SPRING FRONT BOLT
-BOLT LOCK BOLT
^IFRONT SPRING ASSEMBLY
RA PD 53073
REAR SPRING ASbbMbLY
RA PD 53074
Figure 1 96— Front Spring
Rear Bolt
Figure 197— Rear Spring
Front Bolt
h. Installation of Front Spring Bolt (fig. 196). Insert the spring
bolt through the bracket and spring eye from the inside of the bracket.
Install the slotted nut on the spring bolt. Tighten the nut up tight,
then back it off one slot and install the cotter pin.
c. Removal of Rear Spring Bolt (figs. 197 and 198). Remove
lubrication fitting from end of bolt. Remove lock bolt from bracket.
Insert puller screw through puller barrel from closed end and screw
large nut back to head of puller screw. On Command and left side of
Carryall, use washers 54 inch thick between puller barrel and spring
bolt bracket to extend puller out past edge of body. Remove battery
•to get to bolt on right side of Carryall. Screw the threaded end of
the puller screw tightly into the hole in the spring bolt from which the
322
TM 9-808
174-175
SPRINGS AND SHOCK ABSORBERS
lubrication fitting was removed. Center the open end of the puller
barrel around the end of the spring bolt. Hold the puller screw from
turning and screw the large nut against the closed end of the puller
barrel to pull the bolt.
d. Installation of Rear Spring Bolt (fig. 197). Install the spring
bolt so that the lock bolt can be installed through the groove in the
bolt. Install the lock bolt with standard lock washer and nut. Tighten
the nut securely. Remove jack from under the frame. Install battery
(Carryall only).
■SPRING BOLT PULLER
RA PD 53075
Figure 1 98— Removing Rear
Spring Front Bolt w/fh Puiler
41-P-2951-70
^SPRING BOLT PULLER
-LOCK BOLT REMOVED
RA PD 53076
Figure 199— Removing Rear
Spring Shack/e Bolt with Puller
4T-P-295I-70
175. SPRING ASSEMBLIES.
a. Removal of Front Spring Assembly. Remove four nuts from
spring clips. Drive the clips up and off the spring. Remove spring
lower shackle bolt (par. 173 a). Remove spring rear bolt (par. 174 a)
and lift out spring assembly.
b. Installation of Front Spring Assembly. Install spring rear
bolt (par. 174 b). Install spring lower shackle bolt (par. 173 b).
Locate the axle so that when the jack is lowered the spring center bolt
will enter the recess in the spring pad of the axle. Place rubber
bumper on top of the spring at the center and install the spring clips
over the rubber bumper, spring and through the bracket on the axle.
323
TM 9-808
175-176
3/4 -TON 4x4 TRUCK (DODGE)
Remove the jack, then install standard lock washers and nuts on
the clips and securely tighten the nuts.
c. Removal of Rear Spring Assembly, Remove the four nuts
from the spring clips. Drive the clips up and off the spring. Remove
rear spring front bolt (par. 174 c). Remove shackle bolt (par. 173 c)
and lift out spring assembly.
d. Installation of Rear Spring Assembly. Install rear spring
front bolt (par. 174 d). Install shackle bolt (par. 173 d). Locate the
axle so that when the jack is lowered the spring center bolt will enter
the recess in the spring pad of the axle. Place the spring clips over the
spring and through the bracket on the axle. Remove the jack, then
install standard lock washers and nuts on the clips and securely
tighten the nuts.
LINK DISCONNECTED FROM PLATE
PUMPING
^'-^^':iS:':y<
i
#
mm
r^
■ ■ it
^■5^
\
f^*m.:^
\
'1''-
*l:J!°l||ty
\
iSih
^
f
f ■
']
■r
w
.^
FILLINI
5 RA PD 65951
Figure 200-Pilllng Shock Absorber with fluid
176. SHOCK ABSORBERS.
a. Filling Shock Absorber (fig. 200). Use only shock absorber
fluid when filling shock absorbers. Do not use other fluids such as
ordinary engine oil or brake fluid. Disconnect the link at the lower
end (subpar. d below). Wipe off all dirt around the filler plug and
remove the plug. Fill the shock absorber to capacity as shown in
figure 200. Move the shock absorber arm to the extreme positions
several times to pump any air out of the cylinders. Add fluid and
repeat the pumping until all air is expelled and the reservoir filled
to overflowing. Allow excess fluid to drain out to the level of the
324
TM 9-808
176
SPRINGS AND SHOCK ABSORBERS
filler plug hole and install the filler plug, using a new gasket. Connect
the link assembly (subpar. e below).
b. Removal of Shock Absorber Assembly. Disconnect link from
shock absorber arm (subpar. d below). Remove two nuts and bolts
which hold shock absorber to the frame and lift off shock absorber.
c. Installation of Shock Absorber. Place the shock absorber in
the channel of the frame side rail and insert the bolts through the
frame and shock absorber body. Place standard lock washers over
the bolts and install the nuts. Connect link to shock absorber arm
(subpar. e below).
d. Removal of Shock Absorber Link Assembly. Remove nut
from the pin which connects the link to the arm. Remove the pin.
Remove nut from pin which connects link to eyebolt' at axle. Remove
the pin and lift off link assembly.
e. Installation -of Shock Absorber Link Assembly. Place the link
yoke, with the larger bolt hole, over the eyebolt and bushing at the
axle. Install the bolt and nut. Move the yoke at upper end of the link
over the bushing in end of shock absorber arm and install bolt and
nut.
325
TM 9-808
177-179
3/4 -TON 4x4 TRUCK (DODGE)
Section XXXIX
BODY AND SHEET METAL
Paragraph
General description 177
Hood 178
Fenders and splash shields 179
Cowl ventilator 180
Windshield assembly (open bodies) 181
Windshield assembly (closed bodies) 182
Windshield wiper assembly (open bodies) 183
Windshield wiper assembly (closed bodies) 184
Body mounting bolts 185
Interchanging bracket positions (Ambulance) . 186
Fire extinguisher 187
177. GENERAL DESCRIPTION.
a. The vehicle bodies covered by this section of the manual in-
clude all of the types described and illustrated in paragraph 3. Sheet
metal units such as rear fenders and running boards vary in design
to conform with the different body types. The Carryall and Com-
mand are equipped with a 12-volt battery mounted at the rear end
of the right running board. Other models are equipped with a 6-volt
battery located under the hood. Splash shields between the front
fenders and the chassis frame can be removed to make the lower
part of the engine more accessible.
178. HOOD.
a. Removal. Remove the two screws from the hood hinge front
support. Remove the support and tapping plate from the hood
hinge. Disconnect the hood to dash ground strap at the dash. Slide
the hood forward out of the rear support and remove it from the
vehicle.
b. Installation. Slide the center hinge rod into the rear support.
Slide the front hinge support over the end of the hinge rod, and, with
toothed lock washers between the shell and tapping plate, tighten
the screws. Place a toothed lock washer on each side of the ground
strap. Install the bolt and nut and tighten securely.
179. FENDERS AND SPLASH SHIELDS,
a. Removal of Front Fenders.
(1) Remove Lights and Cable Assemblies.
(a) Right or Left Front Fender. Slide the rubber insulator off
the- blackout parking light cable connector located near the terminal
block on the front frame cross member. Disconnect the two head-
326
TM 9-808
179
BODY AND SHEET METAL
light cable wires at the terminal block. Remove the two screws which
attach the headlight cable grommet to the fender and release the
cables from the clip holding them to the radiator shell, then pull
cables away from radiator shell and through opening between shell
and fender splash shield. Screw out blackout parking light cable
loom end from mounting stud and remove mounting stud nut. Re-
move blackout parking light and cable assembly. Remove the nut
from the headlight mounting stud and remove the headlight and
cable assembly.
(b) Left Front Fender Only. Disconnect blackout driving light
cable wire at the terminal block. Remove the two screws which attach
the blackout driving light cable grommet to the fender. Remove the
nut from the blackout driving light and remove blackout driving
light and cable assembly.
(2) Disconnect Fender. Remove the five upper cap screws that
attach the fender to the fender splash shield. Remove the three cap
screws that attach the fenders to the front support and remove the
three cap screws that attach the fender to the rear support.
b. Installation of Front Fender.
(1) Install Fender.
(a) Right or Left Front Fender. Place fender in position on
front support and install the three rear support to fender cap screws
with toothed lock washers. Install the three front support to fender
cap screws assembled with tootljed lock washers. Install the five
upper splash shield to fender cap screws assembled with the special
washers.
(b) Left Front Fender Only. Assemble the three upper splash
shield to fender cap screws with the special washers and cable clips,
to the three center screw holes and attach wiring cable under the
three clips.
(2) Install Lights and Cable Assemblies.
(a) Right or Left Front Fender. Install the blackout parking
light and cable assembly. Connect cable' at connector, then slide
rubber insulator over connector to prevent short circuit. Install the
headlight and cable assembly. Attach the two wires to the terminal
on the terminal block, located on the frame front cross member
matching the colors of the wires with those attached to terminal
block. Attach "the grommet with the two screws.
(b) Left Front Fender Only. Install the blackout driving light
and cable assembly. Attach the wire to the terminal block matching
the color of the wire with the wire attached to terminal block. Attach
the grommet with the two screws.
(3) Aim Lights (par. 105 or 107).
c. Removal of Rear Fenders.
(1) Right or Left Rear Fender. Remove the bolts which
attach the fender to the running board. Remove the cap screws which
attach the fender to the body wheel housing.
327
TM 9-808
179-180
3/4 -TON 4x4 TRUCK (DODGE)
(2) Right Rear Fender (Carryall Only). Remove the cap
screw which attaches the battery cover to the running board. Remove
the cap screw which attaches the cover to the battery hold-down
bracket. Remove the battery hold-down bracket.
d. Installation of Rear Fenders.
(1) Right or Left Rear Fender. Install the cap screws with
toothed lock washers which attach the fender to body wheel housing.
Install the bolts assembled with toothed lock washers which attach
the fender to the running board and install the nuts with toothed
lock washer.
(2) Right Rear Fender (Carryall Only). Install the plain
washers between the fender and running board when installing the
bolts and nuts which attach the fender to the running board. Install
the battery hold-down bracket on fender. Then close the battery
cover and install the battery cover hold-down cap screws.
e. Removal of Front Fender Splash Shields. Remove the cap
screws which attach the lower sides of the splash shield to the front
and rear brackets. Remove the five cap screws which attach the
upper side of the splash shield to the fender. F*ull out shield under
fender.
f . Installation of Front Fender Splash Shields.
(1) Install Right Splash Shield. Place splash shield in posi-
tion and install the five cap screws with special washers, attaching the
upper side of shield to the fender. Install the right front bracket cap
screw and both rear bracket cap screws assembled with toothed lock
washers.
(2) Install Left Splash Shield. Assemble the five upper splash
shield to fender cap screws with the special washers and cable clips
under the three center screws and attach the wiring cable under the
clips. Install the left front bracket cap screw with a toothed lock
washer assembled through the ground strap. Install another toothed
lock washer on the cap screw and install the cap screw through the
front bracket to attach the shield.
180. COWL VENTILATOR.
a. Replacement of Ventilator Lid. Remove the two screws
which attach the lid to the lid hinge and the two screws which attach
the lid to the linkage and lift off the lid. To install, insert the two
screws with lock washers that attach the lid to lid hinge and the
two screws wjth lock washers that attach the lid linkage to lid, but
do not tighten until the lid is adjusted (subpar. b below).
b. Adjustment of Ventilator Lid. Loosen the two screws which
attach the lid to the hinge and the two screws which attach the lid
to the linkage. Close the ventilator in position and hold it tightly
centered in the body opening while tightening the lid to hinge screws
from underneath the cowl. Then tighten the lid to linkage screws.
c. Replacement of Ventilator Weatherstrip. Remove ventilator
lid (subpar. a above), and insert a screwdriver between the ends of
328
TM 9-808
180-181
BODY AND SHEET METAL
the weatherstrip. Pull the weatherstrip out of the cowl recess and
clean out the recess thoroughly. Coat the recess and contacting sur-
face of weatherstrip with cement and install the weatherstrip in the
recess, so the two ends are butted together at the front of the venti-
lator. Install ventilator lid (subpar. a above) and adjust (subpar. b
above).
181. WINbSHIELD ASSEMBLY (OPEN BODIES),
a. Removal.
(1) Remove Windshield Wipers (par. 183).
WINDSHIELD SUPPORT WITH GLASS
■ ASSEMBLED
WINDSHIELD GLASS AND GLASS
FRAME BEING REMOVED FROM
SUPPORT.
SUPPORT BENT UP FOR REMOVAL
OF GLASS
RA PD 53080
Figure 201 -Windshield Support
(Open Bodies)
RA PD 53081
Figure 202— Removing Wind-
shield Glass Assembly
(Open Bodies)
(2) Remove Adjusting Arm Screws. Remove the screw which
attaches the frame to the adjusting arms from the brackets on each
side of the frame. Loosen the adjusting arm lock nuts and carefully
mOve the adjusting arms away from the frame bracket and remove
the spring washers.
(3) Remove Windshield Assembly (figs. 201 and 202). Open
either end of the windshield support hinge where the hinge is bent
over to retain the windshield frame. Disconnect the windshield wiper
flexible tube where it attaches to the metal tube across the top of
the windshield frame. Open the windshield glass and frame assembly
wide and pull the assembly out of the open side of the support hinge.
329
TM 9-808
181-183
3/4 -TON 4x4 TRUCK (DODGE)
b. Installation.
(1) Install Windshield Assembly. Hold the glass and frame
assembly in the fully opened position, with the pull-to handle down
and insert the frame hinge flange into the open end of the support
hinge, then push the glass and frame assembly all the way into the
support hinge.
(2) Attach Adjusting Arms and Line Up Assembl^y. Install the
spring washers on the windshield frame adjusting arm brackets and
attach the arms with the screws. Open and close the glass and frame
assembly to line it up and then tighten the adjusting arm lock nuts.
Bend the end of the support hinge to close the hinge opening. Con-
nect the windshield wiper flexible tube to the windshield frame metal
tube.
(3) Install Windshield Wipers (par. 183).
182. WINDSHIELD ASSEMBLY (CLOSED BODIES).
a. Removal. Remove windshield wipers (par. 184), Open the
windshield wide and remove the six screws which attach the frame
to the windshield hinge. Remove the screw which attaches the frame
to the adjusting arms from the brackets on each side of the frame.
Loosen the adjusting arm lock nuts and carefully move the adjusting
arms away from the frame bracket and remove the spring washers.
Then lift the frame and glass assembly from the windshield hinges.
b. Installation. Place windshield glass and frame assembly on
the hinges and install the six screws to attach the frame and glass to
the hinge. Install the spring washers on the windshield frame adjust-
ing arms. Install windshield wipers (par. 184).
c. Adjustment (fig. 203). Close the windshield glass and frame
assembly tight in the body opening to determine what adjustment
is required. Remove the two header panel cover plates by removing
the plate screws. To raise or lower glass and frame assembly in the
body opening, loosen the adjusting arm lock nuts and open the glass
and frame slightly. Loosen the four screws which attach the body
hinges to the glass and frame hinge brackets. Raise or lower the
assembly to center it in the opening as required; then tighten the
screws. To adjust the glass and frame assembly closer to the body
opening, loosen the four hinge cap screws which attach the hinges to
the body header brackets. Close the glass and frame assembly and
hold it into the opening tightly, while tightening the hinge to body
bracket screws. Replace the two header panel cover plates and install
plate screws.
183. WINDSHIELD WIPER ASSEMBLY (OPEN BODIES).
a. Removal. Remove the nut that attaches the wiper arm and
blade assembly to the motor shaft and remove the arm and blade
assembly. Remove the motor mounting nut and the outer spacer. Pull
the wiper motor toward the inside of the windshield frame and twist
back and forth to release the motor from the flexible tube. Then pull
330
TM 9-808
183-184
BODY AND SHEET METAL
the wiper and inner spacer from the windshield frame upper cross-
piece.
b. Installation. Install the inner spacer on the wiper motor. In-
stall the motor in the windshield frame upper crosspiece and attach
the flexible tube. Install the outer spacer with the spacer flange
against the upper crosspiece and install the motor mounting nut.
Attach the blade and arm assembly to the motor shaft and move the
arm to the right or left as far as it will go. Remove and reset the
blade arm if it is not properly centered in the glass.
WINDSHIELD HINGE TO BODY BRACKET SCREWS -
Figure 203-WlndsMeld Hinge and Wiper Location
(Closed Bodies)
184. WINDSHIELD WIPER ASSEMBLY (CLOSED BODIES).
a. Removal (fig. 203). Remove the header panel cover plate
screws and remove the plate. Remove the nut that attaches the
wiper arm and blade assembly to the motor shaft and remove the
arm and blade assembly. Remove the motor mounting nut and the
outer spacer. Pull the wiper motor toward the inside of the vehicle
and release the flexible tube. Remove the inner spacer.
b. Installation. Install the inner spacer over the motor mounting
hub. Install the motor in the header opening and attach the flexible
tube to the motor. Install the outer spacer over the motcfr hub and
install the mounting nut. Attach the arm and blade assembly to the
motor shaft and move the arm to the right or left as far as it will
go. Remove and reset the blade arm if it is not properly centered
in the glass. Install the header panel cover plate.
331
TM 9-808
185-187
3/4 -TON 4x4 TRUCK (DODGE)
185. BODY MOUNTING BOLTS.
a. Weapon Carrier, Telephone Maintenance, and Emergency
Repair Bodies. The front section or open cab composing windshield,
cowl, and bucket seat assembly is mounted on the frame solidly with
a bolt at the left front corner and with spring-loaded bolts at the
other three corners. The rear body section of the Weapon Carrier
and Telephone Maintenance is solidly mounted to the chassis frame
at six points; the Emergency Repair body is mounted solidly to
frame at four points.
b. Carryall, Ambulance, and Command. The bodies of these
vehicles are mounted solidly to the chassis frame as follows:
(1) Carryall, 10 points.
(2) Ambulance, 14 points.
(3) Command, 8 points.
c. Tightening and Adjusting. To tighten and adjust open cab
mounting bolts, tighten the left front bolt nut securely. Compress
the springs of the three spring-loaded bolts to 3% inches with the
bolt nut. Keep the mounting bolts of the body sections which are
mounted solidly on frame tightened securely.
186. INTERCHANGING BRACKET POSITIONS
(AMBULANCE).
a. In trying to slide two litters on the floor of the Ambulance,
interference occurs between the litter legs, and the rear litter strap
and the bracket assembly. This is particularly true on the older type
wooden litters (the legs on the later type litters have been changed
to provide additional side clearance). Because of this interference,
it is necessary to lift the litter oyer the rear floor strap bracket before
the litter can be slid into place.
b. To prevent interference between rear floor litter strap brackets
and litter legs, interchange the rear floor litter strap brackets and
the brackets molinted on top of the locker boxes on the sides of the
body. To do this, proceed as follows (fig. 204).
(1) Use same center line for this installation. Drill one i%2"in'*^h
hole in the top of the locker box. This hole should be 7^ inches from
the end of the locker, and 1 inch from the outer edge.
(2) Drill two %2'iii<^h holes in the side of the locker box for the
bracket that was on the top of the locker box. These holes should be
23//^ inches up from the floor of the vehicle.
(3) Install the strap and brackets in the same manner as shown
in figure 204, using the same attaching bolts.
(4) This correction should be performed on both sides of the
body in the rear.
187. FIRE EXTINGUISHER.
a. Test the fire extinguisher as explained in paragraph 11. If the
extinguisher contains dirty fluid, empty it and refill with one quart
332
TM 9-808
187
BODY AND SHEET METAL
of underwriter's approved SOS liquid (Specification OF 380) made
especially for this type, extinguisher. Do not use water or any other
chemical intended for other types of fire extinguishers in this extin-
guisher.
b. To refill, remove filler hole plug and pull handle out to full
extent of travel. Pour liquid through filler- hole until extinguisher is
full. Install filler hole plug and pump extinguisher plunger up and
down once or twice to remove trapped air. Push handle down and
lock in position. Remove filler hole plug and add sufficient liquid
to fill the extinguisher. Install filler plug and gasket.
RA PD 35571
Figure 204— Interchanging Bracket Positions (Ambulance)
c. If the test indicates the fluid is clean, but insufficient in quan-
tity, discharge part of the liquid in the extinguisher and fill to level
of lower edge of filler plug opening. Replace plug and tighten
securely.
333
TM 9-808
188
3/4 .TON 4x4 TRUCK (DODGE)
Section XL
WINCH
Paragraph
General description 188
Brake adjustments 189
Drum brake shoe and lining 190
Drive joint shear pin 191
Winch drive shaft 192
Winch assembly 193
188. GENERAL DESCRIPTION.
a. A winch is mounted on the front of the Weapon Carrier and
Command (models WC-52 and WC-57) and is operated by powei
^_ ';:;SAFETy BRAKE HOUSIN^^ ^^RRUA^RAKE SHOE LINING
BAND ADJUSTING AND LOCK NUTS
RA PD 53083
SHOE ADJUSTING AND LOCK NUTS
RA PD 53084
Figure 205-Adiustlng Winch
Safety Brake
figure 206-Adjusting Winch
Drum Brake
from the engine of the vehicle. The power is transmitted through the
vehicle transmission to a power take-off unit, mounted on the side
of the transmission case, then through a drive shaft to the winch
assembly. Operation of the winch is controlled from the driver's com-
partment. A shear pin located in the front universal joint of the
winch drive shaft is expected to shear off before damage occurs,
should the winch be excessively overloaded.
334
TM 9-808
189-190
WINCH
189. BRAKE ADJUSTMENTS.
a. Adjustment of Safety Brake (fig. 205). If load slips when
take-off is in neutral or when shear pin has failed, increase spring
tension on brake spring by turning the adjusting nut on underside of
brake case clockwise. Tighten % turn, then tighten lock nut and test.
Tighten more (by ^4 turns) if necessary. Even if correctly adjusted,
the brake will heat somewhat but if the hand cannot be held on the
brake case, the brake adjustment is too tight.
b. Adjustment of Drum Brake (fig. 206). If the winch drum
spins when the cable is being released, it will be necessary to adjust
WINCH ASSEMBLY r-SHEAR PIN /-SHEAR PIN COTTER PIN
WINCH UNIVERSAL DRIVE JOINT ASSEMBLY— FRONT
Figure 207— Winch Universal Drive Joint Shear Pin
the brake. The brake shoe link and adjusting nuts are mounted at the
inner end of the sliding clutch shifter lever and are accessible for ad-
justment from the underside of the winch when the sliding clutch is
engaged. Loosen the lock nut and turn the adjusting nut to increase
tension on the spring to tighten the brake. Reduce the tension on the
spring to loosen the brake. When adjustment is completed, hold the
adjusting nut and tighten the lock nut.
190. DRUM BRAKE SHOE AND LINING.
a. Removal. Remove cotter pin from lower end of the pin
around which the sliding clutch shifter lever pivots. Pull the pin
out and remove the brake shoe. Remove the rivets which hold the
lining to the shoe.
335
TM 9-808
190-192
3/4 -TON 4x4 TRUCK (DODGE)
b. Installation. Rivet new lining to the shoe. Install coiled spring
over adjustment screw and put the shoe in place. Install the pivot pin
through the brake shoe link and the shifter lever. Place cotter pin
through lower end of the pivot pin. Adjust drum brake (par. 189).
191. DRIVE JOINT SHEAR PIN.
a. Removal (fig. 207). Remove lock wire from set screw in collar
at rear end of winch drive shaft. Loosen set screw in the collar and
slide the drive shaft universal joint of the. winch shaft. Drift broken
shear pin out of winch shaft and universal joint.
SHEAR PIN /-DPIVE JOINT ASSEMBLY- CRONT ^DRIVE SHAFT pSFT SCREW
A COLLAR SET SCREW-^ //
WINCH ASSEMBLY* DRIVE JOINT ASSEMBLY— REAR-'4oWER TAKE-OFF ASSEMBLY
RA PD 53086
Figure 208-Winch Universal Drhre Shaft and Joint
b. Installation (fig. 207). Slide the universal joint over the winch
shaft with the pin holes in line. Use drift to aline holes. Insert shear
pin through universal and winch shaft and install cotter pin through
end of the shear pin. Slide the collar at the rear end of the drive shaft
to ^ to 54 inch from the universal joint yoke on the rear end of
the drive shaft. Tighten the set screw and install lock wire.
192. WINCH DRIVE SHAFT.
a. Removal (fig. 208). Remove lock wires from set screws in
collar at rear end of winch drive shaft and rear universal joint. Loosen
set screws and pull the joint off the power take-off shaft. Remove
drive shaft shear pin (par. 191) and pull the front universal joint and
drive shaft off the winch shaft.
336
TM 9-808
192-193
WINCH
b. Installation (fig. 208). Slide the front universal joint yoke
over the winch shaft and install the drive shaft shear pin (par. 191).
Move the rear universal joint onto the power take-off shaft to i^g inch
from the power take-off housing and tighten the set screws; also,
slide collar at rear end of drive shaft to ^ to % inch from the
universal joint yoke and tighten set screws. Install lock wires.
193. WINCH ASSEMBLY.
a. Removal. Remove lock wire from set screw in collar at rear
end of the drive shaft. Loosen the set screw. Remove cotter pin from
end of the shear pin. Remove the shear pin. Slide the drive shaft
universal joint off the end of the winch shaft. Remove six nuts and
bolts which hold the winch assembly to the frame. Attach chain
or rope from hoist around the left end of the winch drum. Raise
winch slightly and swing it to the right enough so that its frame will
clear the tow hook on the frame left side rail. Lift the winch assembly
out of the chassis frame.
b. Installation. Attach chain or rope from hoist around the left
end of the winch drum and hoist the winch above chassis frame arid
a little to the right of its installed position, so that when it is lowered,
its frame will clear the tow hook on the frame left side rail. Lower the
winch into the chassis and swing it to the left and into position. Install
the six mounting bolts with standard lock washers and nuts. Place
the drive shaft universal over end of winch shaft with shear pin holes
in line, and aline holes. Insert shear pin through the hole and install
cotter pin through end of the shear pin. Slide the collar at the rear
end of the drive shaft back to within 5^ to 54 irich of the rear universal
joint yoke, tighten set screw, and install lock wire.
337
TM 9-808
194
3/4 -TON 4x4 TRUCK (DODGE)
PART THREE-STORAGE AND SHIPMENT
Section XLi
STORAGE AND SHIPMENT
Paragraph
Storage and shipment (general) . 194
Special precautions for storage 195
Methods of securing vehicle on freight cars 196
Overseas shipment 197
Shipment with combat units 198
194. STORAGE AND SHIPMENT (GENERAL).
a. The 5^ -ton truck will usually be shipped uncrated for domestic
shipment. For overseas shipment trucks will usually be shipped
crated in pairs. Preparation for temporary storage (less than 60
days) will be the same as preparation for domestic shipment, and
preparation for indefinite storage (over 60 days) will be the same
as the preparation for overseas shipment.
b. Preparation for . Domestic Shipment and Temporary Stor-
age.
(1) Lubrication. Lubricate the vehicle completely before stor-
age or shipment.
(2) Fuel in Tanks. It will not be necessary to remove the fuel
from the tanks nor to label these tanks under Interstate Commerce
Commission Regulations.
(3) Water in Radiator. Drain the radiator only when there is a
possibility of freezing during storage or shipment. If the water is
drained from the radiator, tie a conspicuous tag to the steering wheel
of each vehicle indicating that the radiator is empty.
(4) Battery. Disconnect the battery by removing the positive
battery cable. Tape the cable and tie it away from the battery.
(5) Unpainted Surfaces. Treat all unpainted and exposed sur-
faces with rust-preventive before the vehicle is stored or shipped.
After cleaning the surface with solvents or a soap solution, treat all
exterior surfaces with a thin film of rust-preventive compound.
Apply preventive cold by spraying or brushing. It will harden to a
tough thin film. Treat surfaces from which it would be difficult to
remove rust-preventives, such as the bore of a gun, with rust-prevent-
ive compound, light. Apply this compound by brushing or slushing.
(6) Tires. For domestic shipment, inflate the tires to about 10
pounds above normal.
(7) Inspection. Make systematic inspection just before shipment
or storage. Make a list of all missing items or broken items that are
not repaired, and attach the list to the steering wheel.
338
STORAGE AND SHIPMENT
IfA 9-808
194
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339
TM 9-808
194-196
3/4 -TON 4x4 TRUCK (DODGE)
c. Preparation for Overseas Shipment and Indefinite Storage.
Observe all precautions given in paragraph 194 b in preparation for
overseas shipment and indefinite storage. Many additional precau-
tions must be taken, especially for overseas shipment. (See AR
850-18.)
195. SPECIAL PRECAUTIONS FOR STORAGE.
a. Take the following precautions when the truck is prepared for
storage.
b. Engine.
(1) Check the engine oil and replenish if necessary.
(2) Remove the air cleaner from the carburetor.
(3) Start the engine and run it at a fast idle, spraying approxi-
mately one pint of lubricating oil preservative (medium) into the
carburetor throat. Turn off the ignition switch immediately after
the oil has been sprayed into the carburetor.
(4) With the ignition switch off, open the throttle wide and turn
the engine over several complete revolutions by means of the start-
ing motor.
(5) Install the air cleaner.
c. Brakes. Release the brakes and block the wheels.
d. Inspections.
(1) Inspect the vehicles weekly for tire leaks or discharged bat-
teries.
(2) Upon removal from storage, repair or replace any items noted
on the tag attached to the steering wheel as still needing repair or
still missing, and perform a complete monthly maintenance inspec-
tion.
196. METHODS OF SECURING VEHICLE ON FREIGHT CARS.
a. There -are two approved methods of blocking the ^-ton trucks
on freight cars as described below.
b. Method 1 (fig. 209).
(1) Blocks B. Place eight blocks B to the front and to the rear
of each front wheel and to the front of each forward rear wheel, and
to the back of each rearward rear wheel. Nail the heel, of the block
to the car floor with five 40-penny nails, and toenail that portion
of the block under the tire to the car floor with two 40-penny nails.
CAUTION: Nail blocks B in such a position that cleats C will clear
face of tires by Y^ inch.
(2) Cleats C. Place two cleats C against the outside face of
blocks B at each front and rear wheel. Nail the lower cleats to the
car floor with three 40-penny nails and the top cleat; to the cleats
below with three 40-penny nails. .Fill the 54 -inch space between tires
and cleats C with burlap or other similar material to prevent chafing
of tires.
340
STORAGE AND SHIPMENT
TM 9-808
197
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341
TM ^-808
196-198
3/4 -TON 4x4 TRUCK (DODGE)
(3) Strapping D. Pass four strands, two wrappings, of No. 8
gage, black annealed wire (D, fig. 209) through the spokes of the
wheels and the stake pockets. Tighten the wires enough to remove
slack. If a box car is used, apply this strapping in similar fashion
and attach it to the floor by the use of blocking or anchor plates.
This strapping is not required when gondola cars are used.
c. Method 2 (fig. 210).
(1) Blocks F. Place one block F across the front and one across
the rear of the front wheels. Place one block F to the front of the
forward rear wheels and one block F to the rear of the rearward rear
wheels. These blocks must be at least eight inches wider than the
over-all width of the vehicle at the car floor.
(2) Cleats E. Place sixteen cleats E against blocks F, as shown
in figure 210.
(3) Cleats C. Wrap cleats C with burlap or other similar material
to prevent chafing of tires. Place one cleat C against the outside of
each front wheel on the top of block F, as shown in figure 210. Nail
the cleats to each block F with two 40-penny nails.
(4) Strapping D. Pass four strands, two wrappings, of No. 8
gage, black annealed wire (D, fig. 210) through the spokes of the
wheels and the stake pockets. Tighten the wires enough to remove
slack. If a box car is used, apply this strapping in similar fashion
and attach it to the floor by the use of blocking or anchor plates.
This strapping is not required when gondola cars are used.
197. OVERSEAS SHIPMENT.
a. The truck will usually be crated for overseas shipment to
protect the truck, to reduce cubic measurement, and to facilitate
stowage. Usually this crate will be made up as a twin pack; that is,
containing two vehicles broken down as much as necessary in order
to save cubic displacement. When such crating is necessary, it should
be performed in accordance with lOSSC-(a), "Introduction to
Ordnance Storage and Shipment Chart, Section (a). Instructions
and Specifications for Packaging Ordnance General Supplies."
198. SHIPMENT WITH COMBAT UNITS.
a. Shipping of Vehicles, Combat Loaded.
(1) Do not disassemble the vehicle. Protect unpainted surfaces
with lubricating oil preservative.
(2) Blocking. Whenever possible, use blocking similar to that
shown in figures 212 and 213. However, special precautions must be
taken to prevent the materiel from moving sideways.
b. Protection During Shipping.
(1) Materials Available. Keep a supply of the required clean-
ing and preserving materials available for servicing while in transit.
(2) Deck Loads. When the materiel is shipped on deck, cover
the vehicle with a closely fitting tarpaulin. Seal all engine openings,
such as the carburetor, air intake, exhaust outlet, oil breather outlet,
342
TM 9-808
198
STORAGE AND SHIPMENT
etc., with waterproof tape. Apply this sealing so that it is easily acces-
sible without disassembly in order that the vehicle may be ready for
immediate action.
c. Inspections. Make daily inspections for signs of corrosion
which should be checked immediately by reapplication of rust-
preventives and lubricating oil. Do not allow salt water to dry on
unprotected surfaces under any circumstances. If possible, after the
materiel has been subjected to salt water flush the materiel with
clean, fresh water.
343
TM 9-808
3/4 .TON 4x4 TRUCK (DODGE)
REFERENCES
PUBLICATIONS INDEXES.
The following publications indexes should be
consulted frequently for latest changes or revisions
to the publications given 'in this list of references
and for new publications relating to materiel
covered in this manual:
Ordnance publications for supply index (index
to SNL's) ASF Cat. ORD-2
OPSI
Index to Ordnance publications (lists FM's,
TM's, TC's, and TB's of interest to Ordnance
personnel, FSMWO's, BSD, S of SR's, OSSC's
and OFSB's. Includes alphabetical listing of
Ordnance major items with publications per-
taining thereto) OFSB I-l
List of publications for training (lists MR's,
'MTP's, T/BA's, T/A's, FM's, TM's, and
TR's, concerning training) FM 21-6
List of training films, film strips, and film bulle-
tins (lists TF's, FS's, and FB's by serial
number and subject) FM 21-7
Military training aids (lists graphic training
aids, models, devices, and displays) FM 21-8
STANDARD NOMENCLATURE LISTS.
34-ton 4x4 truck (Dodge) SNL G-502
Cleaning, preserving, and lubricating materials;
recoil fluids, special oils, and miscellaneous
related items SNL K-1
Interchangeability chart of organization tools
for Ordnance vehicles SNL G-19
Soldering, brazing, and welding materials, gases,
and related items SNL K-2
Tool sets (motor transport) SNL N-19
EXPLANATORY PUBLICATIONS.
Fundamental Principles.
Automotive brakes TM 10-565
Automotive electricity . .• TM 10-580
Automotive lubrication TM 10-540
Automotive power transmission units TM 10-585
Basic Maintenance Manual TiJl 38-250
Chassis, body, and trailer units TM 10-560
Desert operation FM 31-25
Driver's manual TM 10-460
Electrical fundamentals TM 1-455
344
TM 9-808
REFERENCES
Fuels and carburetion TM 10-550
Military motor vehicles AR 850-15
Motor transport FM 25-10
Motor vehicle inspections and preventive main-
tenance services TM 9-2810
Operations in snow and extreme cold FM 31-15
Precautions in handling gasoline AR 850-20
Sheet metal work, body, fender, and radiator
repairs TM 10-450
Standard military motor vehicles TM 9-2800
The internal combustion engine . . TM 10-570
The motor vehicle TM 10-510
Maintenance and Repair.
Cleaning, preserving, lubricating, and welding
materials, and similar items issued by the
Ordnance Department TM 9-850
Cold weather lubrication and service of combat
vehicles and automotive materiel OFSB 6-11
Maintenance and care of pneumatic tires and
rubber treads TM 31-200
Ordnance maintenance: Carburetors (Zenith). . TM 9-1826C
Ordnance maintenance: Electrical equipment
(Auto-Lite) TM 9-1825B
Ordnance maintenance: Electrical equipment
(Delco-Remy) TM 9-1825A
Ordnance maintenance: Fuel pumps TM 9-1828A
Ordnance maintenance: Hydraulic brake system
(Wagner) TM 9-1827C
Ordnance maintenance: Power plant, clutch,
and electrical systems for basic vehicles, %-
ton 4x4, and IJ^-ton 6x6 (Dodge) TM 9-1808A
Ordnance maintenance: Power train, chassis,
and body for basic vehicles, %-ton 4x4, and
114-ton 6x6 (Dodge) . . : TM 9-1808B
Ordnance maintenance: Speedometers and
tachometers (Stewart- Warner) TM 9-1829A
Tune-up and adjustment TM 10-530
Protection of Materiel.
Camouflage FM 5-20
Chemical decontamination, materials and equip-
ment TM 3-220
Decontamination of armored force vehicles. . . . FM 17-59
345
TM 9-808
3/4 -TON 4x4 TRUCK (DODGE)
Defense against chemical attack FM 21-40
Explosives and demolitions . . . ; FM 5-25
Storage and Shipment.
Ordnance storage and shipment chart, group G
major items OSSC-G
Registration of motor vehicles AR 850-10
Rules governing the loading of mechanized and
motorized army equipment, also, major cali-
ber guns, for the United States Army and
Navy, on open top equipment published by
Operations and Maintenance Department of
Association of American Railroads.
Storage of motor vehicle equipment AR 850-18
346
TM 9-808
INDEX
A Pofl* No.
Auxiliary equipment controls and
operation
fire extinguishers
care ^"
fire classifications 38
location 37
operation 38
test . . . ._ 38
winch controls
general 34
to hook on 35
to pull 36
to reverse winch operation .... 36
winch controls 34
winding cable on drum 37
Axles
front 268
rear 281
B
Battery
battery
battery tests 191
electrolyte level 191
installation 192
removal 192
temperature at which battery
will freeze 192
battery ground cable
installation 193
removal 193
battery to cranking motor cable
installation 194
removal 193
general description
battery location 191
data 191
Body and sheet metal
body mounting bolts
tightening and adjusting 332
cowl ventilator
adjustment of ventilator lid . . . 328
replacement of ventilator lid . . 328
replacement of ventilator
weatherstrip 328
fenders and splash shields 326
fire extinguisher ■ 332
general description 326
hood
installation 326
removal '. . . . 326
Pag« No.
interchanging bracket positions
(Ambulance) 332
windshield assembly (closed
bodies)
adjustment 330
installation 330
removal 330
windshield assembly (open bodies)
installation 330
removal 329
windshield wiper assembly
(closed bodies)
installation 331
removal 331
windshield wiper assembly
(open bodies)
installation 331
removal 330
Brakes
foot
hand
287
298
Carburetor 168
Clutch
clutch disk and release bearing
cleaning of parts 254
installation 254
removal 254
clutch pedal
adjustment 252
description 252
general description 252
Cooling system
fan belt
adjustment 181
replacement 181
general description
general 179
radiator cap 180
thermostat control 179
hose replacement 182
maintenance
draining 180
filling 180
flushing 180
radiator 187
thermostat
installation 182
testing 182
347
TM 9-808
3/4 ■
TON 4x4 TRUCK (DODGE)
C— Cont'd Pag* No.
Cooling system— Cont'd
water pump and fan
installation (vehicles with
fan shroud) 186
installation (vehicles without
fan shroud) 185
removal (vehicles with
fan shroud) 186
removal (vehicles without
fan shroud) 183
Data, tabulated
battery
191
engine
133
fuel system
. 165
ignition system
springs and shock absorbers ....
vehicle
. 203
. 319
12
Description of vehicles
data
capacities
14
performance
vehicle specifications
description
13
12
6
differences among models
Ambulance (Model WC-54). . .
Carryall (Model WC-53)
Command (Models WC-56
andWC-57)
10
7
10
Emergency Repair (Model •
WC-60)
10
Telephone Maintenance
(Model WC- 59) .
10
Weapon Carrier (Models
7
Driving controls and operation
body equipment
installation of tarpaulin
(Weapon Carrier)
33
lowering folding top
(Command)
raising folding top (Command) .
(Weapon Carrier)
side curtains (Command)
windshield
29
30
33
32
29
instruments and controls
preparation of new vehicle for
service
15
90
Pag* No.
■ towing the vehicle
pintle hook 28
tow hooks 27
towing precautions 28
towing vehicle to start engine. . 28
use of instruments and controls
in vehicular operation
"breaking-in" speeds 27
driving in four-wheel drive .... 25
driving the vehicle 24
driving up or down steep
grades 26
maximum permissible road
speeds 27
reversing 25
starting the engine 23
starting the engine after
running out of fuel 24
stopping the engine 27
stopping the vehicle 27
Engine — description, maintenance,
and adjustment in vehicle
breather pipe air cleaner 151
crankcase ventilator 152
cylinder head gasket
cleaning and inspection 141
installation 141
removal 140
description and tabulated data
engine numbers 133
general description .' 133
tabulated data 133
engine tune-up 134
installation 158
manifold heat control valve 137
manifolds and gaskets
installation 143
removal 142
oil filter
cleaning 149
installation of cartridge 149
installation of oil filter assembly 149
removal of cartridge 149
removal of oil filter assembly . . 149
oil pan
cleaning 145
installation 145
removal 145
348
TM 9-808
INDEX
E-Cenl'd
Pag* No.
Engine — description, maintenance,
and adjustment in vehicle —
Cont'd
oil pressure relief valve and oil
pump
cleaning and inspection
.. 146
installation of oil pump
.. 148
installation of relief valve . . .
.. 146
removal of oil pump
.. 146
removal of relief valve
.. 146
oil tubes (external)
installation
.. ISO
removal
. . 150
repair
. . 150
removal
.. 154
valves and springs
installation
. . 139
removal
. . . 138
Exhaust system
exhaust pipe
installation
. .. 177
removal
. .. 177
(general descriotion
. .. 177
muffler
installation
. .. 177
removal
. .. 177
tail pipe
installation
. .. 177
removal
. .. 177
First echelon preventive
maintenance services
after- operation and weekly service
procedtfres 53
at-halt service
procedures 51
before-operation service
procedures
during-operation service
procedures
purpose
Foot brakes
bleeding brake system
using hydraulic brake filler . . .
without use of hydraulic filler
tank
brake adjustments 287
adjustment of brake pedal free
travel 290
major brake adjustment 287
48
50
47
291
293
fag* No.
minor brake adjustment 287
brake shoes, linings, and drums
cleaning and inspection of
brakes.., 293
installation of brake shoes 294
removal of brake shoes 294
general description 287
master cylinder
installation 296
removal 296
wheel cylinders
installation 295
removal 295
Frame
bumpers 316
general description 316
Front axle
front axle assembly
cleaning front axle housing
vent 278
differential and carrier
assembly installation 279
differential and carrier
assembly removal 278
installation 280
removal 279
front wheel alinement
checking and adjusting toe-in . . 269
front wheel turning radius 270
general 268
front wheel bearings
adjustment 270
front wheel bearings and oil
seal installation 272
front wheel bearings and oil
seal remqval 271
general description 268
steering arm and tie rod
steering arm installation 278
steering arm removal 278
steering tie rod installation. .. . 278
steering tie rod removal 278
universal drive shaft, bushings,
and oil seals
adjustment of steering
knuckle flange bearings 276
cleaning and inspection of
universal drive assembly 274
installation 276
removal 273
349
TM 9-808
%■
-TON 4x4
F — Cont'd Poge No.
TRUCK (DODGE)
Fuel system
air cleaner
air cleaner assembly
installation 165
air cleaner assembly removal . . 165
filter element installation 165
filter element removal 165
carburetor and governor
adjustment of governor on
engine 166
carburetor assembly
installation 1 70
carburetor assembly removal . . 168
choke control wire installation. 171
choke control wire removal .... 1 70
throttle control wire
installation 171
throttle control wire removal . . 171
throttle stop screw and
idling adjustment 166
fuel filter
cleaning of filter element 1 74
draining of filter 1 74
fuel filter assembly installation . 1 74
fuel filter assembly removal .... 1 74
fuel gage
instrument panel unit
installation 172
instrument panel unit removal . 171
tank unit installation 172
tank unit removal 172
fuel pump
cleaning of strainer bowl
and screen 1 72
fuel pump assembly installation 1 73
fuel pump assembly removal ... 1 73
fuel tank
installation 171
removal 171
fuel tube lengths 176
fuel tubes
installation of fuel filter to fuel
pump tube 175
installation of tank to fuel filter
tube (front section) 175
installation of tank to fuel filter
tube (rear section) 174
removal of fuel filter to fuel
pump tube 175
removal of tank to fuel filter
tube (front section) 1 74
350
Page Ne.
removal of tank to fuel filter
tube (rear section) 174
repairing 175
general description
data, tabulated 165
fuel gage 165
fuel system 163
G
Generating system
general description
generating circuit . 199
types used 198
voltage regulation 198
generator (6-volt)
installation 199
removal 199
generator (12-volt)
installation 200
removal 200
generator regulator
installation 201
removal 201
Hand brake
band and lining
installation 300
removal 300
general description 298
hand brake adjustment
procedure 298
hand brake and linkage
hand brake rod adjustment and
installation 301
hand brake rod removal 301
lever installation .- 301
lever removal 301
hand brake drum
installation 301
removal 301
Ignition system
condenser
installation 206
removal 206
distributor assembly
installation 207
removal 206
distributor (breaker points)
adjustment 205
installation 205
removal 205
TM 9-808
JNDEX
203
I— Cont'd
Ignition system — Cont'd
distributor cap
installation 206
removal 206
distributor rotor
installation 206
removal 206
general description
data
ignition coil and switch
coil installation 208
coil removal 207
switch installation 208
switch removal 208
ignition timing
checking timing with timing
light 204
timing specifications 203
spark plugs
adjustment 204
installation 204
spark plug cables
installation 204
removal 204
Instruments, gages, and miscel-
laneous electrical equipment
ammeter
installation
removal »
general description
heater
horn
instruments and gages
trailer connector
heater (Ambulance)
defroster assembly installation .
defroster assembly removal. . . ,
defroster switch installation . . .
defroster switch removal
heater assembly installation . . .
heater assembly removal
heater switch installation
heater switch removal
horn
adjustment
horn button and wire
installation
horn button and wire removal .
installation
removal
Pag* No. Pag* No.
oil gage
installation 233
removal 233
roof ventilator (Ambulance)
replacement of switch 238
roof ventilator assembly
installation 238
roof ventilator assembly
removal 238
speedometer
cable installation 235
cable removal 235
head installation 235
head removal 234
thermometer
installation 234
removal 233
trailer connector
installation 239
removal 239
voltmeter (Command and
Carryall)
installation 232
removal 232
replacement of voltmeter switch 233
Introduction to manual
scope of manual 5
^^^ Lighting system
231 blackout driving light and switch
aiming of blackout driving light 225
23 1 blackout driving light assembly
231 installation 225
231 blackout driving light assembly
231 removal 224'
blackout driving light switch
237 installation 224
237 blackout driving light switch
237 removal 224
237 sealed beam unit installation . . 224
237 sealed beam unit removal 224
237 blackout parking lights
237 parking light assembly
237 installation 224
parking light assembly removal 224
236 replacement of lamp 224
dome lights
237 dome light assembly
236 replacement (Ambulance) .... 227
236 dome light assembly
236 replacement; (Carryall) 227
THE ARMY LIBRARY
TM 9-808
%■
TON 4x4 TRUCK (DODGE)
L— Cont'd Pag* No.
Lighting system— Cont'd
dome light — Cont'd
dome light switch replacement. 227
lamp replacement 227
general description 220
headlight beam indicator and switch
control switch 223
headlight beam indicator
assembly installation 223
headlight beam indicator
assembly removal 223
replacement of headlight beam 223
replacement of lamp 223
headlights
assembly and installation 221
headlight aiming 222
removal and disassembly 221
sealed beam lamp-unit
installation. 221
sealed beam lamp-unit
removal 221
instrument lights and switch
instrument light socket
replacement 227
instrument light switch
replacement 226
lamp replacement .• . 226
main lighting and blackout switch
circuit breaker installation .... 230
circuit breaker removal 230
switch assembly removal 229
switch installation 230
spotlight (Ambulance)
lamp replacement 227
spotlight assembly installation 228
228
spotlight assembly removal
tail and stop lights
sealed beam unit replacement . . 226
stop light switch replacement . . 226
tail and stop light assembly
replacement 226
Lubrication
introduction 57
Lubrication Guide
lubrication notes 57
reports and records 67
supplies 57
N
New vehicle run-in test
introduction
correction of deficiencies 71
352
Paga No.
run-in test procedures
preliminary service 71
o
Operation under unusual conditions
cold weather operation
antifreeze 42
antifreeze table 42
chassis lubricants 41
engine lubrication 40
gasoline for low temperatures. . 40
general 39
general conditions 44
other lubrication points 43
protection of electrical system . . 43
starting and operation 44
stopping 44
transmission, transfer case
and differentials 41
decontamination 46
flood and submersion
emergency procedure 45
general 45
general 39
hot weather operation
cooling system 45
fuel and exhaust systems 45
ignition system 45
lubrication attention 44
manifold heat control 45
operation in sand, deep mud,
and slippery terrain 39
Organization tools and equipment
special tools 98
standard tools and equipment ... 98
P
Propeller shafts
general description 265
installation 267
removal 265
Radio interference suppression
general 209
servicing and replacing bonded
parts 219
Rear axle
general description 281
rear axle assembly
cleaning rear axle housing vent . 284
differential and carrier
assembly installation 285
R— Cont'd Pag*
Rear axle— Cont'd
rear axle assembly — Cont'd
differential and carrier
assembly removal
rear axle assembly installation .
rear axle assembly removal ....
rear axle drive shafts
installation
removal
rear wheel bearings
adjustment of rear wheel
bearings _• • • •
inner oil seal and bearings
installation
inner oil seal and bearings
removal
outer oil seal installation
outer oil seal removal
Record of modifications
MWO and major unit
replacement record
description
early modifications
instructions for use
References
explanatory publications
fundamental principles
maintenance and repair
protection of materiel
storage and shipment
publications indexes
standard nomenclatur,e lists
s
Second echelon preventive
maintenance services
road test chart
maintenance operations
tools and equipment
Springs and shock absorbers
general description
data
shock absorbers
springs
types of springs used
shackle bolts
shock absorbers
spring assemblies
spring bolts
Starting system
cranking motor
installation
TM 9-808
INDEX
No. Paga No.
removal 196
cranking motor pedal
installation 196
285 removal 196
285 cranking motor switch
285 installation 196
removal 195
284 general description 195
283 Steering
drag link
adjustment 314
281 assembly and installation 315
inspection 315
282 removal and disassembly 315
general description 310
282 steering gear
282 adjustment of steering gear in
282 vehicle 310
installation of steering wheel . . 314
removal of steering wheel 313
steering gear (Pitman) arm
70 installation 314
70 removal 314
70 Storage and shipment
method of securing vehicle on
freight cars 340
344 overseas shipment 342
345 shipment with combat units
345 inspections 343
346 protection during shipping .... 342
344 shipping of vehicles, combat
344 loaded 342
special precautions for storage
brakes 340
engine 340
„. inspections 340
Q, storage and shipment (general)
g, preparation for domestic ship-
ment and temporary storage . 338
preparation for overseas ship-
,,Q ment and indefinite storage. . 340
319 J
319
319 Tires (and wheels) 303.
319 Tools and equipmeiit stowage on the
324 vehicle
323 vehicle tools and equipment
322 care of tools and equipment ... 69
pioneer equipment 69
spare parts kit 68
197 vehicle tools 68
353
TM 9-808
3/4 -TON 4x4 TRUCK (DODGE)
T— Cont'd Pag* No.
Transfer case
control lever and linkage
installation 263
linkage adjustment 263
removal 262
general description 262
transfer case assembly
installation. 264
misalinement 263
removal 263
Transmission and power take-off
general description 256
power take-off control linkage
control lever installation 260
control lever linkage adjustment 261
control lever removal 260
transmission
installation 256
removal 256
Trouble shooting
battery and generating system. . . 108
cooling system 105
clutch 124
engine 99
exhaust system 105
foot brakes 128
front and rear axles 127
fuel system 104
hand brake 129
ignition system 107
instruments, gages, horn, heater
and roof ventilator 120
introduction 99
lighting system 118
propeller shafts 1 26
radio interference suppression. ... 122
springs and shock absorbers 131
starting system 106
steering I30
transfer case 126
transmission 125
wheels and tires 130
winch 132
w
Wheels and tires
general description 303
spare wheel and tire assembly
installation 306
removal 306
Pag* No.
tire casing and tube
inspection 306
installation 306
removal 306
tir& inflation and care
care of tires 304
tire inflation 303
Wheel and tire assembly
installation 306
removal 304
Winch
brake adjustments
adjustment of brake drum 335
adjustment of safety brake .... 335
drive joint shear pin
installation 336
removal 336
drum brake shoe and lining
installation 336
removal 335
general description 334
winch assembly
installation 337
removal 337
winch drive shaft
installation 337
removal 336
Wiring
body wiring assembly (filter to
instrument panel)
description 249
installation' 249
removal 249
description
general 241
wiring assemblies 241
words "right" and "left" 245
generator to regulator wiring
assembly
installation 251
removal 251
lower wiring assembly (junction
block to lights)
description 247
installation 247
removal 247
upper wiring assembly (junction
block to instrument panel)
description 248
installation 248
removal 248
354
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