TM 9 2320 360 34 2

*TM 9- 2320 - 360 - 34 - 2
VOLUME NO. 2
GENERAL SUPPORT
TECHNICAL MANUAL ENGINE MAINTENANCE 19- 1
DIRECT SUPPORT AND
GENERAL SUPPORT MAINTENANCE FUEL SYSTEM 20- 1
MAINTENANCE
TRANSMISSION 22- 1
MAINTENANCE
TRANSFER CASE 22- 1

MAINTENANCE
FRONT AXLE 24- 1

MAINTENANCE
REAR AXLE
MAINTENANCE 25- 1
STEERING SYSTEM 27- 1

MAINTENANCE
WINCHES MAINTENANCE 28- 1
EXPENDABLE/DURABLE B- 1
SUPPLIES AND MATERIALS
ILLUSTRATED LIST OF C- 1
MANUFACTURED ITEMS
TRUCK, TRACTOR, M1070, 8 X 8,
HEAVY EQUIPMENT TRANSPORTER (HET)
TORQUE VALUES D- 1
NSN 2320- 01- 318- 9902
EIC: B5C TOOLS, SUPPLEMENTS, E-1
SPECIAL TOOLS/FIXTURES
SUBJECT INDEX INDEX- 1

DISTRIBUTION STATEMENT A: Approved for public release;
distribution is unlimited.
*Supersedes TM 9-2320-360-34-2 dated 31 March 1994
HEADQUARTERS, DEPARTMENT OF THE ARMY

May 2007
TM 10867A-12&P
2-62
T M 9 --2320 --360 --34 --2
WARNING
Personnel hearing can be PERMANENTLY DAMAGED if exposed to constant high noise levels of
85 dB (A) or greater. Wear approved hearing protection devices when working in high noise level
areas. Personnel exposed to high noise levels shall participate in a hearing conservation program
in accordance with DA PAM 40--501. Hearing loss occurs gradually but becomes permanent over
time.
WARNING
CARBON MONOXIDE (EXHAUST GAS) CAN KILL YOU
Carbon monoxide is a colorless, odorless, DEADLY POISONOUS gas and when breathed deprives
body of oxygen and causes SUFFOCATION. Breathing air with carbon monoxide produces
symptoms of headache, dizziness, loss of muscular control, a sleepy feeling, and coma.
Permanent BRAIN DAMAGE or DEATH may result from severe exposure.
The following precautions MUST be followed to ensure personnel are safe whenever personnel
heater or main or auxiliary engine is operated for any purpose.
DO NOT operate personnel heater or engine of vehicle in enclosed area without adequate
ventilation.
DO NOT idle engine for long periods without ventilator blower operation. If tactical situation
permits, open hatches.
DO NOT drive any vehicle with inspection plates, cover plates, or engine compartment doors
removed unless necessary for maintenance purposes.
NEVER sleep in a vehicle when the heater is operating or the engine is idling.
BE ALERT at all times during vehicle operation for exhaust odors or exposure symptoms. If
either are present, IMMEDIATELY EVACUATE AND VENTILATE the area. Affected personnel
treatment shall be: expose to fresh air; keep warm; DO NOT PERMIT PHYSICAL EXERCISE; if
necessary, give artificial respiration as described in FM 4-25.11 and get medical attention.
BE AWARE; neither the gas particulate filter unit nor field mask for nuclear, biological, and
chemical protection will protect you from carbon monoxide poisoning.
THE BEST DEFENSE AGAINST CARBON MONOXIDE POISONING IS GOOD VENTILATION.
WARNING
Wear eye protection and use care when replacing snap rings and retaining rings.
Snap/retaining rings are under spring tension and can act as projectiles when released and
may cause severe eye injury.
Protective goggles must be worn when drilling. Failure to comply may result in injury to
personnel.
Always wear eye protection and protective clothing when handling glass. Failure to comply
may result in injury.
WARNING
Adhesive--sealants and sealing compounds can burn easily, can give off harmful vapors, and
are harmful to skin and clothing. To avoid injury or death, keep away from open fire and use
in well--ventilated area. If sealing compound gets on skin or clothing, wash immediately with
soap and water.
General purpose cement can burn easily and is harmful to skin and clothing. To avoid injury
or death, keep away from open fire and use in well--ventilated area. If cement gets on skin or
clothing, wash immediately with soap and water.
a
TM 9--2320--360--34--2
WARNING
• Adhesive causes immediate bonding on contact with eyes, skin, or clothing and also gives off
harmful vapors. Wear protective goggles and use in well--ventilated area. If adhesive gets in
eyes, try to keep eyes open; flush eyes with water for 15 minutes and get immediate medical
attention.
• On direct contact, uncured silicone sealant irritates eyes. In case of contact, flush eyes with
water and seek medical attention. In case of skin contact, wipe off and flush with water.
WARNING
Solvent cleaning compound MIL-PRF-680 Type II and III may be irritating to the eyes and skin. Use protective gloves and
goggles. Use in well-ventilated areas. Use respirator as needed. Accidental ingestion can cause irritation of digestive tract
and respiratory tract, may cause lung and central nervous system damage. Can be fatal if swallowed. Inhalation of high/
massive concentrations can cause coma or be fatal. First aid for ingestion: do not induce vomiting. Seek immediate medical
attention. First aid for skin contact: remove contaminated clothing. Wash skin thoroughly with soap and water. If symptoms
persist, seek medical attention. First aid for eye contact: flush with water for 15 minutes or until irritation subsides. If
symptoms persist, seek medical attention. First aid for inhalation: move to fresh air. If not breathing, provide artificial
respiration. If symptoms persist, seek medical attention. Keep away from open flames and other sources of ignition.
Failure to follow this warning may result in injury or death to personnel.
•The flashpoint for type II solvent cleaning compound is 141-198°F (61-92C) and type III is 200-241°F (93-116C).
•Improper cleaning methods and use of unauthorized cleaning solvents may injure personnel and damage equipment.
•Fire extinguishers should be placed nearby when using solvent cleaning compound. Failure to follow this warning may
result in injury or death.
•Cloths or rags saturated with solvent cleaning compound must be disposed of IAW authorized facilities' procedures.
Failure to follow this warning may result in injury.
•Eye shields must be worn when cleaning with a wire brush. Flying rust and metal particles may cause injury.
• Compressed air for cleaning purposes will not exceed 30 psi (207 kPa). Use only with
effective chip guarding and personal protective equipment (goggles/shield, gloves, etc.).
• Steam cleaning creates hazardous noise levels and severe burn potential. Eye, skin, and ear
protection is required. Failure to comply may result in injury to personnel.
• Face shield must be used by personnel operating spray gun. Failure to comply may result in
injury to personnel.
WARNING
When servicing this vehicle, performing maintenance, or disposing of materials such as engine
coolant, transmission fluid, lubricants, batteries, battery acid or CARC paint, consult your Unit/local
hazardous waste disposal center or safety office for local regulatory guidance. If further information
is needed, please contact the Army environmental hotline at 1--800--872--3845. Improper disposal of
this material may result in damage to environment or injury to personnel.
WARNING
• Floor jack must be positioned on flat surface. Placing jack on uneven or soft surface could
result in truck falling, causing serious injury or death to personnel.
• Jackstands must be positioned on flat surface, not more than 10 in. (25.4 cm) from wheels.
Placing jackstands on uneven or soft surface could result in truck falling, causing serious
injury or death to personnel.
• Do not work on any item supported only by jacks or hoist. Always use blocks or proper
stands to support the item prior to any work. Equipment may fall and cause injury or death to
personnel.
• To avoid personal injury, use hoist or get assistance when lifting components that weigh more
than 50 lb (23 kg). Ensure all chains, hooks, slings, and lifting devices are in good condition
and are of correct capacity.
WARNING
Observe the following precautions when working on or around engine/transmission components.
• Use guide straps or rope to guide engine/transmission assembly while lifting. Failure to
comply may result in injury to personnel.
• Grade 8 screws must be used to support engine. Failure to comply may result in engine
falling causing injury or death to personnel.
• Keep out from under heavy parts. Falling parts may result in serious injury to personnel.
b
TM 9--2320--360--34--2
WARNING
Observe the following precautions when working on or around engine/transmission components
(cont).
· When working on a running engine, use caution around rotating parts. Tools, clothing, and
hands may get caught causing serious injury or death to personnel.
· Ensure engine is cool before performing maintenance. Failure to comply may result in severe
burns.
· Engine has may sharp edges. Use caution when using hand tools. Failure to comply may
result in injury to personnel.
WARNING
Observe the following precautions when working on fuel system components.
· Fuel is very flammable and can explode easily. To avoid serious injury or death, keep fuel
away from open fire and keep fire extinguisher within easy reach when working with fuel. Do
not work on fuel system when engine is hot. Fuel can be ignited by hot engine. When
working with fuel, post signs that read NO SMOKING WITHIN 50 FEET OF VEHICLE.
WARNING
Observe the following precautions when working on or around exhaust system components.
· Ensure exhaust manifold and exhaust tube are cool before performing maintenance. Failure
to comply may result in serious injury to personnel.
WARNING
Observe the following precautions when working on or around electrical system components.
· Remove rings, bracelets, watches, necklaces, and any other jewelry before working around
HET Tractor. Jewelry can catch on equipment and cause injury or short across electrical
circuit and cause severe burns or electrical shock. Batteries can explode from a spark.
Battery acid is harmful to skin and eyes. Always wear eye protection when working with
batteries.
· Batteries produce explosive gases. Keep sparks and open flame away from batteries. Failure
to comply may result in serious injury to personnel.
· Use extreme care when measuring voltage while engine is running. Rotating fan blade and
hot engine parts may cause injury.
WARNING
Observe the following precautions when working on or around brake system components.
· Do not use brake drum that exceeds maximum wear specifications. Failure to comply may
result in brake failure and serious injury or death.
· Brake shoes/drum may be coated with dust. Breathing dust may be harmful to personnel. Do
not use compressed air to clean brake shoes/drum. Wear filter mask approved for use against
dust.
· Left and right camshafts are different and not interchangeable. Using wrong camshaft may
result in inoperative brakes and injury to personnel.
c
TM 9--2320--360--34--2
WARNING
Observe the following precautions when working on or around axle components.
· Axles are heavy. Keep hands and feet out from under axle. Failure to comply may result in
· Differential assemblies are heavy. Stay clear of differential assembly when it is supported by
lifting device. If differential falls, serious injury or death may result.
· Axle/suspension is heavy. Keep hands and feet out from under axle. Failure to comply may
result in injury or death to personnel.
· Support axle with transmission lift. Secure axle to transmission lift with strap or chain.
Failure to comply may result in serious injury to personnel.
· Keep hands clear of spring and axle housing when lowering axle. Failure to comply may
result in serious injury to personnel.
· Keep fingers out of pin hole in spring brackets and spring eyes when removing spring pins.
Failure to comply may result in injury to personnel.
WARNING
Observe the following precautions when working on or around cab and frame components.
· Cab weighs 2600 lb (1179 kg). Stay clear of cab when it is supported by lifting device. If cab
falls, serious injury of death may result. Use 10 ft (3 m) guidelines to help guide cab during
removal.
· Do not work on HET Tractor when supported only by jack or hoist. It may fall and cause
severe injury or death.
· Ensure personnel are clear of lifting area. All personnel are within visual sight of each other
and not within 15 ft (4.6 mm) of cab when lifting is in process. Failure to comply may result in
serious injury or death to personnel.
· Do not allow personnel to work between jackstands and cab or within designated danger
zones while lifting device is supporting cab. Failure to comply may result in serious injury or
death to personnel.
· Hood is not designed to be a work platform. Using hood as a work platform may result in
injury or equipment damage.
WARNING
Observe the following precautions when working on or around fifth wheel.
· Rear of fifth wheel plate must be resting on angle stop before performing maintenance.
Failure to comply may result in injury.
WARNING
Observe the following precautions when working on or around suspension system components.
· Keep hands clear of pin and spring when removing pin. Failure to comply may result in
serious injury to personnel.
· Air suspension system may still be pressurized even though AIR PRESS gage reads 0 psi.
Remove air line slowly to allow air to escape. Failure to comply may result in air line blowing
off causing serious injury to personnel.
· Air suspension will drop when air line is removed. Stay clear of suspension. Failure to
comply may result in serious injury to personnel.
d
TM 9--2320--360--34--2
WARNING
Observe the following precautions when working on or around winch system components.
Driver’s side and passenger’s side winches are not interchangeable. Winch cable slot on
drum is on gear end for driver’s side winch and on motor end for passenger’s side winch.
Failure to install correct winch may result in injury to personnel and improper winch
operation.
Plug and valve cartridge locations determine if counterbalance valve is for driver or passenger
side. Plug and valve cartridge must be in correct locations for driver and passenger side
winch. Failure to comply may cause injury to personnel and result in reverse winch operation.
Always wear heavy gloves when handling winch cable. Never let cable run through hands.
Frayed cable can cut hands severely.
Use care when removing cable from drum. End of cable can spring up causing injury to
personnel.
Output shaft is installed differently in winch drum depending on whether winch is for
passenger or driver’s side. For driver’s side winch, splined end of output shaft must be on
cutout end of winch drum. For passenger’s winch, splined end of output shaft must be on end
opposite cutout end of winch drum. Failure to comply may result in improper winding of cable
and injury to personnel.
WARNING
Polyurethane Coating (CARC)
Eye and hearing protection must be worn at all times when using power tools for grinding, cutting, sawing and drilling.
Failure to do so may result in injury to personnel. Chemical Agent Resistant Coating (CARC) paint contains isocyanate
which is highly irritating to skin and respiratory system. High concentrations of isocyanate can produce symptoms of
itching and reddening of skin, a burning sensation in the throat and nose, and watering of the eyes. In extreme
concentrations, isocyanate can cause cough, shortness of breath, pain during respiration, increased sputum production,
and chest tightness. First aid for ingestion: do not induce vomiting. Seek immediate medical attention. First aid for skin
contact: remove contaminated clothing. Wash skin thoroughly with soap and water. If symptoms persist, seek medical
attention. First aid for eye contact: flush with water for 15 minutes or until irritation subsides. If symptoms persist, seek
medical attention. First aid for inhalation: move to fresh air. If not breathing, provide artificial respiration. If symptoms
persist, seek medical attention.
The following precautions must be taken whenever using CARC paint:
•Protective equipment (gloves, goggles, ventilation mask) must be worn when using CARC paint.
•NEVER cut CARC-coated materials without high-efficiency, air-purifying respirators in use.
•DO NOT grind or sand painted equipment without high-efficiency, air-purifying respirators in use.
•BE AWARE of CARC paint exposure symptoms; symptoms can occur a few days after initial exposure.
Seek medical help immediately if symptoms are detected.
•Use only in well-ventilated areas. Check with local environmental office for methods and locations approved
for painting in accordance with local and state environmental regulations.
•ALWAYS use air line respirators when using CARC paint unless air sampling shows exposure to be below
standards. Use chemical cartridge respirator if air sampling is below standards.
WARNING
After Nuclear, Biological, or Chemical (NBC) exposure of vehicle, all air filters shall be handled
with extreme caution. Unprotected personnel may experience injury or death if residual toxic
agents or radioactive material are present. If vehicle is exposed to chemical or biological agents,
servicing personnel shall wear protective mask, hood, protective overgarments, and chemical
protective gloves and boots in accordance with FM 3-11.4. All contaminated air filters shall be
placed in double--lined plastic bags and moved swiftly to a segregation area away from the
worksite. The same procedure applies for radioactive dust contamination. The Company NBC
team should measure radiation prior to filter removal to determine extent of safety procedures
required per the NBC Annex to the unit Standard Operating Procedures (SOP). The segregation
area in which the contaminated air filters are temporarily stored shall be marked with appropriate
NBC placards. Final disposal of contaminated air filters shall be in accordance with local SOP.
Decontamination operation shall be in accordance with FM 3--11.5 and local SOP.
See FM 4-25.11 for additional first aid data.
e/(f blank)
TM 9-2320-360-34-2
LIST OF EFFECTIVE PAGES
Dates of issue for original pages are:
Original...................................... 31 May 2007
TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 661 CONSISTING OF THE

FOLLOWING:
Page * Change
No. No.
Cover ..........................................................0
blank............................................................0
a thru e/(f blank)..........................................0
A/(B blank)..................................................0
i thru iii/(iv blank).......................................0
Pages 19-1 thru 19-130................................0
Pages 20-1 thru 20-26..................................0
Pages 21-1 thru 21-8....................................0
Pages 22-1 thru 22-114................................0
Pages 23-1 thru 23-38..................................0
Pages 24-1 thru 24-14..................................0
Pages 25-1 thru 25-72..................................0
Pages 26-1 thru 26-12..................................0
Pages 27-1 thru 27-57/(27-58 blank) ..........0
Pages 28-1 thru 28-71/(28-72 blank) ..........0
Pages 29-1 thru 29-7/(29-8 blank) ..............0
A-1 and A-2.................................................0
B-1 thru B-5/(B-6 blank).............................0
C-1 thru C-17/(C-18 blank).........................0
D-1 thru D-4................................................0
E-1 thru E-13/(E-14 blank)..........................0
F-1 thru F-14................................................0
INDEX-1 thru INDEX-5/(INDEX 6 blank).0
* Zero In This Column Indicates An Original Page.
A/ (B blank)
* T M 9 --2320 --360 --34 --2
Technical Manual HEADQUARTERS

TM 9--2320--360--34--2 DEPARTMENT OF THE ARMY
WASHINGTON, D.C., 31 May 2007
DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL
TRUCK, TRACTOR, M1070, 8 X 8,

HEAVY EQUIPMENT TRANSPORTER (HET)
(NSN 2320--01--318--9902)
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this publication. If you find any mistakes or if you know of a way to improve the
procedures, please let us know. Submit your DA Form 2028 (Recommended Changes to Equipment
Technical Publications) through the Internet on the Army Electronic Product Support (AEPS) Web site. The
Internet address is https://aeps.ria.army.mil. The DA Form 2028 is located under the Public Applications
section on the AEPS public home page. Fill out the form and click on SUBMIT. Using this form on the AEPS
site will enable us to respond quicker to your comments and to better manage the DA Form 2028 program.
You may also mail, fax, or e-mail your letter or DA Form 2028 directly to: TACOM Life Cycle Management
Command, ATTN: AMSTA-LC-LPIT / TECH PUBS, 1Rock Island Arsenal, Rock Island, IL 61299-7630. The e-mail
address is ROCK-TACOM-TECH-PUBS@conus.army.mil. The fax number is DSN 793-0726 or Commercial
(309) 782-0726.
Distribution Statement A: Approved for public release; distribution is unlimited.
TABLE OF CONTENTS
GENERAL SUPPORT MAINTENANCE
Page
CHAPTER 19 ENGINE MAINTENANCE
Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 --1

Section II Service Upon Receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--1
Section III Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 --2
CHAPTER 20 FUEL SYSTEM MAINTENANCE

Section II Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 --1
CHAPTER 21 COOLING SYSTEM MAINTENANCE

Section II Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 --1
CHAPTER 22 TRANSMISSION MAINTENANCE

Section II Service and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 --1
Section III Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 --3
*Supersedes TM 9-2320-360-34-2 dated 31 March 1994
i
TM 9--2320--360--34--2
TABLE OF CONTENTS (CONT)

Page
CHAPTER 23 TRANSFER CASE MAINTENANCE
Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23--1

Section II Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23--1
CHAPTER 24 FRONT AXLE MAINTENANCE

CHAPTER 25 REAR AXLES MAINTENANCE

CHAPTER 26 BRAKE SYSTEM MAINTENANCE

CHAPTER 27 STEERING SYSTEM MAINTENANCE

CHAPTER 28 WINCHES MAINTENANCE

CHAPTER 29 STORAGE CONTAINER MAINTENANCE

APPENDIX A REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--1
APPENDIX B EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST
Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B--1

Section II Expendable/Durable Supplies and Materials List . . . . . . . . . . . . . . . . . . . . . . . . . B--2
APPENDIX C ILLUSTRATED LIST OF MANUFACTURED ITEMS
Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C--1

Section II Illustrated List of Manufactured Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C--1
APPENDIX D TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--1
ii
TM 9--2320--360--34--2
TABLE OF CONTENTS (CONT)

Page
APPENDIX E COMMON TOOLS, SUPPLEMENTS, AND SPECIAL

TOOLS/FIXTURES LIST
Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E--1

Section II Common Tools, Supplements, and Special
Tools/Fixtures List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E--1
APPENDIX F MANDATORY REPLACEMENT ITEMS
Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F--1

Section II Mandatory Replacement Items List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F--1
SUBJECT INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index--1
iii
iii/(iv blank)
TM 9--2320--360--34--2
CHAPTER 19
ENGINE MAINTENANCE
Contents Para Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--1 19--1
General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--2 19--1
Engine to Engine Stand Installation/Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--3 19--3
Engine Block Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--4 19--8
Front End Plate Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--5 19--27
Rear End Plate Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--6 19--31
Cylinder Head Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--7 19--35
Main Bearing and Crankshaft Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--8 19--57
Flywheel Housing Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--9 19--72
Piston, Connecting Rod, and Liner Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--10 19--82
Cam Follower and Push Rod Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--11 19--96
Camshaft and End Bearing Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--12 19--100
Idler Gear Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--13 19--114
Crankshaft Cover, Front Oil Seal, and Oil Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--14 19--120
Engine Brake Retarder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--15 19--127
Section I. INTRODUCTION
19--1. INTRODUCTION
This chapter contains maintenance instructions for removal, installation, and repair of the engine at the
General Support maintenance level. Some subassemblies and parts must be removed before the engine
and components can be accessed. They are referenced to other paragraphs of this manual or TM
9--2320--360--20.
Section II. SERVICE UPON RECEIPT

19--2. GENERAL MAINTENANCE INSTRUCTIONS
a. Follow these maintenance instructions when removing and installing engine:
(1) When unpacking items, remove packing material (for example: barrier paper, tape,
plastic bags, and protective caps).
(2) Cap or tape over engine inlets and exhaust ducts to prevent foreign objects from
getting inside the engine. Keep dust, dirt, and other objects out of internal parts of
the engine.
CAUTION
Do not use tape to close off fuel or oil openings. Adhesive surface of tape will
mix with fuel or oil and will get in the engine lines.
(3) Cap or tape over open tubes, hoses, fittings, and engine openings as soon as parts
are taken off.
(4) Use suitable container to catch oil and coolant when removing hoses, fittings, and
plugs.
(5) Handle and store removed engine components carefully.
(6) Inspect parts as removed for breaks, dents, cracks, surface defects, or other obvious
damage. Turn in bad parts. Set aside good parts for later use.
19--1
TM 9--2320--360--34--2
19--2. GENERAL MAINTENANCE INSTRUCTIONS (CONT)

(7) When possible, replace gaskets, packings, and seals removed during repair work.
Replace lockwire, lockwashers, and cotter pins at time of reassembly.
(8) Replace broken, worn, or burned electrical wiring.
(9) Replace broken, frayed, crimped, or soft flexible hoses. Replace stripped or
damaged fittings. Replace entire connected flexible hoses if fittings are damaged.
(10) Tag and mark shims, connectors, wires, valves, fittings, and mating ends of lines
before disconnecting or removing. Identify similar parts to ensure correct assembly.
(11) Use hoists, jacks, and other aids when lifting engine.
b. Follow these inspection instructions when removing and installing engine:
(1) Inspect mounting surfaces and surfaces in contact with gaskets, seals, or machined
surfaces. Look for burrs or scratches which might damage parts or seals upon
installation. Remove any defects found.
(2) Remove drain plugs from engine system components and inspect sediment sticking
to plug. Grit or fine metal particles may indicate actual or potential component failure.
A few fine particles are normal. This inspection will help to show defective parts
before internal inspection of the components.
(3) Inspect hose surfaces for broken or frayed fabric. Check for breaks caused by sharp
kinks or contact with other parts of the vehicle. Inspect fitting threads for damage.
Replace any defective parts. After assembly and during initial vehicle operation
period, check for leaks. Inspect wiring harnesses for chafed or burned insulation.
Inspect terminal connectors for loose connections and broken parts. Visually inspect
castings and weldments for cracks.
Section III. MAINTENANCE PROCEDURES
19--2
TM 9--2320--360--34--2
19--3. ENGINE TO ENGINE STAND INSTALLATION/REMOVAL
This task covers:

a. Installation c. Follow--On Maintenance
b. Removal
INITIAL SETUP
Equipment Conditions Tools and Special Tools (Cont)

Sending units and attachments removed Sling Assemblies (2) (Item 160, Appendix E)
(TM 9--2320--360--20). Stand, Engine (Item 181, Appendix E)
Starter removed (TM 9--2320--360--20). Wrench, Torque, 0--175 Lb--Ft (Item 236,
150 amp circuit breakers removed Appendix E)
(TM 9--2320--360--20).
24--volt (front) alternator/bracket removed Materials/Parts
(TM 9--2320--360--20). Compound, Sealing, Pipe Thread
Exhaust manifolds removed (para 3--23). (Item 28, Appendix B)
Air box drains removed (para 3--9). Tags, Identification (Item 56, Appendix B)
Air box covers removed (para 3--8). Ties, Cable, Plastic (Item 60, Appendix B)
Lockwasher (Item 120, Appendix F)
Tools and Special Tools Screws (13) (Item 275, Appendix F)
Tool Kit, Genl Mech (Item 202, Appendix E)
Plate, Adapter (Item 7, Appendix E) Personnel Required
Two
a. Installation
(1) Remove electrical connector (1) from
electrical connector (2).
(2) Remove screw (3), lockwasher (4), and
ether start temperature sensor (5) from
engine assembly (6). Discard lockwasher.
NOTE
Location of plastic cable ties 14
should be marked before 7 8 9
12 13
removal. 2
(3) Remove plastic cable tie (7) from engine

wire harness (8) and hose no. 2630 (9).
(4) Remove hose no. 2761 (10) from
adapter (11). 7
(5) Remove adapter (11) from engine
assembly (6). 10
11
(6) Remove plastic cable tie (7) from hose no.
2761 (10) and hose no. 2682 (12).
6
(7) Remove hose no. 2682 (12) from 1
elbow (13). 5
(8) Remove elbow (13) from adapter (14). 4
3
assembly (6).
19--3
TM 9--2320--360--34--2
19--3. ENGINE TO ENGINE STAND INSTALLATION/REMOVAL (CONT)

elbow (15).
(11) Remove elbow (15) from adapter (16).
assembly (6).
15 16
(13) Remove fuel line (17) from elbow (18).

(14) Install adapter plate (19) on engine 17
assembly (6) with 13 screws (20) with aid of
assistant.
6 20 19
18
WARNING
Engine assembly weighs 2605
lb (1182 kg). Stay clear of
engine assembly when it is
supported by lifting device. If
engine falls, serious injury or
death may result.
6
(15) Install suitable lifting device on engine
assembly (6).
19--4
TM 9--2320--360--34--2
WARNING
Stand clear of engine when 6
supported by lifting device.
Engine may fall and cause
22
serious injury to personnel. 23
(16) Mount engine assembly (6) and adapter
plate (19) on engine stand (21) with six
washers (22) and screws (23). Torque to
147 lb--ft (200 N.m).
(17) Remove lifting device from engine
assembly (6).
19
21
b. Removal
(1) Install lifting device on engine assembly (1).
WARNING 1
Stand clear of engine when
(2) Support engine assembly (1) with lifting

device.
3
2
(3) Remove six screws (2), washers (3),

and engine assembly (1) from engine
stand (4).
(4) Place engine assembly (1) on suitable
supports.
(5) Remove lifting device from engine
assembly (1).
19--5
TM 9--2320--360--34--2
19--3. ENGINE TO ENGINE STAND INSTALLATION/REMOVAL (CONT)
(6) Remove 13 screws (5) and adapter plate (6)

from engine assembly (1). 7
(7) Install fuel line (7) on elbow (8).
1 5 6 8
WARNING
Pipe thread sealing com-
pound can burn easily, can
give off harmful vapors, and
is harmful to skin and cloth-
ing. To avoid injury or death, 13
keep away from open fire and 11 9
use in well--ventilated area. If
pipe thread sealing com-
pound gets on skin or cloth-
ing, wash immediately with
soap and water.
(8) Coat threads of two adapters (9 and 10) and

elbows (11 and 12) with pipe thread sealing
compound.
(9) Install adapter (10) on engine assembly (1). 10
12
(10) Install elbow (12) on adapter (10).
(11) Install hose no. 2630 (13) on elbow (12).
1
(12) Install adapter (9) on engine assembly (1).
(13) Install elbow (11) on adapter (9).
19--6
TM 9--2320--360--34--2

11 15 18 13 23
15 14
NOTE
Plastic cable ties should be
positioned in locations marked
during removal.
(15) Install plastic cable tie (15) on hose

no. 2682 (14) and hose no. 2761 (16).
16
WARNING 17
pound can burn easily, can 1
give off harmful vapors, and 22
is harmful to skin and cloth- 19
keep away from open fire and 21
soap and water.
(16) Coat threads of adapter (17) with pipe

thread sealing compound.
(17) Install adapter (17) on engine assembly (1).
(18) Install hose no. 2761 (16) on adapter (17).
(19) Install plastic cable tie (15) on hose no. 2630
(13) and engine wire harness (18).
(20) Install ether start temperature sensor (19) on
engine assembly (1) with new lockwasher
(20) and screw (21).
(21) Install electrical connector (22) on electrical
connector (23).
c. Follow--On Maintenance
(1) Install air box covers (para 3--8).
(2) Install air box drains (para 3--9).
(3) Install exhaust manifolds (para 3--23).
(4) Install 24--volt (front) alternator/bracket (TM 9--2320--360--20).
(5) Install 150 amp circuit breakers (TM 9--2320--360--20).
(6) Install starter (TM 9--2320--360--20).
(7) Install sending units and attachments (TM 9--2320--360--20).
19--7
TM 9--2320--360--34--2
19--4. ENGINE BLOCK REPAIR
This task covers:

a. Disassembly d. Testing
b. Cleaning/Inspection e. Follow--On Maintenance
c. Assembly
INITIAL SETUP
Equipment Conditions Equipment Conditions (Cont)

Sending units and attachments removed Blower removed (para 4--6).
(TM 9--2320--360--20). Aftercooler removed (para 5--7).
Starter removed (TM 9--2320--360--20). Engine brake retarder wire harnesses removed
150 amp circuit breakers removed (para 6--16).
(TM 9--2320--360--20). Engine brake retarders removed (para 3--26).
24--volt (front) alternator/bracket removed Rocker arms removed (para 3--18).
(TM 9--2320--360--20). Injectors removed (para 4--2).
Exhaust manifolds removed (para 3--23). SRS/TRS sensor removed (para 3--7).
Air box drains removed (para 3--9). Cylinder heads removed (para 3--10).
Air box covers removed (para 3--8). Oil pan removed (para 3--20).
Engine mounted on engine stand (para 19--3). Oil pressure regulator valve removed (para 3--22).
Fan removed (TM 9--2320--360--20). Oil pressure relief valve removed (para 3--21).
Fan belts removed (TM 9--2320--360--20). Crankshaft cover, front oil seal, and oil pump
Fan clutch removed (TM 9--2320--360--20). removed (para 19--14).
Electronic control module (ECM) removed Engine block breather tube removed (para 3--6).
(TM 9--2320--360--20). Flexplate assembly removed (para 3--17).
Thermostats removed (TM 9--2320--360--20). Flywheel housing removed (para 19--9).
DDEC oil pressure sensor removed Blower drive support removed (para 4--8).
(TM 9--2320--360--20). Camshafts and end bearings removed
DDEC oil temperature sensor removed (para 19--12).
(TM 9--2320--360--20). Idler gear removed (para 19--13).
Rocker covers removed (TM 9--2320--360--20). Rear end plate removed (para 19--6).
Fuel injector wire harnesses removed Front end plate removed (para 19--5).
(para 4--3). Pistons, connecting rods, and liners removed
12--volt (rear) alternator/bracket removed (para 19--10).
(TM 9--2320--360--20). Main bearings and crankshaft removed
Oil cooler and housing removed (para 3--19). (para 19--8).
Left thermostat housing removed (para 5--3).
Right thermostat housing removed (para 5--4). Tools and Special Tools
Secondary fuel filter housing removed Tool Kit, Genl Mech (Item 202, Appendix E)
(para 4--13). Compressor Unit, Air (Item 24, Appendix E)
Water pump removed (para 5--5). Gage, Depth, Micrometer (Item 48, Appendix E)
Vibration damper and front cover removed Gage, Dial, Cylinder Bore (Item 49, Appendix E)
(para 3--15). Goggles, Industrial (Item 57, Appendix E)
Water pump drive gear removed (para 3--24). Remover/Installer, Core Plug Plug (Item 133,
Crankshaft pulley removed (para 3--12). Appendix E)
Crankshaft vibration damper removed Remover/Installer, Water Inlet Adapter,
(para 3--14). Aftercooler (Item 134, Appendix E)
Turbocharger removed (para 4--11). Sling Assemblies (2) (Item 160, Appendix E)
Air inlet adapter removed (para 4--5). Socket, Pipe Plug (Item 165, Appendix E)
Fuel supply pump removed (para 4--4). Testing Kit, Cylinder Block Pressure (Item 192,
Blower accessory drive hub removed (para 4--9). Appendix E)
Tachometer drive gear removed (para 3--25).
19--8
TM 9--2320--360--34--2
19--4. ENGINE BLOCK REPAIR (CONT)
INITIAL SETUP (CONT)
Tools and Special Tools (Cont) Materials/Parts (Cont)

Wrench Set, Socket, 3/4 In. Drive (Item 231, Compound, Sealing and Lubricating (Item 27,
Appendix E) Appendix B)
Wrench, Torque, ,0--600 Lb--Ft (Item 233, Compound, Sealing, Pipe Thread (Item 28,
Wrench, Torque, 0--300 Lb--In. (Item 235, Oil, Lubricating (Item 45, Appendix B)
Appendix E) Gaskets (8) (Item 27, Appendix F)
Wrench, Torque, 0--175 Lb--Ft (Item 236, Gasket (Item 34, Appendix F)
Appendix E) Gasket (Item 38, Appendix F)
Wrench, Torque, 0--75 Lb--In. (Item 237, Gasket (Item 48, Appendix F)
Appendix E) Lockwashers (2) (Item 127, Appendix F)
Seal Rings (34) (Item 258, Appendix F)
Materials/Parts Seal Rings (16) (Item 271, Appendix F)
Antifreeze, Permanent (Item 12, Appendix B) Shims, Head (4) (Item 322, Appendix F)
Compound, International, No. 2 (Item 21,
Appendix B)
a. Disassembly
WARNING
Engine has may sharp edges. 1
Use caution when using hand
tools. Failure to comply may
result in injury to personnel.
3
2
(1) Install lifting device on engine block (1).
WARNING
Engine weighs 2605 lb (1182
kg). Stand clear of engine
when supported by lifting
device. Engine may fall and
cause serious injury or death
to personnel.
(2) Support engine block (1) with lifting device. 6

5
(3) Remove six screws (2), washers (3), and
engine block (1) from engine stand (4). 4
(4) Place engine block (1) on floor.

(5) Remove lifting device from engine block (1).
(6) Remove 13 screws (5) and adapter plate (6)
from engine block (1).
19--9
TM 9--2320--360--34--2
10
(7) Remove oil galley plugs (7 and 8), elbow (9),
and plug (10) from front of engine block (1).
7
9
(8) Remove drain cock (11) three plugs (12),

and two plugs (13) from front of engine
block (1).
13
(9) Remove fitting (14) from front of engine
block (1). 14
12
13
12 11
(10) Remove oil galley plug (15) from rear of

engine block (1). 1
(11) Remove oil galley plug (16) from rear of
engine block (1).
NOTE
Do step (12) only if dowels are
damaged. Do not remove 15
dowels just to clean engine
block.
16
(12) Remove two dowels (17) from rear of engine
block (1).
(13) Remove two cup plugs (18) from bottom of
engine block (1). 17
18 17
19--10
TM 9--2320--360--34--2
(14) Remove plug (19) from right side of engine

block (1).
(15) Remove drain cock (20) from right side of
engine block (1).
(16) Remove elbow (21) and fitting (22) from
right side of engine block (1). 24
(17) Remove oil galley plugs (23 and 24) from 19
side of engine block (1).
(18) Remove elbow (25) and reducer bushing 23
(26) from right side of engine block (1).
(19) Remove plug (27) from right side of engine 26
block (1).
25
23
20
22
21
27
(20) Remove two plugs (28) from left side of 31

engine block (1).
30
(21) Remove two plugs (29) from left side of
engine block (1).
(22) Remove elbow (30) and reducer bushing 29
(31) from left side of engine block (1).
28
28 29
19--11
TM 9--2320--360--34--2
(23) Remove oil plug (32) from left side of engine

block (1).
(24) Remove drain cock (33) from left side of
engine block (1).
33
(25) Remove four screws (34), cover plate (35),
and gasket (36) from left side of engine
block (1). Discard gasket.
(26) Remove four expansion plugs (37) from both
right and left sides of engine block (1).
32
37
36
35
34
42
40
38
41
39
39
(27) Remove protective plug (38) and gasket (39)

from top of engine block (1) using core plug
remover (40). Discard gasket.
(28) Remove aftercooler water inlet adapter (41)
and gasket (39) from top of engine block (1)
using aftercooler inlet adapter remover (42).
Discard gasket.
19--12
TM 9--2320--360--34--2
44 43
44
(29) Remove two pipe plugs (43) from top of 43
engine block (1).
NOTE
Do steps (30) thru (32) only if
plugs and dowels are damaged.
Do not remove just to clean
engine block.
(30) Remove three dowels (44) from top of

engine block (1). 1
(31) Remove two dowels (45) from front of
engine block (1).
45
47
46
NOTE
Position of plugs must be
marked before removal.
47
(32) Remove 14 plugs (46) from bottom cylinder
head screw holes (47).
47
19--13
TM 9--2320--360--34--2

b. Cleaning/Inspection
(1) Scrape gasket material and sealant from
engine block surfaces. 2
WARNING
High pressure steam may
blow particles into eyes, may
cause severe burns, and
creates hazardous noise
levels. Eye, skin, and hearing
protection is required to
prevent injury to personnel.
1
NOTE
Oil and water galleries in engine
block must be thoroughly steam
cleaned.
(2) Steam clean engine block.
WARNING
Compressed air for cleaning
purposes will not exceed 30
psi (207 kPa). Use only with
effective chip guarding and
personal protective
equipment (goggles/shield, 4
gloves, etc.).
(3) Dry engine block with compressed air. 3
(4) Inspect grooves (1) and lands (2) for pitting

and erosion.
5
NOTE
Main bearing caps must be
installed in proper positions in 3 5
engine block as marked during
removal (para 19--8). Ensure
caps are firmly seated in engine
block and that main bearing
shells are removed.
FRONT
REAR
(5) Install 5 main bearing caps (3) in bottom of

engine block (4) with 10 screws (5). Torque
1 2 3 4 5
to 20 lb--in. (2.3 N.m).

(6) Seat caps (3) by striking with soft--faced
hammer.
(7) Tighten screws (5) to 50 lb--ft (68 N.m), then 5
to 110 lb--ft (149 N.m), and then to 250 lb--ft
(339 N.m).
19--14
TM 9--2320--360--34--2
7
NOTE
· All measurements should
be made with engine block 4
on floor, not in engine stand.
· All eight cylinders are 6
measured the same. Follow
steps (8) thru (11).
(8) Measure cylinder bore (6) at position A

using cylinder checking gage (7).
Measurement cannot be greater than 5.3635
in.
(136.23 mm).
(9) Measure cylinder bore (6) at position B.
in. (135.62 mm).
(10) Measure cylinder bore (6) at position C.
in. (132.55 mm).
(11) Measure cylinder bore (6) at position D.
in. (132.55 mm). A
(12) Replace engine block (4) if any cylinder bore

(6) is beyond limits listed above or if a B
sealing problem has occurred at position B.
Also, the taper between C and D and C
out--of--roundness must not exceed 0.0010

in. (0.025 mm). D
(13) Measure flatness of engine block (4)

crosswise between all cylinders using
straight edge and feeler gage. If block (4)
varies more than 0.003 in. (0.076 mm),
replace engine block (4).
(14) Measure flatness of engine block (4) contact
surface lengthwise using straight edge and
feeler gage. If block (4) varies more than
0.0070 in. (0.178 mm), replace engine
block (4).
19--15
TM 9--2320--360--34--2
9
NOTE
Cylinders may be counterbored
to either of two depths.
(15) Measure depth of counterbore (8) using

depth gage. If depth is not between 0.4755
in. (12.13 mm) and 0.4770 in. (12.12 mm) or
between 0.4905 in. (12.50 mm) and 0.4920 8 4
in. (12.50 mm) and cannot be brought into
limits by installing cylinder liner insert,
(16) If counterbore (8) varies more than 0.0015
in. (0.04 mm) around edge of cylinder,
NOTE
If two adjacent cylinders have
different counterbore depth
ranges measured in step (15)
above, step (17) does not apply.
(17) If difference between any one adjacent

cylinder counterbore (8) measured at their
closest point (9) is more than 0.0015 in.
(0.04 mm), replace engine block (4). 5
3
(18) Measure each main bearing bore (10) 4

diameter with bore gage (11). If main 11
bearing bore diameter is less than 4.812 in.
(122.22 mm) or greater than 4.813 in.
(122.25 mm) replace engine block (4).
(19) Remove five main bearing caps (3) and
screws (5) from engine block (4).
(20) Inspect dowel holes (12) in engine block (4)
for oversized holes or damage. Replace
engine block if damaged or oversized. 12 10
(21) Inspect threaded holes for stripped or

crossed threads. Use a tap to clean
threads.
(22) Inspect machined surfaces for flatness,
burrs, and scratches. If surfaces cannot be
cleaned by lapping, replace engine block
(4).
19--16
TM 9--2320--360--34--2
c. Assembly
WARNING
Sealing compounds can burn
easily, can give off harmful
vapors, and are harmful to
skin and clothing. To avoid
injury or death, keep away
from open fire and use in 2
well--ventilated area. If
sealing compound gets on
skin or clothing, wash
immediately with soap and 1
2
water.
NOTE
There are 14 plugs, 7 in each
cylinder bank. Apply small
quantity of sealing and
lubricating compound to thread
area above plug. Do not let
sealant get onto threads of
cylinder head screws. Allow
sealant to set for 12 hours
before performing pressure
check.
(1) Coat threads of plugs (1) with sealing and

lubricating compound.
NOTE 2
Top of plugs must be 1.980-- 7
2.070 in. (50.29--52.58 mm) 3
below surface of engine block 5 4
when installed.
6
(2) Install 14 plugs (1) in cylinder head screw 4
holes (2). 8
(3) Coat threads of protective plug (3) and pipe

plugs (4) with pipe thread sealing
compound.
(4) Install new gasket (5) and protective plug (3)
in air box (6) using core plug installer (7).
Torque to 230--270 lb--ft (312--366 N.m).
(5) Install two pipe plugs (4) on top of engine
block (8). Torque to 168--192 lb--in.
(19--22 N.m).
19--17
TM 9--2320--360--34--2

9
NOTE 8
Do step (6) only if dowel pins
were removed.
(6) Install three dowel pins (9) in top of engine

block (8) until flush with surface of engine
block.
WARNING
ing. To avoid injury or death,
keep away from open fire and
ing, wash immediately with 8
soap and water. 9
NOTE
Front face views of engine block
10
are shown.
(7) Coat threads plugs (10 and 11), elbow (12),

drain cock (13), plug (14), pipe plugs (15
and 16) and fitting (17) with pipe thread
sealing compound. 11
(8) Install plug (10) in front of engine block (8).

(9) Install plug (11) in front of engine block (8). 14
(10) Install elbow (12) in front of engine block (8).
(11) Install drain cock (13) in front of engine 13 12
block (8).
8
(12) Install plug (14) in front of engine block (8).
Torque to 168--192 lb--in. (19--22 N∙m).
16
(13) Install three plugs (15) in front of engine
block (8). 17
(14) Install two plugs (16) in front of engine

block (8).
(15) Install fitting (17) in front of engine block (8).
15
16
15
19--18
TM 9--2320--360--34--2
WARNING
Pipe thread sealing compound can burn easily, can give off harmful vapors,
and is harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well--ventilated area. If pipe thread sealing
compound gets on skin or clothing, wash immediately with soap and water.
NOTE 8
Rear face of engine block is
shown.
(16) Coat threads oil galley plugs (18 and 19)

and two cup plugs (20) with pipe thread
sealing compound. 18
(17) Install oil galley plug (18) in rear of engine
block (8).
19
(18) Install oil galley plug (19) in rear of engine
block (8).
NOTE 21
Do step (19) only if dowels were 20 21
removed.
(19) Install two dowels (21) in rear of engine

block (8).
(20) Install two cup plugs (20) in bottom of 8
engine block (8).
(21) Coat threads of plug (22), drain cock (23),
fitting (24), elbow (25), plug (26), reducer
bushing (27), elbow (28), and plugs (29 and
30) with pipe thread sealing compound.
(22) Install plug (22) in right side of engine
block (8).
(23) Install drain cock (23) in right side of engine
block (8). 30
(24) Install fitting (24) in right side of engine 22
block (8).
(25) Install elbow (25) in fitting (24).
(26) Install plug (26) in right side of engine
block (8). 27
(27) Install reducer bushing (27) in right side of 28
engine block (8).
29
(28) Install elbow (28) in reducer bushing (27).
(29) Install oil galley plug (29) in right side of
(30) Install pipe plug (30) in right side of engine 24
block (8). 25
26
19--19
TM 9--2320--360--34--2
(31) Install two plugs (31) in left side of engine

block (8). 8
WARNING
use in well--ventilated area. If 31
pipe thread sealing com- 32
pound gets on skin or cloth- 33
soap and water. 31
32
(32) Coat threads of plugs (32), oil plug (33),
reducer bushing (34), and elbow (35) with
pipe thread sealing compound.
(33) Install two plugs (32) in left side of engine
block (8).
(34) Install oil plug (33) on left side of engine
block (8).
(35) Install reducer bushing (34) in left side of
engine block (8).
(36) Install elbow (35) in reducer bushing (34).
(37) Coat threads of drain cock (36) and
expansion plugs (37) with pipe thread
sealing compound.
(38) Install drain cock (36) in left side of engine 8
block (8).
(39) Install four expansion plugs (37) on right and
left sides of engine block (8).
(40) Install new gasket (38) and cover plate (39)
on engine block (8) with four screws (40). 36
NOTE
Do step (41) only if dowels were
removed.
(41) Install two dowels (41) in front of engine 37

41
block (8) until they stick out 0.375 in.
38
(9.53 mm).
39
40
19--20
TM 9--2320--360--34--2
d. Testing
5
(1) Coat two new seal rings (1) with lubricating
oil.
2 1
(2) Install two new seal rings (1) in grooves (2)
of each cylinder of engine block (3).
(3) Install cylinder insert (4) into each cylinder
recess.
4
NOTE
It may be necessary to seat
liners in engine block with
soft--faced mallet. 3
(4) Install eight cylinder liners (5) in engine

block (3).
11 8
(5) Install eight new compression gaskets (6) in 7

cylinders (7). 3
(6) Install 2 new oil hole seals (8) and 32 water

hole seals (9) in 34 counterbored holes (10)
in each side of engine block (3).
(7) Install four shims (11) one at each end of
cylinder head contact surface of each side of
engine block (3).
9
10
12
13
(8) Install gasket (12) and water inlet cover
plate (13) on right side front of engine block
(3) with two lockwashers (14), screws (15),
and nuts (16).
14 15
16
19--21
TM 9--2320--360--34--2

(9) Install 2 plates (17) from engine block test kit
on right and left cylinder banks of engine
block (3) with 20 spacers (18) and screws
(19). Torque screws to 100 lb--ft (136 N.m).
(10) Connect air line to fitting (20). Route air line 24
from above engine block to prevent
antifreeze solution from draining into hose.
22
(11) Pour 1 gal (3.8 L) of antifreeze into engine
block water jacket through hole for 23 19
aftercooler water inlet adapter (21). Top off 21
engine block water jacket with water. 8 18
WARNING
Pipe thread sealing com- 17
soap and water.
(12) Coat threads of engine block pressure test

core plug (22) with pipe thread sealing
compound.
20
(13) Install gasket (23) and engine block
pressure test core plug (22) in hole for
aftercooler water inlet adapter (21) using
core plug remover/installer (24). Torque
plug to 230--270 lb--ft (312--366 N∙m).
WARNING
Use care when using high air
pressure. Ensure connec-
tions and seals are tight be-
fore applying pressure. High
air pressure can blow out
parts, hoses, or debris with
force. Explosive force may
cause injury and damage
equipment. Personal protec-
tive equipment will be used
(goggles/shield, gloves, etc.).
(14) Apply 40 psi (276 kPa) pressure to engine block (3). Maintain
pressure for at least 2 hours.
(15) After test period, inspect engine block (3) for leaking antifreeze. If
leaks are found in engine block (3), replace engine block.
(16) Loosen air line from fitting (20) to allow air pressure to escape.
(17) Remove air line from fitting (20).
19--22
TM 9--2320--360--34--2
24
(18) Open drain cocks (25) and drain antifreeze 22

and water from engine block (3). 19
23
(19) Remove 20 screws (19), spacers (18), and 2 21
plates (17) from engine block (3). 18
(20) Remove engine block pressure test core
plug (22) and gasket (23) from aftercooler 17
water inlet adapter (21) using core plug
remover/installer (24). Discard gasket.
25
3
25
24
27
3
(21) Install new gasket (26) and aftercooler water 26
inlet adapter (27) on engine block (3) using 12
aftercooler water inlet adapter installer (24).
Torque to 230--250 lb--ft (312--339 N.m). 13
(22) Remove two screws (15), nuts (16),

lockwashers (14), water inlet cover plate
(13) and gasket (12) from right side of
engine block (3). Discard lockwashers and
gasket. 14 15
16
11 8
(23) Remove eight compression gaskets (6) from 7

3
cylinders (7). Discard gaskets.
(24) Remove 4 shims (11), 2 oil hole seals (8)
and 32 water hole seals (9) from 34
counterbored holes (10) on each side of
engine block (3).
9
10
19--23
TM 9--2320--360--34--2
(25) Remove eight cylinder liners (5) from engine

block (3).
5
(26) Coat cylinder liners (5) with lubricating oil.
(27) Remove cylinder liner inserts (4) from each 2 1
cylinder recess.
(28) Remove two seal rings (1) from grooves (2)
of each cylinder of engine block (3).
4
WARNING
psi (207 kPa). Use only with 3
personal protective equip-
ment (goggles/shield, gloves,
etc.).
(29) Dry engine block (3) with compressed air.

(30) Coat engine block (3) machined surfaces
with lubricating oil to prevent rust.
(31) Install adapter plate (28) on engine block (3)

with 13 screws (29) with aid of assistant.
WARNING
Engine assembly weighs 2605
lb (1183 kg). Stay clear of
engine assembly when it is
supported by lifting device. If
engine falls, serious injury or 31
death may result. 32
(32) Install suitable lifting device on engine

block (3).
WARNING
Stand clear of engine when
3
(33) Mount engine block (3) and adapter plate 28 29
(28) on engine stand (30) with six washers
30
(31) and screws (32). Torque to 147 lb--ft
(199 N.m).
(34) Remove lifting device from engine block (3).
19--24
TM 9--2320--360--34--2
e. Follow--On Maintenance
(1) Install main bearings and crankshaft (para 19--8).
(2) Install pistons, connecting rods, and liners (para 19--10).
(3) Install front end plate (para 19--5).
(4) Install rear end plate (para 19--6).
(5) Install idler gear (para 19--13).
(6) Install camshafts and end bearings (para 19--12).
(7) Install blower drive support (para 4--8).
(8) Install flywheel housing (para 19--9).
(9) Install flexplate assembly (para 3--17).
(10) Install engine block breather tube (para 3--6).
(11) Install crankshaft cover, front oil seal, and oil pump (para 19--14).
(12) Install oil pressure relief valve (para 3--21).
(13) Install oil pressure regulator valve (para 3--22).
(14) Install oil pan (para 3--20).
(15) Install cylinder heads (para 3--10).
(16) Install SRS/TRS sensor (para 3--7).
(17) Install injectors (para 4--2).
(18) Install rocker arms (para 3--18).
(19) Install engine brake retarders (para 3--26).
(20) Install engine brake retarder wire harnesses (para 6--16).
(21) Install aftercooler (para 5--7).
(22) Install blower (para 4--6).
(23) Install tachometer drive gear (para 3--25).
(24) Install blower accessory drive hub (para 4--9).
(25) Install fuel supply pump (para 4--4).
(26) Install air inlet adapter (para 4--5).
(27) Install turbocharger (para 4--11).
(28) Install crankshaft vibration damper (para 3--14).
(29) Install crankshaft pulley (para 3--12).
(30) Install water pump drive gear (para 3--24).
(31) Install vibration damper and front cover (para 3--15).
(32) Install water pump (para 5--5).
(33) Install secondary fuel filter head (para 4--13).
(34) Install right thermostat housing (para 5--4).
(35) Install left thermostat housing (para 5--3).
(36) Install oil cooler and housing (para 3--19).
(37) Adjust valve clearance, engine brake retarder, and fuel injector timing (para 3--27).
19--25
TM 9--2320--360--34--2
e. Follow--On Maintenance (Cont)

(38) Install 12--volt (rear) alternator/bracket (TM 9--2320--360--20).
(39) Install fuel injector wire harnesses (para 4--3).
(40) Install rocker covers (TM 9--2320--360--20).
(41) Install DDEC oil temperature sensor (TM 9--2320--360--20).
(42) Install DDEC oil pressure sensor (TM 9--2320--360--20).
(43) Install thermostats (TM 9--2320--360--20).
(44) Install electronic control module (ECM) (TM 9--2320--360--20).
(45) Install fan clutch (TM 9--2320--360--20).
(46) Install fan belts (TM 9--2320--360--20).
(47) Install fan (TM 9--2320--360--20).
(48) Remove engine from engine stand (para 19--3).
19--26
TM 9--2320--360--34--2
19--5. FRONT END PLATE REPAIR
This task covers:

a. Removal c. Follow--On Maintenance
b. Installation
INITIAL SETUP

Sending units and attachments removed Water pump drive gear removed (para 3--24).
(TM 9--2320--360--20). Blower accessory drive hub removed (para 4--9).
Starter removed (TM 9--2320--360--20). Engine brake retarder wire harnesses removed
150 amp circuit breakers removed (para 6--16).
24--volt (front) alternator/bracket removed Rocker arms removed (para 3--18).
(TM 9--2320--360--20). Injectors removed (para 4--2).
Exhaust manifolds removed (para 3--23). SRS/TRS sensor removed (para 3--7).
Air box drains removed (para 3--9). Cylinder heads removed (para 3--10).
Air box covers removed (para 3--8). Oil pan removed (para 3--20).
Engine mounted on engine stand (para 19--3). Flexplate assembly removed (para 3--17).
Fan removed (TM 9--2320--360--20). Flywheel housing removed (para 19--9).
Fan belts removed (TM 9--2320--360--20). Camshafts and end bearings removed
Fan clutch removed (TM 9--2320--360--20). (para 19--12).
Electronic control module (ECM) removed
(TM 9--2320--360--20). Tools and Special Tools
Thermostats removed (TM 9--2320--360--20). Tool Kit, Genl Mech (Item 202, Appendix E)
DDEC oil pressure sensor removed Wrench, Torque, 0--175 Lb--Ft (Item 236,
(TM 9--2320--360--20). Appendix E)
Rocker covers removed (TM 9--2320--360--20).
Fuel injector wire harnesses removed Materials/Parts
(para 4--3). Grease, Automotive and Artillery (Item 32,
12--volt (rear) alternator/bracket removed Appendix B)
(TM 9--2320--360--20). Gasket (Item 42, Appendix F)
Left thermostat housing removed (para 5--3). Gasket (Item 52, Appendix F)
Right thermostat housing removed (para 5--4). Lockwashers (2) (Item 122, Appendix F)
Secondary fuel filter head removed
(para 4--13).
Water pump removed (para 5--5).
Vibration damper and front cover removed
(para 3--15).
19--27
TM 9--2320--360--34--2
19--5. FRONT END PLATE REPAIR (CONT)
a. Removal
(1) Remove five screws (1) from front end
plate (2). 5
(2) Remove two screws (3), and lockwashers 7

(4), and front end plate (2) from engine block
(5). Discard lockwashers. 6
8
(3) Remove gasket (6) and gasket (7) from 2
engine block (5). Discard gaskets. 8
CAUTION
Support front end plate on flat,
even surface when removing
1
screw inserts to prevent warping
or bending end plate.
NOTE
Do step (4) only if screw inserts
are stripped. 4 1
(4) Remove three screw inserts (8) from front 3
end plate (2).
b. Installation
CAUTION 5
Support front end plate on flat,
even surface when installing 4
screw inserts to prevent warping
3
or bending end plate.
1
2
NOTE 1
Do step (1) only if screw inserts
were removed.
(1) Install three screw inserts (1) in front end 6

plate (2).
(2) Coat new end plate gasket (3) with grease.
(3) Install new gasket (3) and new gasket (4) on
engine block (5).
(4) Position front end plate (2) on engine block 7 6
(5) with five screws (6). Do not tighten.
8
(5) Position two new lockwashers (7) and
screws (8) in front end plate (2). Do not
tighten.
19--28
TM 9--2320--360--34--2
NOTE
· Camshaft end bearings are
temporarily installed to align
front plate. 5
9
· Holes in front end plate for 2
camshaft end bearings are
not the same size. Smaller
hole is accurately machined
for alignment purposes and
is always located on right
side of engine as viewed
from the rear.
(6) Install two camshaft end bearings (9) into 6

front end plate (2) and engine block (5).
8
(7) Tighten five screws (6) to 31--35 lb--ft
(41--47 N.m).
(8) Tighten two screws (8) to 71--75 lb--ft
(96--102 N.m).
(9) Remove two end bearings (9) from front end 6
plate (2) and engine block (5).
(6) Install SRS/TRS sensor (para 3--7).
19--29
TM 9--2320--360--34--2
19--5. FRONT END PLATE REPAIR (CONT)
c. Follow--On Maintenance (Cont)

(19) Install 12--volt (rear) alternator (TM 9--2320--360--20).
(27) Install fan (TM 9--2320--360--20).
19--30
TM 9--2320--360--34--2
19--6. REAR END PLATE REPAIR
This task covers:

a. Removal d. Installation
b. Disassembly e. Follow--On Maintenance
c. Assembly
INITIAL SETUP

Sending units and attachments removed Turbocharger removed (para 4--11).
(TM 9--2320--360--20). Air inlet adapter removed (para 4--5).
Starter removed (TM 9--2320--360--20). Blower accessory drive hub removed (para 4--9).
150 amp circuit breakers removed Blower removed (para 4--6).
(TM 9--2320--360--20). Engine brake retarder wire harnesses removed
24--volt (front) alternator/bracket removed (para 6--16).
Exhaust manifolds removed (para 3--23). Rocker arms removed (para 3--18).
Air box drains removed (para 3--9). Injectors removed (para 4--2).
Air box covers removed (para 3--8). Cylinder heads removed (para 3--10).
Engine mounted on engine stand (para 19--3). Oil pan removed (para 3--20).
Fan removed (TM 9--2320--360--20). Flexplate assembly removed (para 3--17).
Fan belts removed (TM 9--2320--360--20). Flywheel housing removed (para 19--9).
Fan clutch removed (TM 9--2320--360--20). Blower drive support removed (para 4--8).
Electronic control module (ECM) removed Camshafts and end bearings removed
(TM 9--2320--360--20). (para 19--12).
Thermostats removed (TM 9--2320--360--20). Idler gear removed (para 19--13).
DDEC oil pressure sensor removed
(TM 9--2320--360--20). Tools and Special Tools
Rocker covers removed (TM 9--2320--360--20). Tool Kit, Genl Mech (Item 202, Appendix E)
Fuel injector wire harnesses removed Wrench, Torque, 0--175 Lb--Ft (Item 236,
(para 4--3). Appendix E
12--volt (rear) alternator/bracket removed
(TM 9--2320--360--20). Materials/Parts
Left thermostat housing removed (para 5--3). Grease, Automotive and Artillery (Item 32,
Right thermostat housing removed (para 5--4). Appendix B)
Secondary fuel filter head removed Gasket (Item 50, Appendix F)
(para 4--13). Lockwashers (2) (Item 106, Appendix F)
Vibration damper and front cover removed
(para 3--15).
Water pump drive gear removed (para 3--24).
19--31
TM 9--2320--360--34--2
19--6. REAR END PLATE REPAIR (CONT)
a. Removal
9
NOTE
Note position of special washer
before removing from rear end
plate. 4
(1) Remove screw (1), special washer (2), and
dummy hub (3) from rear end plate (4).
(2) Remove screw (5) and lockwasher (6) from
rear end plate (4). Discard lockwasher.
(3) Remove four screws (7), end plate (4) and
gasket (8) from engine block (9). Discard
gasket.
7
8
3
2 7 6 3
b. Disassembly 5
1
CAUTION
Support rear end plate on flat 2
even surface when removing 3
screw inserts to prevent warping 3
or bending of end plate.
NOTE
Do steps (1) and (2) only if
screw inserts are stripped.
(1) Remove two screw inserts (1) from rear end
plate (2).
1
(2) Remove eight screw inserts (3) from rear
end plate (2). 1
c. Assembly
2
CAUTION 1
Support rear end plate on flat 1
even surface when installing
screw inserts to prevent
warping or bending end plate.
NOTE
screw inserts were removed.
(1) Press eight screw inserts (1) into back of 3
rear end plate (2).
(2) Press two screw inserts (3) into front of rear
end plate (2).
19--32
TM 9--2320--360--34--2
d. Installation
(1) Coat new gasket (1) with grease and install
over dowels (2) onto engine block (3).
(2) Install rear end plate (4) on dowels (2).
(3) Position four screws (5) on rear end plate
(4). Do not tighten.
(4) Position new lockwasher (6) and screw (7) 3
on rear end plate (4). Do not tighten.
NOTE 1
Special washer is installed in 4
same position as noted during
removal.
(5) Install special washer (8) on screw (9) with

grooved side facing head of screw (9).
NOTE
Align dowel in dummy hub with
hole in rear end plate.
5
(6) Install dummy hub (10), special washer
2
(8), and screw (9) on rear end plate (4).
NOTE 10
· Camshaft end bearings are 8 5 7 6
temporarily installed to align 9
rear end plate.
· Holes in front and rear end
plates for camshaft end
bearings are not the same
size. Smaller hole is
accurately machined for
alignment purposes and is 3 5
always located on right side
of engine as viewed from
the rear. 4
(7) Install two camshaft end bearings (11) in 11

rear end plate (4) and engine block (3).
(8) Tighten four screws (5) to 31--35 lb--ft
(41--47 N.m).
(9) Tighten screw (7) to 103--110 lb--ft (140--149
5
N.m).
9
(10) Tighten screw (9) to 90 lb--ft (122 N.m).
(11) Remove two end bearings (11) from rear
end plate (4) and engine block (3).
7
5
(1) Install idler gear (para 19--13).
(3) Install blower drive support (para 4--8).
19--33
TM 9--2320--360--34--2
19--6. REAR END PLATE REPAIR (CONT)

e. Follow--On Maintenance (Cont)
(12) Install blower (para 4--6).
(14) Install air inlet adapter (para 4--5).
(15) Install turbocharger (para 4--11).
(31) Install fan (TM 9--2320--360--20).
19--34
TM 9--2320--360--34--2
19--7. CYLINDER HEAD REPAIR
This task covers:

a. Disassembly d. Inspection
b. Cleaning e. Assembly
c. Pressure Testing f. Follow--On Maintenance
INITIAL SETUP

Cylinder head on clean work surface. Remover, Broken Bridge Guide (Item 131,
Cam followers and push rods removed Appendix E)
(para 19--11). Remover, Valve Guide (Item 143, Appendix E)
Socket, Deep Well, 9/16 In. (Item 164,
Tools and Special Tools Appendix E)
Tool Kit, Genl Mech (Item 202, Appendix E) Tester, Spring (Item 190, Appendix E)
Blocks, Wooden (Figure C--3, Appendix C) Threading Set, Screw (Item 193, Appendix E)
Caliper Set, Micrometer (Item 15, Appendix E) Wire Brush, Brass (Item 211, Appendix E)
Compressor Unit, Air (Item 24, Appendix E) Wrench, Torque, 0--600 Lb--Ft (Item 233,
Compressor, Valve Spring (Item 25, Appendix E) Appendix E)
Extractor Set, Screw (Item 38, Appendix E) Wrench, Torque, 0--175 Lb--Ft (Item 236,
Fixture, Test, Head (Item 44, Appendix E) Appendix E)
Gage, Depth, Micrometer (Item 48, Appendix E)
Gage Set, Telescoping (Item 56, Appendix E) Materials/Parts
Grinding Kit, Valve Seat, Electric (Item 58, Adhesive--Sealant (Item 9, Appendix B)
Appendix E) Chips, Soap (Item 15, Appendix B)
Grinding Machine, Valve Face (Item 59, Compound, Sealing, Pipe Thread (Item 28,
Goggles, Industrial (Item 57, Appendix E) Dye, Prussian Blue (Item 30, Appendix B)
Indicator, Dial (Item 73, Appendix E) Oil, Lubricating (Item 45, Appendix B)
Installer, Bridge Guide (Item 76, Appendix E) Cleaning Compound, Solvent (Item 54, Appendix B)
Installer, Valve Guide (Item 85, Appendix E) Tags, Identification (Item 56, Appendix B)
Installer, Valve Seat Insert (Item 86, Tape, Masking (Item 58, Appendix B)
Appendix E) Cap, Valve Spring (32) (Item 6, Appendix F)
Installer, Water Nozzle (Item 87, Appendix E) Gaskets (8) (Item 14, Appendix F)
Puller Assembly, Valve Seat (Item 121, Gaskets (2) (Item 45, Appendix F)
Appendix E) Packing, Assortment (Item 156, Appendix F)
Reconditioning Set (Item 127, Appendix E) Seals, Valve Guide (32) (Item 320, Appendix F)
Remover Set, Valve Bridge Guide (Item 139, Washers, Pressure (8) (Item 337, Appendix F)
Appendix E)
a. Disassembly
1
(1) Remove eight connectors (1) and pressure 3
washers (2) from cylinder head (3). Discard 2
pressure washers.
19--35
TM 9--2320--360--34--2
19--7. CYLINDER HEAD REPAIR (CONT)
NOTE
· It may be necessary to drill 4
3
6
plugs and remove with an 4
easy out. 7
· Do steps (2) and (3) for right
cylinder head only.
· Do steps (4)and (5) for left
cylinder head only.
(2) Remove two plugs (4), plug (5), elbow (6),

and elbow (7) from front of cylinder head (3). 5
RIGHT FRONT
10
9
8
(3) Remove two plugs (8), two plugs (9), two

plugs (10), and fitting (11) from rear of
cylinder head (3).
(4) Install plug (9) in plug (12).
9 12 11
3
RIGHT REAR
13 14 13
17
(5) Remove two plugs (13), plug (14), plug (15), 16

elbow (16), elbow (17), and adapter (18)
from front of cylinder head (3)
15
18
3
LEFT FRONT
19--36
TM 9--2320--360--34--2
20 21 19
(6) Remove two plugs (19), plug (20), plug (21),
and elbow (22) from rear of cylinder
head (3).
3 22
LEFT REAR
(7) Remove four screws (23), washers (24), two 27 25

cover plates (25), and two gaskets (26) from
26
water inlet ports (27). Discard gaskets.
(8) Remove fuse plug (28) from cylinder
head (3).
27
23
24
28
26 3
25 23
24
(9) Remove nine pipe plugs (29), three plugs

(30), and engine brake wire harness
connector (31) from cylinder head (3).
29 30 31 29 29 29 30 29
19--37
TM 9--2320--360--34--2
35
NOTE
Wooden block must cover all
33
exhaust valves.
(10) Turn cylinder head so valve springs (32) are 34

up. Place cylinder head (3) on wooden
block.
(11) Install valve spring compressor (33) in one
of rocker arm bracket screw holes (34).
(12) Compress spring (32) and remove two valve
spring locks (35). Discard valve spring
locks.
32
(13) Slowly release pressure on spring (32). 36

Remove spring cap (36) and spring (32). 37
32
NOTE 38
Compressed air may ease
removal of washers from valve
guide.
33
(14) Remove valve guide seal (37) and washer
(38). Discard seal.
(15) Repeat steps (11) thru (14) for each
spring (32).
(16) Remove valve spring compressor (33) from
cylinder head (3).
3
NOTE
Secure valve stems with tape
prior to rotating cylinder head to 3
keep valves from falling out.
(17) Slowly rotate cylinder head (3) on its side.
CAUTION
Valves must be installed in their
original position. Failure to do
39
so may result in poor seating
and loss of engine performance.
NOTE
Tag all valves before removal.
(18) Remove all valves (39) from cylinder

head (3).
19--38
TM 9--2320--360--34--2
b. Cleaning
WARNING
Solvent cleaning compound MIL-PRF-680 Type II and III may be irritating to the eyes and skin. Use protective
gloves and goggles. Use in well-ventilated areas. Use respirator as needed. Accidental ingestion can cause
irritation of digestive tract and respiratory tract, may cause lung and central nervous system damage. Can be
fatal if swallowed. Inhalation of high/massive concentrations can cause coma or be fatal. First aid for ingestion:
do not induce vomiting. Seek immediate medical attention. First aid for skin contact: remove contaminated
clothing. Wash skin thoroughly with soap and water. If symptoms persist, seek medical attention. First aid for
eye contact: flush with water for 15 minutes or until irritation subsides. If symptoms persist, seek medical attention.
First aid for inhalation: move to fresh air. If not breathing, provide artificial respiration. If symptoms persist, seek
medical attention. Keep away from open flames and other sources of ignition. Failure to follow this warning may
result in injury or death to personnel.
•Fire extinguishers should be placed nearby when using solvent cleaning compound. Failure to follow this warning
may result in injury or death.
•Eye shields must be worn when cleaning with a wire brush.
Flying rust and metal particles may cause injury. 1
(1) Clean stripped cylinder head (1) with

solvent cleaning compound.
(2) Remove carbon from valves (2).
WARNING
2
personal protective
equipment (goggles/shield,
gloves, etc.).
(3) Dry all parts with compressed air.
c. Pressure Testing 1
NOTE
Perform magnetic particle and
fluorescent penetrant inspec-
tions before pressure testing to
locate exterior cracks.
(1) Replace cylinder head (1) if any cracks are
detected.
19--39
TM 9--2320--360--34--2
19--7. CYLINDER HEAD REPAIR (CONT) 2

5
NOTE
Cylinder head must be pressure 4
tested before cylinder head
repair.
3
(2) Install four injectors (22), clamps (3), washers
(4), and screws (5) in injector tubes (6).
Torque to 240--300 lb--in. (27.1--33.9 N.m).
6
1
(3) Position cylinder head (1) so bottom faces

up.
(4) Align test fixture (7) on bottom of cyulinder
head (1) so rubber stoppers cover water
nozzles (8).
CAUTION 9
Do not overtighten hold--down
cap screws. Rubber stopper 7
could distort enough to seal off
outer diameter of waer nozzle. 1 12
A leak would not be deteted
from outer diameter. Damage to 11
equipment may result.
15
(5) Install six screws (9) and nuts (10) on test
fixture (7). Torque to 48--60 lb--in. 16
(7--8 N.m). 8
(6) Install two tie down plates (11) on cylinder
head (1) with four screws (12), washers
(13), and nuts (14).
13
10
(7) Install end plate (15) on thermostat end of
cylinder head (1) with three screws (16). 14
18 17
1
(8) Install rear plug (17) and pipe plug (18) in
left rear of cylinder head (1).
LEFT REAR
19--40
TM 9--2320--360--34--2
(2) Install air hose (20) on end plate (15) and

apply 40 psi (276 kPa) to cylinder head (1).
(3) Check for air leaks with soap solution
around eight water nozzles (8) and bottom
of cylinder head (1) with soap solution.
(4) Check for air leaks with soap solution at top 15
and bottom of injector tubes, oil galleys,
exhaust ports, fuel manifolds, and top and 1
bottom of cylinder head (1).
20
7
8 12
11
(5) Slowly relieve air pressure and remove air
supply. 15
(6) Loosen air hose (20) from end plate (15) to 1 16
allow air pressure to escape. 20
(7) Remove air hose (20) from end plate (15).
(8) Remove six nuts (10), screws (9), four
screws (12), washers (13), nuts (14), two tie
down plates (11), and test fixture (7) from
cylinder head (1).
13
(9) Remove three screws (16) and end plate 10
(15) from cylinder head (1).
14
2
5
(10) Remove four injectors (2), screws (5),
washers (4), and clamps (3) from cylinder 4
head (1).
3
WARNING
Compressed air for cleaning 1
personal protective
gloves, etc.).
(11) Dry cylinder head (1) with compressed air.
19--41
TM 9--2320--360--34--2
NOTE 1
· Do steps (19) and (20) for
right cylinder head only.
· Do steps (21)and (22) for
left cylinder head only.
21
(12) Remove plug (21) from front of cylinder RIGHT FRONT
head (1).
(13) Remove plug (22), plug (23), and plug (9)

from rear of cylinder head (1).
22
RIGHT REAR 23
1
(14) Remove plug (24) from front of cylinder
head (1).
LEFT FRONT 24
25
(15) Remove plug (25), plug (26), and plug (27)

from rear of cylinder head (1).
26
27 LEFT REAR
19--42
TM 9--2320--360--34--2
(16) Remove eight screws (28), four covers (29),

and gaskets (30) from top of cylinder
head (1). 28
29
1 30
d. Inspection
NOTE
Maximum cylinder head war-
page along lines 1 thru 5 is
0.004 in. (0.101 mm). Maximum
warpage along lines 6 thru 11 is
0.008 in. (0.200 mm).
(1) Inspect bottom of cylinder head (1) for

warpage using straight edge and feeler
gage.
(2) Replace cylinder head (1) if warpage
exceeds specifications.
(3) Inspect cam follower bores (2) in cylinder 1
head (1) for scoring or wear. 1 2 3 4 5
(4) Clean light score marks on cam follower

bores (2) using crocus cloth moistened with
6
diesel fuel.
7
NOTE 8
9
Standard diameter of cam fol- 10
lower bore is between 1.062 in.
(26.975 mm) and 1.063 (27.000 11
mm). Maximum bore diameter
is 1.065 in. (27.051 mm).
(5) Measure inside diameter of cam follower 2 2 2 2

bores (2). Replace cylinder head (1) if any
cam follower bore failed inspection.
19--43
TM 9--2320--360--34--2
(6) Inspect injector tubes (3) for scoring, cracks,

or damage. 3
NOTE
Do steps (7) thru (11) for any
injector tubes that failed
inspection or leaked during
pressure testing.
(7) Install injector tube installer (4) in injector

tube (3).
1
6
(8) Tap on pilot (5) to loosen injector tube (3).

(9) Remove injector tube installer (4), injector 5
tube (3), and pilot (5) from cylinder head (1).
Discard injector tube. 3
4
(10) Remove and discard preformed packing (6).
7 7 7
(11) Inspect eight water nozzles (7) for looseness

or damage.
7 7
NOTE
Do steps (12) thru (17) for any
water nozzles that failed
inspection. 8
9
(12) Insert tapping tool (8) into water nozzle (7).
(13) Tap threads 0.5 in. (1.3 cm) deep in water
nozzle (7).
7
(14) Remove tapping tool (8).
(15) Install screw (9) in threaded hole.
(16) Pull on screw (9) to remove water nozzle
(7).
19--44
TM 9--2320--360--34--2
(17) Inspect valve guides (10) for cracks, 10

chipping, scoring, or excessive wear.
NOTE
Minimum inside diameter of
valve guide is 0.3125 in. (7.938
mm). Maximum inside diameter
is 0.3140 in. (7.976 mm).
(18) Measure inside diameter of valve

guides (10).
10
NOTE
Do steps (19) and (20) for any 11
valve guide that failed
inspection.
(19) Support cylinder head (1) on two 3 in. (7.62 1

cm) high wooden blocks.
(20) Drive valve guide (10) from bottom of
cylinder head (1) using valve guide
remover (11).
(21) Inspect valve bridge guides (12) for cracks,

chipping, scoring, or excessive wear.
10
NOTE
Do steps (22) thru (27) if valve
bridge guides fail inspection. 18
(22) File two notches (13) 1/16 in. (1.588 mm)

deep in opposite sides of valve bridge guide 17
(12) approximately 1--1/4 to 1--1/2 in.
(31.75--38.11 mm) from top. 16
(23) Place washer (14) over valve bridge

guide (12). 15
(24) Slide guide remover (15) over guide (12)
and align setscrews (16) with notches (13) in 16
guide (12).
12
(25) Tighten setscrews (16). 14
(26) Place spacer (17) over guide remover (15).
12
(27) Thread nut (18) on guide remover (15) and
13
turn clockwise to remove valve bridge guide
19--45
TM 9--2320--360--34--2
(28) Visually inspect valves (19) for cracks or

bent valve stem.
NOTE 19
Minimum diameter of valve stem
is 0.309 in. (7.849 mm). Maxi-
mum diameter is 0.310 in.
(7.874 mm).
(29) Measure stem diameter of valves (19).

(30) Replace any valve (19) that failed
inspection.
(31) Visually inspect valves (19) for pitting or
ridges on valve face. If pitting or ridges are
found, valve must be refaced.
20
(32) Inspect valve springs (20) for pit marks or

cracks.
NOTE
Minimum spring load is 25 lb
(11.35 kg) when spring is com-
pressed to 1.80 in. (45.72 mm).
(33) Test spring load of valve springs (20) using 21

spring tester (21).
(34) Replace valve springs (20) that fail
inspection.
22 23
(35) Inspect spring seats (22) and spring caps
(23) for cracks or damage. Replace
unserviceable parts.
19--46
TM 9--2320--360--34--2
(36) Inspect valve seat inserts (24) for excessive

or uneven wear, pitting, or cracks.
NOTE
· Worn or pitted valve seat in-
serts that are not severely
damaged may be repaired
by refacing. 26
· Do steps (37) thru (39) to

remove valve seat inserts
that failed inspection and 25
cannot be refaced.
24
(37) Position collet (25) flush with bottom of valve 1
seat insert (24).
(38) Press handle (26) down and remove valve
seat insert (24) from cylinder head (1).
(39) Measure diameter of valve seat insert
counterbore in cylinder head (1). Replace
cylinder head (1) if measurement is not
between 1.440 in. (36.576 mm) and 1.441
in. (36.601 mm).
e. Assembly
3
NOTE 1
Do steps (1) thru (5) if valve 2
guides were removed.
4
(1) Place cylinder head (1) in press with top
facing up.
(2) Install internally threaded end of valve guide
(2) in guide installer (3).
(3) Position valve guide (2) squarely on guide
bore (4) in cylinder head (1).
(4) Press guide installer (3) gently to start valve
guide (2) in straight.
(5) Press valve guide (2) until guide installer (3)
contacts bottom of counterbore in cylinder
head (1).
19--47
TM 9--2320--360--34--2
NOTE 1
Do steps (6) thru (9) if valve
bridge guides were removed.
7
(6) Place cylinder head (1) in press with top
facing up.
5
WARNING
Adhesive--sealant can burn
easily, can give off harmful 6
vapors, and is harmful to skin
and clothing. To avoid injury
or death, keep away from
open fire and use in well--
ventilated area. If adhesive--
sealant gets on skin or cloth-
soap and water.
(7) Coat undercut end of valve bridge guide (5)

with adhesive--sealant.
(8) Start undercut end of valve bridge guide (5)
10
in bore (6) in cylinder head (1).
(9) Position bridge guide installer (7) over valve
bridge guide (5) and press guide until
installer contacts cylinder head (1).
8
NOTE 9
Do steps (10) Thru (12) if valve 1
seat insert was removed.
(10) Place cylinder head (1) on wooden blocks

with bottom facing up.
(11) Place valve seat insert (8) in bore (9).
(12) Drive valve seat insert (8) in bore (9) with
valve insert installer (10) until seated in
cylinder head (1).
19--48
TM 9--2320--360--34--2
NOTE
If new valves and valve seats
are being used, do steps (20)
thru (28) before continuing with
step (13).
(13) Lightly coat valve face (11) with Prussian 13

blue dye.
NOTE
Do not rotate valve when
performing steps (16) thru (19).
8
11
(14) Lower stem of valve (12) into valve guide (2)
and let valve (12) drop against valve seat
insert (8). 2
12
(15) Push up on stem of valve (12) until valve
face (11) is about 1 in. (2.543 cm) above
valve seat insert (8).
(16) Release stem of valve (12) while applying
downward pressure against head of valve
(12) until valve face (11) makes contact with
valve seat insert (8).
(17) Repeat steps (15) and (16) several times to
get good imprint in Prussian blue dye.
(18) Remove valve (12) using care to avoid
smearing Prussian dye.
(19) Inspect contact surface (13). Imprint in
Prussian blue dye should have an even seat
mark all the way around the center of valve
face (11).
NOTE
Do steps (20) thru (28) to reface
valves and valve seat inserts if 13 14
parts are new or pitted, or an
uneven imprint was obtained. 60°
31°
(20) Use 31 degree grinding wheel and grinder 15°
on valve seat insert (8).
(21) Use 60 degree grinding wheel to open throat
of valve seat insert (8). 8
(22) Grind contact surface (13) of valve seat
insert (8) with a 15 degree grinding wheel to
narrow width of seat from 5/64 in. (1.984 12
mm) to 3/64 in. (1.91 mm).
(23) Valve (12) must be refaced at a 30 degree
angle. Valve head thickness (14) must be
no less than 0.031 in. (0.79 mm).
19--49
TM 9--2320--360--34--2
1 15
NOTE
Head of valve must not protrude 11
more than 0.006 in. (0.152 mm)
above cylinder head or be
recessed more than 0.023 in.
(0.584 mm). If beyond limit, 13
valve seat insert must be
replaced.
(24) Measure valve recess (15) when valve (12) 8

is seated against valve seat insert (8). 12
(25) Install gage block and dial indicator (16) in

valve bore (9).
NOTE
Runout must be measured to 16
ensure valve is directly centered
in valve guide. If measurement
exceeds 0.002 in. (0.05 mm),
check for bent valve guide
before regrinding valve seat
insert.
9
1
(26) Rotate dial indicator (16) and observe
runout.
NOTE
Tag valves to aid in installation.
(27) Recheck contact surface (13) between valve

face (11) and valve seat insert (8) with
Prussian blue dye. Do steps (13) thru (19).
(28) Clean cylinder head (1) and valves (12)
thoroughly.
19--50
TM 9--2320--360--34--2
CAUTION
Water nozzles must be installed 17 18 17
so holes are pointed toward
cylinder. Failure to comply may
result in improper coolant flow
and engine overheating.
NOTE
· Do step (29) if water
nozzles were removed.
· Ensure water nozzle fits 18
tightly.
· Water nozzles must be flush 18
19
or recessed less than 0.015
in. (0.38 mm) below cylinder
head surface. 17
· End two water nozzles have
one hole. Six water nozzles
between cylinders have two
holes.
1
(29) Install water nozzle (17 or 18) into cylinder
head (1) with nozzle holes facing in direction
of arrows using water nozzle installer (19).
NOTE
Do steps (30) thru (49) if injector 23
tubes were removed.
(30) Install new preformed packing (20) in 22

counterbore (21) of cylinder head (1).
(31) Install injector tube (22) in injector bore of 1
cylinder head (1) using injector tube
installer (23). 20
(32) Install pilot (24) in bottom of injector tube 21

installer (23).
NOTE 23
Tube flange at seal ring end
may protrude 0.120 in. (3.048 24
mm) above cylinder head cast-
ing. Seal is formed when O--
ring is pressed between head 21
counterbore and outside diame-
ter of injector tube. Tube flange
is used to retain seal ring in
1
head counterbore.
(33) Drive injector tube (22) into bore (21) of

cylinder head (1).
19--51
TM 9--2320--360--34--2

(34) Remove pilot (24) and install upsetting die
(25) in injector tube installer (23). 24 25
(35) Tighten upsetting die (25) to 30 lb--ft (41

N.m) to flare lower end of injector tube (22).
(36) Remove injector tube installer (23) and
upsetting die (25). 23
NOTE
Reamer must be turned in
clockwise direction only when
inserting and withdrawing
reamer. Movement in opposite
direction will dull cutting edges.
(37) Place few drops of lubricating oil on cutting

edge of reamer (26) and carefully insert in
injector tube (22).
CAUTION
Ensure all metal chips and
shavings are removed prior to 23
each reaming operation. Failure 1
to comply may result in damage
to equipment. 22
(38) Slowly turn reamer (26) clockwise,

withdrawing frequently to remove chips. 25
Continue cutting until shoulder of cutting
edge on reamer (26) contacts injector
tube (22).
WARNING
personal protective
gloves, etc.).
1 26
(39) Clean out all metal chips with compressed 22
air.
(40) Install pilot (24) in reamer (26).
(41) Place few drops of cutting oil on pilot (24). 24
(42) Turn reamer (26) until lower end of injector
tube (22) is flush with or up to 0.005 in.
(0.127 mm) below finished surface on
bottom of cylinder head (1).
(43) Clean out all metal chips with compressed
air.
(44) Remove reamer (26) and pilot (24).
19--52
TM 9--2320--360--34--2
(45) Install injector gage (27) in injector tube (22).

(46) Zero sled gage dial indicator (28) on finished
surface of cylinder head (1).
NOTE
1
· Tip of injector gage must be 27
flush with or up to 0.014 in. 22
(0.356 mm) above or below
finished surface of cylinder 28
head.
· If injector gage is more than
0.014 in. above cylinder
head surface, replace
injector tube.
· If injector gage is more than
0.014 in. below cylinder
head surface, ream injector
tube with nut reamer. Refer
to step (48).
(47) Hold injector gage (27) in injector tube (22)

and move sled gage dial indicator (28) onto
tip of injector gage (27). Note dial indicator
reading and determine difference from zero
reading. Remove sled gage dial indicator
(28) and injector gage (27).
NOTE 29
· Do step (48) only if nut 22
reaming is required.
· Remove a little metal at a
time and recheck
measurement when using
nut reamer. Always clean
out injector tube before
taking a reading.
(48) Remove excess stock from injector tube (22)

using nut reamer (29).
19--53
TM 9--2320--360--34--2
(49) Install valves (12) in valve bores (9).

1
NOTE
· Secure valve stems with
tape prior to rotating cylin- 12
der head to keep valves
from falling out.
· Wooden block must cover 9
all exhaust valves.
(50) Place cylinder head (1) on wooden blocks

with valve stems facing up.
33
32
(51) Remove tape from valves (12).
31
30
(52) Install washer (30), valve guide seal (31),

spring (32), and spring cap (33).
(53) Install spring compressor (34) in one of

1
rocker shaft screw holes (35).
CAUTION 36
Compress spring only enough to
permit installation of two--piece
34
valve spring retainer. Com-
pressing spring too far may
result in damage to oil seal. 35
(54) Apply pressure on spring compressor (34)

and compress spring (32).
1
(55) Install two valve spring locks (36) in groove
at stem end of valve (12).
(56) Slowly release pressure on spring (32),
ensuring valve spring locks (36) are in place. 32
(57) Remove spring compressor (34) from
cylinder head (1).
12
(58) Turn cylinder head (1) on its side when all

valves (12) have been installed.
(59) Tap stem end of each valve (12) with plastic
hammer to seat valve spring locks (36). 12
19--54
TM 9--2320--360--34--2
WARNING
1
soap and water.
(60) Coat threads of nine plugs (37) and three

compound.
(61) Install nine pipe plugs (37) and three plugs 37 38 39 37 37 37 38 37
(38) in cylinder head (1).
(62) Install engine brake retarder wire harness
42
connector (39) in cylinder head (1). 45
41 46
44
40 47
(63) Install four new gaskets (40) and covers (41)
on cylinder head (1) with screws (42).
(64) Coat threads of fuse plug (43) with pipe
48
(65) Install fuse plug (43) in cylinder head (1).
(66) Install two new gaskets (44) and cover 43
plates (45) on water inlet ports (46) with 1
four washers (47) and screws (48). 45
46
44 48
47
NOTE 51
· Do steps (67) thru (72) for 49 52 50
left cylinder head only.
· Do steps (73) thru (78) for
right cylinder head only.
(67) Install plug (49) in rear of cylinder head (1).

(68) Coat threads of plugs (50 thru 53) and elbow
(54) with pipe thread sealing compound.
(69) Install two plugs (50), two plugs (51), plug 53 54
(52), plug (53), and elbow (54) in rear of 1
cylinder head (1).
LEFT REAR
19--55
TM 9--2320--360--34--2

56 55
60
WARNING
pipe thread sealing com- 59 57
LEFT FRONT
soap and water. 65
(70) Coat threads of plugs (55 thru 58), adapter

(59), elbow (60), and elbow (61) with pipe 63 1
(71) Install two plugs (55), plug (56), plug (57),
and plug (58) in front of cylinder head (1).
(72) Install adapter (59), elbow (60), and elbow
(61) in front of cylinder head (1).
64 62 67 66
(73) Install plug (62) in rear of cylinder head (1).
(74) Coat threads of plugs (63 thru 66) and fitting RIGHT REAR
1
(75) Install two plugs (63), two plugs (64), two 68 71
68
plugs (65), plug (66), and fitting (67) in rear
of cylinder head (1). 72
(76) Coat threads of plugs (68 thru 70) and

elbows (71 and 72) with pipe thread sealing
compound.
(77) Install two plugs (68), plug (69), and plug
(70) in front of cylinder head (1).
70 69
(78) Install elbow (71) and elbow (72) in front of
cylinder head (1). RIGHT FRONT
74
1
73
(79) Install eight new pressure washers (73) and
new connectors (74) in cylinder head (1).
Torque to 40--45 lb--ft (102--115 N.m).
f. Follow--On Maintenance
Install cam followers and push rods (para 19--11).
19--56
TM 9--2320--360--34--2
19--8. MAIN BEARING AND CRANKSHAFT REPAIR
This task covers:

a. Removal c. Installation
b. Cleaning/Inspection d. Follow--On Maintenance
INITIAL SETUP

Sending units and attachments removed Oil pan removed (para 3--20).
(TM 9--2320--360--20). Oil pressure regulator valve removed
Starter removed (TM 9--2320--360--20). (para 3--22).
150 amp circuit breakers removed Oil pressure relief valve removed (para 3--21).
(TM 9--2320--360--20). Crankshaft cover, front oil seal, and oil pump
24--volt (front) alternator/bracket removed removed (para 19--14).
(TM 9--2320--360--20). Flexplate assembly removed (para 3--17).
Exhaust manifolds removed (para 3--23). Flywheel housing removed (para 19--9).
Air box drains removed (para 3--9). Camshafts and end bearings removed
Air box covers removed (para 3--8). (para 19--12).
Engine mounted on engine stand (para 19--3). Pistons, connecting rods, and liners removed
Fan removed (TM 9--2320--360--20). (para 19--10).
Fan belts removed (TM 9--2320--360--20).
Fan clutch removed (TM 9--2320--360--20). Tools and Special Tools
Electronic control module (ECM) removed Tool Kit, Genl Mech (Item 202, Appendix E)
(TM 9--2320--360--20). Caliper Set, Micrometer (Item 15, Appendix E)
Thermostats removed (TM 9--2320--360--20). Caliper, Vernier, 0--6 In. (Item 16, Appendix E)
DDEC oil pressure sensor removed Dial Indicator, Magnetic (Item 32, Appendix E)
(TM 9--2320--360--20). Remover, Bearing Shell (Figure C--10,
Rocker covers removed (TM 9--2320--360--20). Appendix C)
Idler gear removed (para 19--13). Sling, Endless Strap (Item 161, Appendix E)
Fuel injector wire harnesses removed Wrench Set, Socket, 3/4 In. (Item 231,
(para 4--3). Appendix E)
12--volt (rear) alternator/bracket removed Wrench, Torque, 0--600 Lb--Ft (Item 233,
(TM 9--2320--360--20). Appendix E)
Left thermostat housing removed (para 5--3). Wrench, Torque, 0--150 Lb--In. (Item 234,
Right thermostat housing removed (para 5--4). Appendix E)
Crankshaft pulley removed (para 3--12). Wrench, Torque, 0--175 Lb--Ft (Item 236,
Crankshaft vibration damper and cover Appendix E)
removed (para 3--15).
Blower accessory drive hub removed Materials/Parts
(para 4--9). Compound, International, No. 2 (Item 21,
Engine brake retarder wire harnesses removed Appendix B)
(para 6--16). Oil, Lubricating (Item 45, Appendix B)
Engine brake retarders removed (para 3--26). Plastigage (Item 50, Appendix B)
Rocker arms removed (para 3--18). Tags, Identification (Item 56, Appendix B)
Injectors removed (para 4--2).
Cylinder heads removed (para 3--10). Personnel Required
Two
19--57
TM 9--2320--360--34--2
19--8. MAIN BEARING AND CRANKSHAFT REPAIR (CONT)

1
a. Removal 2 3
(1) Rotate engine block (1) on engine stand so

crankshaft (2) is up.
(2) Install dial indicator (3) on engine block.
(3) Adjust dial indicator (3) to zero while
assistant pushes crankshaft (2) toward
indicator with pry bar.
(4) Remove pry bar and push crankshaft (2) in
opposite direction. Note end play.
10
(5) Remove six screws (4) and timing gear (5) 1 7
6
from crankshaft (2). 8
(6) Remove seven screws (6) and washers (7) 7
from bearing cap stabilizers (8 and 9).
9
(7) Remove 10 screws (10) and washers (7) 5
from bearing cap stabilizers (8 and 9). 2
(8) Remove four bearing cap stabilizers (8 and
9) from bottom of engine block (1).
19--58
TM 9--2320--360--34--2
(9) Install four screws (10) in front main bearing

cap (11) and rear main bearing cap (12).
Torque to 50 lb--ft (68 N∙m). 10
(10) Strike front main bearing cap (11) and rear
main bearing cap (12) with soft--face
hammer. Torque to 110 lb--ft (149 N∙m). 11 15
2
(11) Strike front main bearing cap (11) and rear
main bearing cap (12) with soft--face
hammer. Torque to 250 lb--ft (339 N∙m). 12
(12) Install spacer (13) and screw (14) on front of
crankshaft (2). 14
13
NOTE
· Bearing caps are numbered
1 thru 5 for identification
during installation.
· If bearing shells are to be
reused, tag and mark them
for installation.
(13) Remove three center bearing caps (15) from

crankshaft (2).
15
(14) Remove lower bearing shells (16) from three

center bearing caps (15).
16
CAUTION
Bearings are notched on one
side and only come out one 19
way. Do not attempt to force
bearing out incorrectly. Failure 17
to equipment.
18
NOTE
Turn crankshaft to aid in
removing bearing shell from
under bearing journal.
(15) Push upper bearing shell (17) out from

under crankshaft main bearing journal no. 2
(18) with bearing shell remover (19) while
assistant turns screw (14) to turn
crankshaft (2).
19--59
TM 9--2320--360--34--2
17
(16) Repeat step (15) for crankshaft main
bearing journals no. 3 (20) and no. 4 (21). 18 3 2
21
(17) Read runout of main bearing journals (18,
20, and 21) with dial indicator (3) while
assistant turns screw (14) to turn
crankshaft.
(18) Maximum allowable runout for journals (18
and 21) is 0.002 in. (0.05 mm). Maximum
allowable runout for journal (20) is 0.004 in. 2 12
(0.10 mm).
14
(19) Remove four screws (10) and two bearing 20
caps (11 and 12) from crankshaft (2). 10
11
11
(20) Remove lower bearing shell (17) from

bearing cap (11).
16
12
NOTE 22
Tag and mark thrust bearing 22
before removal.
(21) Remove lower bearing shell (16) and two

lower thrust bearings (22) from bearing
cap (12).
16
19--60
TM 9--2320--360--34--2
CAUTION
Store crankshaft on end.
Crankshaft may bend if stored 2
on side.
(22) Attach lifting device to crankshaft (2).
WARNING
Crankshaft weighs 185 lb (84
kg). Keep out from under
crankshaft when it is sup-
ported by lifting device. If
crankshaft falls, serious
injury or death may result.
(23) Guide crankshaft (2) while assistant 1

operates lifting device to remove crankshaft.
17
24
(24) Remove two remaining upper bearing shells

(17) from bearing surfaces (23) at front and 23
rear of engine block (1).
(25) Remove two thrust bearings (24) from rear
upper bearing surface (23).
24
CAUTION
Upper bearing shells have a
through slot for lubrication. 25
Upper bearing shells are in- 1
stalled in cylinder block. Failure 17
to comply will block off oil flow
and damage to equipment may
result.
NOTE 26
If runout measured during test-
ing is not within limits, do steps 23
(26) thru (36) to see if bearing
shell caused crankshaft runout.
(26) Align tab (25) on new upper bearing shell

(17) with slot (26) on engine block rear main
bearing surface (23).
19--61
TM 9--2320--360--34--2
1 17
NOTE
Ensure both ends of bearing
shell are flush with bearing cap
mounting surfaces.
(27) Install another new bearing shell (17) on 23
bearing surface (23) at front of engine
block (1).
(28) Align tabs (27) with slots (28) and install two 11
new bearing shells (16) on bearing caps (11
and 12). Make sure both ends of bearing
shells are flush with bearing cap mounting 12 22
surfaces (29).
NOTE 16 22
28
Grooved sides of thrust bearing
point away from bearing cap.
(29) Install two new thrust bearings (22) on rear
main bearing cap (12). 27
29
(30) Coat crankshaft front and rear main bearing 28
16
journals (30) with oil.
WARNING 27
2
crankshaft falls, serious
(31) Attach lifting device to crankshaft (2).
30
(32) Guide crankshaft while assistant operates
lifting device to install crankshaft (2). 30
NOTE
Thrust bearings are installed
only at bearing surface on rear
of engine block.
(33) Push crankshaft (2) to front and install new 24
thrust bearing (24). Push crankshaft to rear
and install other new thrust bearing (24).
19--62
TM 9--2320--360--34--2
(34) Install two main bearing caps (11 and 12).

11
(35) Do steps (9) thru (11). 12
(36) Repeat steps (17) and (18). If crankshaft
runout is still too high, replace
crankshaft (2).
(37) Do steps (19) thru (25).
WARNING
Fuel is very flammable and
can explode easily. To avoid
serious injury or death, keep
flame away from fuel and
keep fire extinguisher within
easy reach when working with
fuel. Do not work on fuel
system when engine is hot.
Fuel can be ignited by hot
engine. When working with
fuel, post signs that read NO
SMOKING WITHIN 50 FEET of
vehicle.
3
(1) Clean crankshaft (1) and bearing caps (2) 2
with clean diesel fuel and a lint--free cloth. 9 4
6 1
(2) Remove four plugs (3) from crankshaft (1). 10
(3) Flush oil passages (4) in crankshaft (1) with
stiff wire brush.
(4) Install four plugs (3) on crankshaft (1).
Torque to 120--144 lb--in. ( 13.6--16.3 N∙m).
(5) Visually inspect crankshaft (1) for signs of
scoring, grooving, or overheating. 7 5
6
(6) Inspect crankshaft connecting rod journals 6
(5) and main bearing journals (6) for deep
scratches. Replace crankshaft (1) if
7
damaged.
(7) Inspect connecting rod journals (5) and main
bearing journals (6) for signs of cracks at
journal oil holes (7) or joining points (8) of 8
connecting rod journal (5) and main bearing
journals (6). Replace crankshaft (1) if
damaged.
(8) Inspect crankshaft keyways (9) for signs of
cracks or wear. Replace crankshaft (1) if
damaged.
(9) Inspect rear oil seal contact surface (10) for
deep scratching. If scratches cannot be
smoothed out with crocus cloth, replace
crankshaft.
19--63
TM 9--2320--360--34--2
(10) Inspect crankshaft rear main bearing thrust 1

surfaces (11) for grooving. Replace
crankshaft (1) if deep grooves are present
in thrust surfaces.
11
12
(11) Inspect timing gear (12) for chipped teeth.

Replace if damaged.
(12) Measure and note thickness of two lower

thrust bearings (13).
NOTE 13
· Refer to table 19--1 for
steps (16) and (17).
steps (18) thru (21). 14
15
(13) Measure diameter of five main bearing 1
journals (14) at several different spots.
(14) Measure diameter of four connecting rod
journals (15) at different spots on each.
(15) Replace crankshaft (1) if journals (14 and
15) are outside limits shown in table 19--1.
(16) Measure width of connecting rod journals
(15).
14
(17) Replace crankshaft if journals (15) are 15
outside limits shown on table 19--2.
(18) Add together thickness of two lower thrust
bearings measured in step (12).
(19) Subtract total in step (18) from 0.244 in.
(6.20 mm).
(20) Subtract result in step (19) from crankshaft
end play measured in removal, step (4).
(21) Find amount of crankshaft end play from
step (20) in table 19--3 and read what size
thrust bearings to use.
19--64
TM 9--2320--360--34--2
Table 19--1. Main Bearing and Connecting Rod Journal Diameter Specifications
Minimum Diameter:
Main Bearing Journals (14) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4985 in. (114.25 mm)
Connecting Rod Journals (15) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9985 in. (76.15 mm)
Maximum Journal Out of Round
All Journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0005 in. (0.013 mm)
Maximum Taper
All Journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0040 in. (0.010 mm)
Table 19--2. Connecting Rod Journal Width Specifications

Maximum Width
Connecting Rod Journals (15) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.652 in. (67.36 mm)
Table 19--3. Crankshaft End Play Specifications
Crankshaft end play found in step (20) Use this size thrust bearing
Less than 0.016 in. (0.41 mm) Standard 0.122 in. (3.1 mm)
0.017--0.026 in. (0.43--0.66 mm) Oversized 0.127 in. (3.23 mm)
0.027--0.036 in. (0.69--0.91 mm) Oversized 0.132 in. (3.35 mm)
More than 0.36 in. (0.91 mm) Replace crankshaft
19--65
TM 9--2320--360--34--2

c. Installation
CAUTION
Do not handle bearing shells and thrust bearings more than necessary for
installation. Sweat from hands may damage bearing shells and thrust bearings.
NOTE
Bearing surfaces are numbered 1
1 thru 5 from front to rear of
engine block. Repeat steps (1) 2
and (2) for four other main
bearing surfaces.
3
(1) Align tab (1) on upper rear main bearing
shell (2) with slot (3) on bearing surface of
engine block (4).
4
CAUTION
Upper bearing shells have a
through slot for lubrication.
Upper bearing shells are in-
stalled in cylinder block. Failure
to comply will block off oil flow
and damage to equipment may 5
result.
(2) Install shell (2) on bearing surface of engine

block (4). Ensure both ends of shell are
flush with bearing cap mounting surfaces (5).
(3) Coat bearing shells (2) with oil after 7
6
installation.
(4) Coat five crankshaft main bearing journals
(6) with oil.
WARNING
crankshaft falls, serious 8
(5) Attach lifting device (7) to crankshaft (8). 9

(6) Install crankshaft (8) while assistant
operates lifting device.
NOTE
Install thrust bearing with
grooved side toward crankshaft.
(7) Push crankshaft (8) to front and install rear

main thrust bearing (9). Push crankshaft (8)
to rear and install other rear main thrust
bearing (9).
19--66
TM 9--2320--360--34--2
(8) Align tab (10) with slot (11) and install lower
rear main bearing shell (12) in rear bearing 13
cap (13). Ensure both ends of bearing shell
are flush with rear bearing cap (13) 16
mounting surfaces. 16
(9) Install four other main bearing shells (10) on

other main bearing caps (14 and 15).
NOTE
Install thrust bearing with 12
grooved side away from bearing
cap. 11
(10) Install two lower thrust bearings (16) on rear

bearing cap (13). 10
NOTE
Wipe oil from bearing shells and
crankshaft main bearing journals
13
before doing steps (11) thru (13). 18 C
L
(11) Place strip of plastigage (17) across width of

bearing shell (12) 0.25 in. (6.35 mm) from
center (18).
(12) Do step (11) for four remaining bearing
caps (14 and 15).
12
17
19
(13) Position five bearing caps (13, 14, and 15)

on bearing cap mounting surface (5).
15
(14) Strike bearing caps (13, 14, and 15) with
soft--face hammer. 14
15
(15) Install 10 screws (19) on bearing caps (13, 15
14, and 15). Torque to 50 lb--ft (68 N∙m).
(16) Strike bearing caps (13, 14, and 15) with 5
(17) Tighten 10 screws (19) to 110 lb--ft (149
N∙m) then to 230--240 lb--ft (312--325 N∙m).
(18) Remove 10 screws (19) and 5 bearing
caps (13, 14, and 15).
19--67
TM 9--2320--360--34--2
(19) Measure width of plastigage (17) with 17 12

measuring strip (20). Width must be no
more than 0.0051 in. (0.13 mm) or less than
0.0016 in. (0.04 mm). If greater, replace
bearing shells (12).
(20) Wipe plastic gage from five main bearing

journals (6) or bearing shells (12). Coat
those surfaces with lubricating oil.
20
15
14
(21) Install five bearing caps (13, 14, and 15) on 15
15
bearing cap mounting surface (5).
(22) Strike bearing caps (13, 14, and 15) with 5
(23) Position four bearing cap stabilizers (21 and

22) on engine block (4).
(24) Install seven washers (23) and screws (24)

on bearing cap stabilizers (21 and 22).
Tighten screws finger tight.
WARNING
Sealing compound can burn
vapors, and is harmful to skin 4
24
and clothing. To avoid injury 21
or death, keep away from 23
ventilated area. If sealing
compound gets on skin or
clothing, wash immediately 8
with soap and water.
(25) Coat threads of 10 screws (19) and surfaces

of stabilizers (21 and 22) with small amount
of sealing compound no. 2.
22
(26) Install 10 screws (19) finger tight.
19--68
TM 9--2320--360--34--2
(27) Strike bearing caps (14 and 15) with soft 19 14 15

face--hammer. 15
(28) Tighten eight screws (19) on four front 15
bearing caps (14 and15) to 40--50 lb--ft
(54--68 N∙m) starting with middle two
caps (15).
(29) Strike bearing caps (14 and 15) with
soft--face hammer and torque eight screws
(19) to 110 lb--ft (149 N∙m).
NOTE
New bearing cap screws are
tightened to 230--240 lb--ft
(312--325 N∙m).
(30) Strike bearing caps (14 and 15) with

soft--face hammer and torque eight screws
(19) to 250--260 lb--ft (339--352 N∙m).
(31) Tighten two screws (19) on rear bearing cap

(13) to 40--50 lb--ft (54--68 N∙m).
(32) Strike both ends of crankshaft (8) two or
three blows with soft--face hammer.
(33) Strike rear bearing cap (13) with soft--face
hammer.
(13) to 110 lb--ft (149 N∙m).
(35) Strike rear bearing cap (13) with soft--face
hammer. 24
13
NOTE 19
New bearing cap screws are
tightened to 230--240 lb--ft
(312--325 N∙m).

(13) to 250--260 lb--ft (339--352 N∙m).
(37) Tighten seven screws (24) to 70--75 lb--ft
(95--102 N∙m).
NOTE
Crankshaft will turn freely if all
bearings are properly installed.
8
(38) Rotate crankshaft (8) to ensure it turns
freely.
19--69
TM 9--2320--360--34--2
NOTE
28
Align dowel pin on crankshaft 27
with hole in gear.
(39) Install timing gear (25) on crankshaft (8)

with six screws (26).
(40) Install spacer (27) and screw (28) on end
of crankshaft (8).
(41) Hold screw (28) while assistant torques six
screws (26) to 40 lb--ft (54 N∙m).
(42) Remove screw (28) and spacer (27) from
crankshaft (8).
8
26
25
4
(43) Install dial indicator (29) on engine block (4). 8 29
(44) Adjust dial indicator to zero while assistant

pushes crankshaft (8) toward indicator (29)
with pry bar.
(45) Read end play while assistant pushes
crankshaft away from dial indicator (29) with
pry bar. Minimum end play is 0.004 in. (0.10
mm) and maximum end play is 0.018 in.
(0.46). If end play is outside limits, replace
crankshaft (8).
d. Follow--On Maintenance
(1) Install pistons, connecting rods, and liners (para 19--10).
(5) Install crankshaft cover, front oil seal, and oil pump (para 19--14).
19--70
TM 9--2320--360--34--2
d. Follow--On Maintenance (Cont)

(6) Install oil pressure relief valve (para 3--21).
(7) Install oil pressure regulator valve (para 3--22).
(15) Install crankshaft vibration damper and cover (para 3--15).
(28) Install fan (TM 9--2320--360--20).
19--71
TM 9--2320--360--34--2
19--9. FLYWHEEL HOUSING REPAIR
This task covers

a. Removal d. Assembly
b. Disassembly e. Installation
c. Cleaning/Inspection f. Follow--On Maintenance
INITIAL SETUP
Equipment Conditions Materials/Parts

Sending units and attachments removed Cloth, Crocus (Item 16, Appendix B)
(TM 9--2320--360--20). Compound, Sealing, Pipe Thread
Starter removed (TM 9--2320--360--20). (Item 28, Appendix B)
150 amp circuit breakers removed Grease, Automotive and Artillery
(TM 9--2320--360--20). (Item 32, Appendix B)
24--volt (front) alternator/bracket removed Oil, Lubricating, (Item 45, Appendix B)
(TM 9--2320--360--20). Cleaning Compound, Solvent (Item 54, Appendix B)
Exhaust manifolds removed (para 3--23). Tags, Identification (Item 56, Appendix B)
Air box drains removed (para 3--9). Gaskets (2) (Item 61, Appendix F)
Air box covers removed (para 3--8). Gasket (Item 51, Appendix F)
Engine mounted on engine stand (para 19--3). Lockwashers (6) (Item 121, Appendix F)
DDEC oil pressure sensor removed Lockwashers (7) (Item 127, Appendix F)
(TM 9--2320--360--20). Screws (6) (Item 279, Appendix F)
12--volt (rear) alternator/bracket removed Screws (3) (Item 278, Appendix F)
(TM 9--2320--360--20). Seal, Oil (Item 317, Appendix F)
Blower accessory drive hub Washer, Copper (Item 334, Appendix F)
removed (para 4--9).
Oil pan removed (para 3--20). Personnel Required
Flexplate assembly removed (para 3--17). Two
Tools and Special Tools

Compressor Unit, Air (Item 24, Appendix E)
Eyes, Lifting (Figure C--12, Appendix C)
Goggles, Industrial (Item 57, Appendix E)
Guide Screws (4) (Item 61, Appendix E)
Sling, Endless Strap (Item 161, Appendix E)
Wrench, Impact, Electric, 1 In. (Item 223,
Appendix E)
Wrench, Torque, 0--175 Lb--Ft (Item 236,
Appendix E)
19--72
TM 9--2320--360--34--2
a. Removal
NOTE
Tag and mark hoses before
removal.
(1) Remove two fuel hoses (1) from elbows (2)

on fuel block (3).
(2) Disconnect fuel pressure transducer (4) from
STE/ICE engine wire harness (5).
NOTE
Left and right brackets are 12 7 6 13
removed the same way. Left 8
side is shown.
14
(3) Remove four screws (6), washers (7), and
lockwashers (8) from two brackets (9).
Discard lockwashers. 11
10
(4) Remove two screws (10), lockwashers (11),
and brackets (9) from cylinder heads (12).
Discard lockwashers.
(5) Install two lifting eyes (13) on flywheel 1

2
housing (14).
3
(6) Support flywheel housing (14) with lifting 5
device. 4
16
17
NOTE
Tag and mark all screws before
removal.
(7) Remove six screws (15) from flywheel 15

housing (14). Discard screws.
(8) Remove six screws (16) and washers (17)
from flywheel housing (14).
14
19--73
TM 9--2320--360--34--2
19--9. FLYWHEEL HOUSING REPAIR (CONT)
21
22
(9) Install four guide screws (18) in flywheel
housing (14).
(10) Remove four screws (19) and lockwashers
(20) from flywheel housing (14). Discard
lockwashers.
(11) Remove three screws (21) and washers (22) 20
from flywheel housing (14). Discard screws. 14
19
(12) Remove five screws (23) from access 18

cover (24).
(13) Remove screw (25) and copper washer (26) 14
from access cover (24). Discard copper 27
washer. 24
23
(14) Remove access cover (24) and gasket (27)
from flywheel housing (14). Discard gasket.
26
25
(15) Remove three nuts (28), lockwashers (29), 36

screws (30), washers (31), and fuel block (3) 32 33
from access cover (32). Discard
lockwashers. 28
29
(16) Remove two screws (33), screw (34), and 31
washer (35) from access cover (32). 30
14
(17) Remove access cover (32) and gasket (36) 35
from flywheel housing (14). Discard gasket.
34
3
19--74
TM 9--2320--360--34--2
14
(18) Remove two screws (37) and washers (38) 38

from flywheel housing (14).
37
(19) Remove two screws (39) from rear of
flywheel housing (14). 39
37
38
41
(20) Remove screw (40) from access hole (41).
40
43
13
WARNING
Ensure lifting device is 14
secured. Keep hands and
feet out from under flywheel
housing when removing from
engine. Falling parts may
cause serious injury to
personnel.
(21) Remove flywheel housing (14) from rear of

engine block (42) and place on flat work
surface, engine side up.
(22) Remove gasket (43) from engine block (42)
and flywheel housing (14). Discard gasket.
(23) Remove four guide screws (18) from engine
block (42). 18 42
(24) Remove two lifting eyes (13) from flywheel
housing (14).
19--75
TM 9--2320--360--34--2
b. Disassembly
(1) Remove pipe plug (1) from bottom of
flywheel housing (2).
(2) Remove pipe plug (3) from backside of
(3) Remove crankshaft rear oil seal (4) from
flywheel housing (2). Discard oil seal.
c. Cleaning/Inspection 4
CAUTION
Use care when scraping gasket
material from machined surface
of housing or housing will be
damaged.
3
(1) Scrape gasket material from housing.
2 1
WARNING
Solvent cleaning compound MIL-PRF-680 Type II and III may be irritating to the eyes and skin. Use protective gloves and goggles.
Use in well-ventilated areas. Use respirator as needed. Accidental ingestion can cause irritation of digestive tract and respiratory
tract, may cause lung and central nervous system damage. Can be fatal if swallowed. Inhalation of high/massive concentrations
can cause coma or be fatal. First aid for ingestion: do not induce vomiting. Seek immediate medical attention. First aid for skin
contact: remove contaminated clothing. Wash skin thoroughly with soap and water. If symptoms persist, seek medical attention.
First aid for eye contact: flush with water for 15 minutes or until irritation subsides. If symptoms persist, seek medical attention.
First aid for inhalation: move to fresh air. If not breathing, provide artificial respiration. If symptoms persist, seek medical attention.
Keep away from open flames and other sources of ignition. Failure to follow this warning may result in injury or death to personnel.
(2) Clean metal parts with solvent cleaning compound.

WARNING
Compressed air for cleaning purposes will not exceed 30 psi (207 kPa).
Use only with effective chip guarding and personal protective equipment
(3) Dry metal parts with compressed air.
(4) Inspect housing for cracks or other damage.
CAUTION
Crankshaft must be clean and smooth
or oil seal lip will be damaged when
flywheel housing is installed.
NOTE
Polishing motion should be clockwise
around end of crankshaft.
(5) Polish end of crankshaft with crocus cloth wet with lubricating oil.
(6) Replace all damaged parts.
19--76
TM 9--2320--360--34--2
d. Assembly
WARNING
soap and water.
(1) Coat threads of pipe plugs (1 and 2) with

(2) Install pipe plug (1) in backside of flywheel
housing (3). 1
(3) Install pipe plug (2) in bottom of flywheel 3 2
housing (3).
4 3
e. Installation 1
(1) Install two lifting eyes (1) in flywheel
housing (2). 2
(2) Coat gear train teeth (3) with lubricating oil.
(3) Set flywheel housing (2), engine side up, on
flat surface.
(4) Coat engine side of flywheel housing (2)
with grease.
(5) Install new gasket (4) on engine side of
(6) Coat gasket (4) with grease.
(7) Install four guide screws (5) in engine
block (6).
(8) Install lifting device while assistant positions
flywheel housing (2) over crankshaft (7) and 5 6
against engine block (6). 7
19--77
TM 9--2320--360--34--2
9
NOTE
Do not tighten any screws until
all are installed. All hardware is
torqued at the end of the
procedure.
(9) Install new screw (8) in access hole (9).
2
11
12
(10) Install two screws (10) on engine rear cover
plate (11) and flywheel housing (2).
13
(11) Install two washers (12) and screws (13) on
10
13
12
(12) Coat new gasket (14) with grease.

(13) Install new gasket (14) and access cover
(15) on flywheel housing (2) with washer
(16) and screw (17).
(14) Install two screws (18) on flywheel
housing (2).
14
(15) Install fuel block (19) on flywheel housing (2) 15
with three washers (20), screws (21), new 18
lockwashers (22), and nuts (23). 23
22
20
21
2
16
17
19
19--78
TM 9--2320--360--34--2
(16) Install four new lockwashers (24) and

screws (25) in flywheel housing (2). 27
1
(17) Install three washers (26) and new screws 26
(27) in flywheel housing (2).
(18) Install six new screws (28) in flywheel
housing (2).
(19) Remove lifting device from lifting eyes (1).
(20) Remove two lifting eyes (1) from flywheel
housing (2). 24
(21) Remove four guide screws (5) from engine 2
block (6). 25
(22) Install six washers (29) and screws (30) in 28

29
2
37
30 32
35
36
33
34
NOTE
Left and right brackets are
installed the same way. Left
side is shown.
(23) Install two brackets (31) on cylinder heads 31

(32) with new lockwashers (33) and
screws (34).
(24) Install four new lockwashers (35), washers 41
(36), and screws (37) on two brackets (31). 40
Torque to 46 lb--ft (62 N.m). 19
39
(25) Install fuel pressure transducer (38) on
STE/ICE engine wire harness (39). 38
(26) Install two fuel hoses (40) on elbows (41) on

fuel block (19).
19--79
TM 9--2320--360--34--2

7
9
NOTE
Screws are numbered to show
tightening sequence. Tighten in
order shown.
(27) Tighten screws 1 thru 6 to 90--100 lb--ft

(122--136 N∙m). 5
8
(28) Tighten screws 7 thru 9 to 40--45 lb--ft
(54--61 N∙m). 3
1 2
4
CAUTION
When using crankshaft front
screw to bar over engine, al-
ways turn in clockwise direction.
Turning over in counterclock-
wise direction may loosen screw
and vibration damper. Serious
damage to engine may result. 42
(29) Turn crankshaft screw (42) clockwise, while

assistant tightens screws 10 thru 12 to
40--45 lb--ft (54--61 N∙m). 17
18
16
21 20 19 15
14
22
23 13
(30) Tighten screws 13 thru 27 to 25--30 lb--ft 24

(35--41 N∙m).
25 30
NOTE
26
Screws were installed from front 32
side of flywheel housing. 27
12
31
(31) Tighten screws 28 and 29 to 40--45 lb--ft 11
28
(54--61 N∙m). 29
10
(32) Tighten screw 30 to 30--35 lb--ft
(41--47 N∙m).
(33) Tighten screws 31 and 32 to 137--147 lb--ft
(186--200 N∙m).
19--80
TM 9--2320--360--34--2
(34) Coat new gasket (43) with grease.

(35) Install new gasket (43), access cover (44),
new copper washer (45), and screw (46)
on flywheel housing (2). Do not tighten.
(36) Install five screws (47) on access cover
(44). Do not tighten.
(37) Tighten six screws (46 and 47) to 25--30
lb--ft (35--41 N∙m).
(38) Tighten two screws (18) to 25--30 lb--ft
(35--41 N∙m).
(1) Install crankshaft rear oil seal (para 3--16).
(1.1) Install flexplate assembly (para 3--17).
19--81
TM 9--2320--360--34--2
19--10. PISTON, CONNECTING ROD, AND LINER REPAIR
This task covers:

INITIAL SETUP
Equipment Conditions Tools and Special Tools

Sending units and attachments removed Tool Kit, Genl Mech (Item 202, Appendix E)
Starter removed (TM 9--2320--360--20). Clamp Set, Cylinder Liner Holddown (3)
150 amp circuit breakers removed (Item 18, Appendix E)
(TM 9--2320--360--20). Compressor, Ring (Item 20, Appendix E)
24--volt (front) alternator/bracket removed Compressor Unit, Air (Item 24, Appendix E)
(TM 9--2320--360--20). Gage Set, Piston (Item 55, Appendix E)
Exhaust manifolds removed (para 3--23). Gage, Cylinder Liner Depth (Item 47, Appendix E)
Air box drains removed (para 3--9). Gage, Piston, Groove (Item 51, Appendix E)
Air box covers removed (para 3--8). Goggles, Industrial (Item 57, Appendix E)
Engine mounted on engine stand (para 19--3). Remover and Installer, Piston Ring (Item 135,
Fan removed (TM 9--2320--360--20). Appendix E)
Fan belts removed (TM 9--2320--360--20). Remover Assembly, Cylinder Liner (Item 130,
Electronic control module (ECM) remove Appendix E)
(TM 9--2320--360--20). Retainer Tool, Piston Pin (Item 144, Appendix E)
Thermostats removed (TM 9--2320--360--20). Scale, Spring, 0--50 Lb (Item 145, Appendix E)
Rocker covers removed (TM 9--2320--360--20). Tester, Vacuum Gage Leak Detector Set
Fuel injector wire harnesses removed (Item 191, Appendix E)
(para 4--3). Wrench, Torque, 0--175 Lb--Ft (Item 236,
Left thermostat housing removed (para 5--3). Appendix E)
Right thermostat housing removed (para 5--4).
Engine brake retarder wire harnesses Materials/Parts
removed (para 6--16). Compound, International, No. 2 (Item 21,
Engine brake retarders removed (para 3--26). Appendix B)
Rocker arms removed (para 3--18). Oil, Lubricating (Item 45, Appendix B)
Injectors removed (para 4--2). Rags (Item 51, Appendix B)
Cylinder heads removed (para 3--10). Cleaning Compound, Solvent (Item 54, Appendix B)
Oil pan removed (para 3--20). Tags, Identification (Item 56, Appendix B)
Bearing Shells (Item 2, Appendix F)
Cylinder Kit (Item 10, Appendix F)
Personnel Required
Two
19--82
TM 9--2320--360--34--2
a. Removal
CAUTION 3
Do not rotate crankshaft in 1
counterclockwise direction.
Serious damage to engine may
result.
NOTE
Repeat steps (1) thru (4) for
each cylinder liner.
(1) Move piston (1), by rotating camshaft screw

(2) clockwise, so top is just above air inlet
ports in cylinder liner (3). 2
(2) Place clean rag on top of piston to catch
carbon deposits as they are removed from
cylinder liner (3).
(3) Scrape carbon ridge from top of cylinder
liner (3).
4
8
(4) Remove rag and carbon residue from
cylinder liner (3). 5
7
CAUTION
Do not use scribe or punch to
mark piston, connecting rod, or 6
cylinder head mounting surface.
Leaks may result.
(5) Turn engine block (4) upside down.

Remove two nuts (5) from bearing cap
screws (6).
(6) Remove connecting rod bearing cap (7) with
bearing shell (8). Discard bearing shell.
1
CAUTION
Ensure shoulder of connecting
rod does not catch on lip of cyl- 9
inder liner when removing piston
with connecting rod.
NOTE
4
· It may be necessary to tap
piston out of liner.
· Cylinder liner may come out
with piston.
(7) Push piston (1) and connecting rod (9) out

through engine block (4) while assistant
removes piston from engine block (4).
19--83
TM 9--2320--360--34--2
19--10. PISTON, CONNECTING ROD, AND LINER REPAIR (CONT)

(8) Discard bearing shell (10). Place bearing
cap (7), and two nuts (5) back on two
1
bearing cap screws (6) to keep matched
parts together. 10 9
7
(9) Remove seven remaining pistons (1) and
connecting rods (9).
(10) Turn engine so cylinder head bank is facing 5
up.
NOTE
· If cylinder liners are being 6
re--used, matchmark cylin-
der liner and engine block
so the liner is installed in the 14
13
same position in the block
bore.
· Matchmark cylinder liner
and engine block on side 11
opposite camshaft.
12
· Crankshaft may have to be
turned to allow for clearance
of special tool.
(11) Remove cylinder liner with tool set as
follows:
(a) Ease lower shoe and bolt
assembly (11) down into liner
(12). Place shoe on bottom
edge of liner with flat on shoe
parallel with crankshaft bore.
(b) Hold lower shoe and bolt
assembly (11) in pulling 17
position. Place upper shoe (13)
with flat in same position as
lower shoe over threaded end of
bolt. Thread nut (14) down on 16
bolt assembly (11). Ensure 15
pilots on both shoes are seated
properly.
(c) Place bridge assembly (15)
(open end down) over upper
shoe and against block.
(d) With thrust bearing (16) on bolt
(17), install bolt through bridge
assembly (15) strap hole.
(e) Thread bolt (17) into female
threaded portion of bolt
assembly (11).
(f) Turn bolt (17) clockwise and
withdraw liner (12) from block.
Remove tool from liner.
19--84
TM 9--2320--360--34--2
18
NOTE 19
Tag liner insert noting cylinder
number.
(12) Remove cylinder liner insert (18).

(13) Remove two cylinder liner seal rings (19).
Discard seal rings.
b. Disassembly 5
(1) Place connecting rod (1) in soft--jawed vise.
(2) Remove three upper piston rings (2) using
6
piston ring remover and installer (3).
Remove four lower piston rings (4) by hand. 2
Discard all piston rings.
(3) Remove oil ring expander (5) from each 4
lower piston ring groove. Discard expander.
1
(4) Punch hole in two piston pin retainers (6). 8
Remove both retainers.
(5) Loosen two screws (7) on connecting
rod (1). 7
(6) Remove connecting rod (1) and piston (8)

from vise.
NOTE 1 8
Matchmark connecting rod and
piston before removing
connecting rod.
(7) Remove two screws (7) and spacers (9)

from connecting rod (1). 9
(8) Remove connecting rod (1) from piston (8).
7
19--85
TM 9--2320--360--34--2
NOTE
Matchmark piston pin, piston 10
crown, piston skirt, and piston 11
pin bearing before removal.
(9) Remove piston pin (10) from piston
skirt (11).
(10) Separate piston crown (12) from piston 13
skirt (11).
(11) Remove rubber seal ring (13) from piston 14
crown (12). Discard seal ring.
(12) Remove piston pin bearing (14) from piston
crown (12). Discard bearing.
12
c. Cleaning/Inspection
WARNING
goggles. Use in well-ventilated areas. Use respirator as needed. Accidental ingestion can cause irritation of digestive
tract and respiratory tract, may cause lung and central nervous system damage. Can be fatal if swallowed. Inhalation
of high/massive concentrations can cause coma or be fatal. First aid for ingestion: do not induce vomiting. Seek
immediate medical attention. First aid for skin contact: remove contaminated clothing. Wash skin thoroughly with
soap and water. If symptoms persist, seek medical attention. First aid for eye contact: flush with water for 15 minutes
or until irritation subsides. If symptoms persist, seek medical attention. First aid for inhalation: move to fresh air. If not
breathing, provide artificial respiration. If symptoms persist, seek medical attention. Keep away from open flames and
other sources of ignition. Failure to follow this warning may result in injury or death to personnel.
(1) Clean all metal parts with solvent

cleaning compound. 3
(2) Clean ring grooves and oil holes in pistons
with paint brush and solvent cleaning compound. 2
WARNING
effective chip guarding and 1
personal protective
gloves, etc.).
(3) Dry parts with compressed air.
(4) Inspect all parts for damage. Replace
damaged parts.
(5) Check fire ring groove (1) of piston crown (2)
with piston groove gage tool (3).
19--86
TM 9--2320--360--34--2
NOTE
Piston crown, bearing, and pin 3
must be replaced as an
assembly.
2
(6) Slide NO--GO wire of piston groove gage
tool (3) completely around groove (1). If
wire is below flush at any one area, replace
crown (2).
(7) Slide GO wire of groove gage tool (3) 1
completely around groove (1). Wire should
be flush with or slightly higher than top edge
of groove.
(8) Measure diameter of piston skirt (4) and 4

check for roundness using micrometer.
Diameter must be between 4.8304 and
4.8314 in. (122.69 and 122.72 mm).
NOTE 7
Piston skirt is installed upside
down in liner.
(9) With cylinder liner (5) installed on engine

block (6), install piston skirt (4) and feeler
gage in liner (5) at same time. Have 6 5 4
assistant attach piston gage set (7) and
check clearance in four places 90 degrees
apart.
NOTE
Feeler gage size is determined
by amount of wear in piston skirt
and liner.
(10) Select largest feeler gage thickness that will

require a pull of less than 6 lb (2.7 kg).
Clearance will be 0.001 in. (0.25 mm)
greater than feeler gage thickness when it is
withdrawn with a pull of 6 lb (2.7 kg).
Clearance must be between 0.007 and
0.011 in. (0.18 and 0.28 mm).
19--87
TM 9--2320--360--34--2
(11) Insert new piston rings (8), one at a time

inside cylinder liner (5) far enough to be in
area of ring travel 2--3 in. (25--75 mm) deep. 8
Use piston skirt to position ring parallel with
top of cylinder liner.
NOTE
End of rings must be filed if gap
is too small. File from outer sur- 5
face to inner surface. Ends of
rings must remain square.
9
(12) Measure ring gap (9) with feeler gage.
Three compression rings should have a gap
of 0.025--0.045 in. (0.63--1.1 mm). Two oil
rings (upper slotted) should have a gap of
0.007--0.017 in. (0.18--0.43 mm). Two oil
rings (lower) should have a gap of
0.010--0.025 in. (0.25--0.63 mm).
NOTE
11
· Top ring has two punch
marks on black side.
· Black side of ring faces top 10
of piston.
(13) Install new top compression ring (10) with

two punch marks (11) up on top groove of
piston crown (2).
2
(14) Measure clearance between compression
ring (10) and groove; clearance should be
0.001--0.005 in. (0.025--0.13 mm). Remove
top compression ring (10).
12
(15) Insert new middle compression ring (12) in
middle groove on piston crown (2);
clearance should be 0.004--0.007 in.
(0.10--0.18 mm).
2
19--88
TM 9--2320--360--34--2
(16) Insert new lower compression ring (13) in

lower groove on side of piston crown (2); 13
clearance should be 0.004--0.007 in.
(0.10--0.18 mm).
d. Assembly
(1) Place piston crown (1) top end down on
work bench. 5
(2) Install new piston pin bearing (2) in piston 4
crown (1).
(3) Coat new rubber seal ring (3) with
lubricating oil.
(4) Install rubber seal ring (3) on piston 3
crown (1).
(5) Push piston skirt (4) down into position on 2
piston crown (1).
(6) Coat piston pin (5) with lubricating oil.
(7) Align hole in piston skirt (4) with hole in
piston crown (1). 1
(8) Install piston pin (5) with threaded holes
toward bottom of piston skirt (4).
(9) Place piston crown (1) and skirt (4) in
soft--jawed vice.
NOTE
· Place domed end of retainer
tool against retainer.
4
· Strike tool just hard enough
8
to defect retainer and seat
evenly in piston.
(10) Install piston pin retainers (6) in piston skirt
(4) at each side of piston pin (5) using piston
pin retainer tool (7).
(11) Use leak detector (8) to apply 10 in. (254 7
mm) of vacuum to each piston pin retainer
(6). There should be no loss of pressure. 6
5
(12) If loss of pressure occurs, repeat steps (10)
and (11).
(13) Remove piston crown (1) and skirt (4) from
vise.
19--89
TM 9--2320--360--34--2
(14) Install two spacers (9) on two screws (10).
WARNING
International no. 2 compound
can burn easily, can give off
harmful vapors, and is harm-
ful to skin and clothing. To 11
avoid injury or death, keep 4
away from open fire and use
in well--ventilated area. If no.
2 compound gets on skin or
10
(15) Coat threads and head contact surface of
two screws (10) with international no. 2
compound.
(16) Insert connecting rod (11) in piston skirt (4). 1
(17) Install screws (10) finger tight.
(18) Place connecting rod (11) in soft--jawed vise. 14
(19) Tighten two screws (10) to 55--60 lb--ft (75--81 N.m).
NOTE
Replace piston rings in sets only.
13
(20) Coat ring grooves in piston crown (1) and
skirt (4) with lubricating oil. 12
NOTE
Position ring gaps 120 degrees
apart around piston crown.
(21) Install new lower piston ring (12) in bottom 4

groove of piston crown (1).
(22) Install new middle piston ring (13) in center
groove of piston crown (1).
NOTE
· Black side of top ring faces
top of piston.
· Top ring has two punch
marks on black side.
(23) Install new top piston ring (14) (ring with

beveled sides) in top groove of piston 15
crown (1).
(24) Install two new oil ring expanders (15) on
piston skirt (4) with ends pointing up.
(25) Remove piston from vise and place upside
down on hard work surface.
19--90
TM 9--2320--360--34--2
NOTE
· Install oil rings with beveled
edge facing piston crown.
· Top oil ring has chrome
beveled edge.
· Both lower oil rings have
notches.
(26) Install new chrome and orange oil ring (16)

with gap positioned 180 degrees from gap in
expander ring (15).
(27) Install new black and orange oil ring (17)
with gap positioned 90 degrees from gap in
oil ring (16).
(28) Install new oil ring (18) with notched side
toward connecting rod and gap positioned 16
180 degrees from gap positioned in
expander ring (15). 17
(29) Install new oil ring (19) with notched side
toward connecting rod and gap positioned 18 15
90 degrees from gap in oil ring (18).
19
e. Installation
(1) Wipe cylinder bore (1), counterbore (2), 5
seal rings grooves (3), and cylinder
liner (4) clean.
(2) Install two new cylinder liner seal 4
rings (5) in engine block (6).
(3) Coat inner surface of cylinder seal 7
rings (5) with lubricating oil.
5 6
(4) Install previously tagged liner
insert (7) in counterbore (2) of engine
block (6). 1
(a) Push cylinder liner (4) in
cylinder block until liner flange
rests on insert (7). Do not use
3
excessive force to install liner.
Liner should slide smoothly in
place. Gently seat with 2
soft--faced mallet.
19--91
TM 9--2320--360--34--2

(b) Clamp liner (4) in place with
hold down clamp (8) and two 4
screws (9). Torque to 50 lb--ft 7
(68 N.m).
(c) Measure distance from top of
liner (4) to top of block with
cylinder liner depth gage (10). 9
Liner flange must be 0.0418--
0.0482 in. (1.06--1.22 mm)
8
below surface of block. Even
though all liners are within these
specifications, there must not be
over 0.0015 in. (0.038 mm)
difference between two adjacent 4
liners when measured along
cylinder longitudinal centerline.
If above limits are not met,
install different thickness insert,
install liner in another cylinder
bore, and recheck or use new 10
cylinder liner.
(d) Remove screws (9), hold down
clamp (8), and cylinder liner (4).
Do not remove liner insert (7).
(5) Coat piston rings (11) with lubricating oil. 11

(6) Install piston (12) in ring compressor (13).
(7) Coat inside of cylinder liner (4) with
lubricating oil.
15
(8) Hold cylinder liner (4) flange end down on
wooden blocks. Place ring compressor (13)
with piston and connecting rod (14) on
cylinder liner (4). 14
NOTE
Matchmarks align cylinder liner 12
and engine block.
13
(9) Align numbers on connecting rod (14) and
rod bearing cap (15) with matchmark on
4
cylinder liner (4).
(10) Push piston into cylinder liner (4) until
compression rings pass cylinder liner 16
ports (16).
(11) Remove ring compressor (13) from cylinder
liner (4).
19--92
TM 9--2320--360--34--2
(12) Remove two nuts (17), bearing cap (18),

and bearing shell (19). 4
(13) Coat new connecting rod bearing shell (19) 6 20

with lubricating oil.
(14) Position crankshaft connecting rod journal
(20) of cylinder being worked on to bottom of
its travel.
(15) Coat journal (20) with lubricating oil.
(16) Align matchmark on cylinder liner (4) and
engine block (6).
19
18
17
CAUTION
Distance from center of con-
necting rod bolts to edges of
connecting rods are not equal.
Narrow sides (A) of two con-
necting rods, on crankshaft
A
journal, must face each other.
Failure to comply will damage
connecting rod. A
NOTE 20 12
Pistons should be installed so
that each crankshaft connecting 4
rod journal has two pistons
attached before moving to next
crankshaft connecting rod 11
journal.
11
(17) Slide cylinder liner (4) with piston (12) and
connecting rod assembly (11) into engine 6
block (6) while assistant guides connecting
rod assembly over crankshaft journal (20).
(18) Seat connecting rod (11) firmly on
crankshaft journal (20).
19--93
TM 9--2320--360--34--2
19 17
18
(19) Install cap (18) and new bearing shell (19)
over two studs (21).
(20) Install two nuts (17) on two studs (21).
Torque to 60--70 lb--ft (81--95 N.m).
21
12 4 8
NOTE
Hold down clamps are installed 9
over each piston and liner.
(21) Install hold down clamp (8) over cylinder

liner (4) with two screws (9).
(22) Repeat steps (5) thru (21) for remaining
pistons (12) and liners (4).
(23) After all liners and pistons have been
installed, remove screws (9) and hold down
clamps (8).
22
(24) Check that clearance between each

connecting rod attached to same crankshaft
journal is 0.008--0.016 in. (0.2--0.4 mm)
using feeler gage (22).
19--94
TM 9--2320--360--34--2
(9) Adjust valve clearance, engine brake retarder, and fuel injector timing
(para 3--27).
(15) Install fan (TM 9--2320--360--20).
19--95
TM 9--2320--360--34--2
19--11. CAM FOLLOWER AND PUSH ROD REPAIR
This task covers

INITIAL SETUP

Cylinder head on clean work surface. Oil, Lubricating (Item 45, Appendix B)
Cleaning Compound, Solvent (Item 54, Appendix B)
Tools and Special Tools Tags, Identification (Item 56, Appendix B)
Tool Kit, Genl Mech (Item 202, Appendix E) Lockwashers (2) (Item 118, Appendix F)
Blocks, Wooden (Figure C--3, Appendix C)
Caps, Vise Jaw (Item 17, Appendix E)
Dial Indicator, Magnetic (Item 32, Appendix E)
Gage, Feeler (Item 50, Appendix E)
Vise, Machinist’s (Item 207, Appendix E)
Wrench, Torque, 0--300 Lb--In. (Item 235,
Appendix E)
a. Removal
2
(1) Remove exhaust valve bridges (1) from
bridge guides (2).
NOTE
Tag cam follower and asso-
ciated parts so they may be
installed in original location.
2
Cam followers are replaced
the same way. Only one is
shown. 3
(2) Set cylinder head (3) on side on 1 in. (25

mm) wooden blocks.
(3) Remove two screws (4) and lockwashers (5)
from cam follower guide (6). Discard
lockwashers. 7 8
(4) Remove cam follower guide (6) from
cylinder head (3).
(5) Remove cam follower (7) and push rod
assembly (8) from cylinder head (3) as one
unit.
(6) Remove cam follower (7) from push rod
assembly (8). 4 5 6
19--96
TM 9--2320--360--34--2
(7) Remove locknut (9), spring (10), and lower

spring seat (11) from push rod (12). 11 10 9
12
NOTE
Spring retainer must point in
proper direction when installed.
Mark direction of spring retainer
before removal.
(8) Remove spring retainer (13) from top side of

cylinder head (3).
(9) Remove upper spring seat (14) from cylinder
head (3).
13
WARNING 14
persist, seek medical attention. First aid for eye contact: flush with water for 15 minutes or until irritation subsides. If symptoms
persist, seek medical attention. First aid for inhalation: move to fresh air. If not breathing, provide artificial respiration. If
symptoms persist, seek medical attention. Keep away from open flames and other sources of ignition. Failure to follow this
warning may result in injury or death to personnel.
•Fire extinguishers should be placed nearby when using solvent cleaning compound. Failure to follow this warning may result
in injury or death.
(1) Clean cam follower (1) with solvent cleaning compound. 3

(2) Inspect cam follower (1) for damage.
CAUTION
If clearance in step (3) is more 2
than 0.023 in. (0.58 mm) or the
clearance in step (4) is more 1
than 0.010 in. (0.25 mm), go to
disassembly. Damage to equip-
ment may result.
(3) Check side clearance between cam follower
(1) and roller (2) to ensure it is not more
than 0.023 in. (0.58 mm). If clearance is
more than 0.023 in. (0.58 mm), go to disassembl y.
(4) Place cam follower (1) in soft--jawed vise on
roller end of tube. Check for more than 0.010 in.
(0.25 mm) pin--to--bushing clearance using
dial indicator (3). If clearance is more than
0.010 in.(0.25 mm), replace cam follower.
19--97
TM 9--2320--360--34--2
19--11. CAM FOLLOWER AND PUSH ROD REPAIR (CONT)
c. Installation
(1) Install spring retainer (1) in top of cam
follower bore (2) in cylinder head (3).
1 2 3
(2) Install lower spring seat (4), spring (5),

upper spring seat (6), and nut (7) on push
rod (8).
(3) Install push rod (8) in bottom of cylinder
head (3). 7
6
5
8
4 3
(4) Position cam follower (9) so oil hole (10)

points away from exhaust valves (11).
(5) Install cam follower (9) over push rod (8) 11
and in cylinder head (3). 9
(6) Install other push rods and cam followers in 8

same manner.
10 12
19--98
TM 9--2320--360--34--2
(7) Install cam follower guide (12) on cylinder

head (3) with two new lockwashers (13) and
screws (14).
(8) Tighten screws (14) to 180 lb--in. (20.3 N.m). 12
13 3
14
NOTE
There must be a minimum of
0.005 in. (0.13 mm) clearance
between cam follower guide and 12
cam follower.
(9) Insert 0.005 in. (0.13 mm) feeler gage (15)

between cam follower guide (12) and legs of
cam followers (9).
(10) If there is not enough clearance, loosen
screws (14), move guide (12), and repeat
step (9).
15 9 14
16
17
(11) Install exhaust valve bridges (16) on bridge

guides (17).
17
19--99
TM 9--2320--360--34--2
19--12. CAMSHAFT AND END BEARING REPAIR
This task covers:

INITIAL SETUP

Starter removed (TM 9--2320--360--20). Compressor Unit, Air (Item 24, Appendix E)
150 amp circuit breakers removed Dial Indicator, Magnetic (Item 32, Appendix E)
(TM 9--2320--360--20). Drill Set, Twist (Item 33, Appendix E)
24--volt (front) alternator/bracket removed Drill, Electric, Portable (Item 34, Appendix E)
(TM 9--2320--360--20). Gage Set, Telescoping (Item 56, Appendix E)
Exhaust manifolds removed (para 3--23). Gage, Feeler (Item 50, Appendix E)
Air box drains removed (para 3--9). Goggles, Industrial (Item 57, Appendix E)
Air box covers removed (para 3--8). Press, Hydraulic, 60--Ton (Item 116, Appendix E )
Engine mounted on engine stand (para 19--3). Puller, Camshaft Gear (Item 123, Appendix E)
Fan removed (TM 9--2320--360--20). Puller Kit, Mechanical, Slide Hammer (Item 125,
Fan belts removed (TM 9--2320--360--20). Appendix E)
Fan clutch removed (TM 9--2320--360--20). Pulley Remover, Camshaft Gear and
Electronic control module (ECM) removed Water Pump (Item 136, Appendix E)
(TM 9--2320--360--20). Socket, Sockethead Screw, 1/4 In. (Item 171,
Thermostats removed (TM 9--2320--360--20). Appendix E)
DDEC oil pressure sensor removed V--blocks (Item 206, Appendix E)
(TM 9--2320--360--20). Wrench Set, Socket, 3/4 In. Drive (Item 231,
Rocker covers removed (TM 9--2320--360--20). Appendix E)
Fuel injector wire harnesses removed Wrench Set, Socket, 3/8 In. Drive (Item 232,
12--volt (rear) alternator/bracket removed Wrench, Torque, 0--600 Lb--Ft (Item 233,
(TM 9--2320--360--20). Appendix E)
Left thermostat housing removed (para 5--3). Wrench, Torque, 0--300 Lb--In. (Item 235,
Right thermostat housing removed (para 5--4). Appendix E)
Secondary fuel filter housing removed Wrench, Torque, 0--175 Lb--Ft (Item 236,
Vibration damper and front cover removed Materials/Parts
(para 3--15). Adhesive--Sealant (Item 3, Appendix B)
Water pump drive gear removed (para 3--24). Grease, Automotive and Artillery (Item 32,
Blower accessory drive hub removed Appendix B)
(para 4--9). Oil, Lubricating (Item 45, Appendix B)
Engine brake retarder wire harnesses removed Rags (Item 51, Appendix B)
(para 6--16). Cleaning Compound, Solvent (Item 54, Appendix B)
Engine brake retarders removed (para 3--26). Tags, Identification (Item 56, Appendix B)
Rocker arms removed (para 3--18). Gasket (Item 33, Appendix F)
Injectors removed (para 4--2). Lockwashers (6) (Item 140, Appendix F)
Cylinder heads removed (para 3--10). Lockwasher (Item 141, Appendix F)
Oil pan removed (para 3--20). Seal, Oil (Item 312, Appendix F)
Flexplate assembly removed (para 3--17).
Flywheel housing removed (para 19--9).
19--100
TM 9--2320--360--34--2
a. Removal
(1) Remove four screws (1), adapter (2), and 1 2 3 4

retainer (3) from left camshaft gear (4).
(2) Remove four screws (5) and adapter (6)

from right camshaft gear (7).
NOTE
Shop cloth is used between
camshaft gears to prevent
turning. 5
7
(3) Place a clean shop cloth between 6
gears (4 and 7).
10
13
12
(4) Remove nut (8), lockwasher (9),
and balance pulley (10) from 9
front of camshaft (11). Discard
lockwasher. 11
(5) Remove woodruff key (12) and

spacer (13) from end of left
camshaft (11).
17
19
18
(6) Remove six lock screws (14) from 15

two end bearings (15 and 16) and
(7) Remove end bearing (15) and

gasket (18) from right camshaft (19).
11
(8) Remove end bearing (16) from 14 20
camshaft (11).
16
(9) Remove oil seal (20) from end
bearing (16). Discard seal.
19--101
TM 9--2320--360--34--2
19--12. CAMSHAFT AND END BEARING REPAIR (CONT)
17
(10) Remove six intermediate bearing lockscrews

(21) from engine block (17). 29
11
(11) Remove nut (22) from rear end of left 25 28
camshaft (11).
(12) Remove screw (23) and washer (24) from
rear end of right camshaft (19).
(13) Remove cloth from between gears. 22
23
CAUTION 21
When using front crankshaft
capscrew to bar over engine, al- 4
ways turn in a clockwise direc-
24
tion. Turning over in a counter-
clockwise direction may loosen 19
7
the capscrew and vibration
damper. Serious damage to en-
gine may result.
(14) Turn gears (4 and 7) to reach rear end

camshaft bearing screws (25) using screw
(26) on front end of crankshaft (27).
(15) Remove three camshaft rear end bearing
screws (25) and lockwashers (28) from each
rear camshaft bearing (29). Discard
lockwashers. 26
27
CAUTION
Use care when removing cam-
shafts. Camshafts may be
damaged by scraping or hitting
engine block or hard surface. 17
NOTE 19
Tag and mark all parts to aid in
assembly.
(16) Remove two camshaft assemblies (11 and

19) from rear of engine block (17).
11
19--102
TM 9--2320--360--34--2
b. Disassembly
(1) Remove gear (1) and thrust washer (2) from
end of camshaft (3) using camshaft gear
puller and remover (4).
(2) Remove woodruff key (5) from end of
camshaft (3).
(3) Remove end bearing (6) and thrust washer
(7) from end of camshaft (3).
1
4
5 6
7 2
3
NOTE 9
Tag and mark three camshaft
bearings to aid in installation.
3
(4) Remove six lock rings (8) and three
camshaft intermediate bearings (9) from
camshaft (3).
9
(5) Repeat steps (1) thru (4) for other camshaft.
19--103
TM 9--2320--360--34--2
NOTE 3
There are two plugs in end of
camshafts. All plugs are
removed the same way.
(6) Position camshaft (3) in soft--jawed vise. 10
(7) Drill 31/64 in. (8.3 mm) hole in center of
plug (10).
(8) Enlarge hole in plug (10) from 31/64 to 1/4
in. (8.3 to 6.4 mm).
(9) Enlarge hole in plug (10) from 1/4 to 5/16 in.
(6.4 to 7.9 mm).
(10) Remove plug (10) from camshaft (3) using
slide hammer.
WARNING
Cloths or rags saturated with solvent cleaning compound must be disposed of IAW authorized facilities' procedures.
" Eye shields must be worn when cleaning with a wire brush. Flying rust and metal particles may cause injury.
(1) Clean all camshaft parts with solvent

cleaning compound.
WARNING
Compressed air for cleaning 1
etc.).
(3) Inspect camshaft (1) for scratches or
damage.
(4) Damaged keyways may be filed smooth.
(5) Threaded holes may be retapped.
19--104
TM 9--2320--360--34--2
1
NOTE
Flat measurement must not
exceed 0.003 in. (0.076 mm).
(6) Measure flat spots (2) on 12 cam lobes

using a straightedge (3) and 0.003 in. (0.076
mm) feeler gage (4). Replace camshaft if
measurement exceeds 0.003 in. 4
(0.076 mm).
2
3
(7) Measure and record diameters of three

bearing journals (5). Replace camshaft (1) if 6
any diameter is less than 1.4980 in. 1
(38.049 mm).
5
(8) Measure and record diameters of two end
bearing journals (6). Replace camshaft (1) if
6
any diameter is less than 1.4980 in.
(38.049 mm).
7
(9) Measure and record inside diameter of four 8
end bearing bushings (7 and 8).
(10) Take measurement recorded in step (8) and
subtract it from measurement recorded in
step (9). Total difference may not exceed
0.006 in. (0.15 mm).
19--105
TM 9--2320--360--34--2
(11) Place lower half (9) of three intermediate

11
bearings (10) together with top half (11).
(12) Install six lock rings (12) over three
intermediate bearings (10). 9
(13) Measure and record inside diameter of three 10
intermediate bearings (10).
(14) Take measurement recorded in step (7) and 12
subtract from measurement recorded in
step (13).
(15) Replace three intermediate bearings (10) if
clearance exceeds 0.009 in. (0.23 mm).
15
13 14
(16) Inspect spacers (13) and oil seal (14).
Replace if damaged.
(17) Inspect two camshaft gears (15) for worn or
damaged teeth. Replace if damaged.
16
(18) Place camshaft end bearing journals (6) in V
blocks and use magnetic dial indicator (16)
to check center bearing surface for runout. 6
Runout should not exceed 0.002 in.
(0.05 mm).
(19) If runout exceeds 0.002 in. (0.05 mm),
replace camshaft.
(20) Repeat steps (1) thru (19) for other
camshaft.
19--106
TM 9--2320--360--34--2
d. Assembly
WARNING
soap and water.
(1) Coat sides of two camshaft plugs (1) with

adhesive--sealant. 2
NOTE
Camshaft plugs should be
installed to a depth of 1.940--
1
2.060 in. (49.28--52.32 mm).
(2) Install two plugs (1) in end of camshafts (2).
NOTE
Steel faces of thrust washers 3
4
3
are next to bearing. 2
(3) Coat steel faces of two thrust washers (3)

with grease.
(4) Position thrust washer (3) against each end
of camshaft rear end bearing (4).
(5) Coat camshaft rear bearing journal (5) with 5
lubricating oil.
(6) Install two thrust washers (3) and camshaft
rear end bearing (4) on camshaft (2).
7
6
2 8
(7) Install woodruff key (6) in keyway at rear of

camshaft (2).
(8) Align camshaft gear (7) with key (6).
(9) Press gear (7) onto shoulder of
camshaft (2).
(10) Repeat steps (3) thru (9) for other camshaft.
(11) Install nut (8) on left camshaft (2). Tighten
finger tight.
19--107
TM 9--2320--360--34--2
(12) Install capscrew (9) and spacer (10) on right 2

camshaft (2). Tighten finger tight. 10
9
(13) Coat camshaft intermediate bearing journals 12

(11) with lubricating oil.
11
(14) Position 12 halves of intermediate bearing
(12) on camshaft journals (11).
NOTE
Bottom half of intermediate
bearings do not have holes. 12
(15) Install six lock rings (13) over bottom half of 2

three intermediate bearings (12).
(16) Repeat steps (13) thru (15) for other
camshaft. 13
e. Installation
(1) Install left camshaft (1) in engine block (2). 3
1
(2) Install right camshaft (3) in engine block (2).
19--108
TM 9--2320--360--34--2
(3) Align left camshaft gear (4), right camshaft
A
gear (5), idler gear (6), and crankshaft timing
A
gear (7) so timing marks on gears line up as 5
shown. 4
(4) Slide camshaft gears (4 and 5) in place until
VR R
camshaft gears and idler gear (6) are fully R
meshed.
(5) Check timing marks again to ensure gears
(4, 5, 6, and 7) are aligned as shown. 6
R
A
R
(6) Turn gear (5) to reach all rear end bearing
screw holes.
7
(7) Install three new lockwashers (8) and
screws (9) on each camshaft rear end
bearing (10 and 11) and engine block (2).
Torque to 40 lb--ft (54 N.m).
10
9 8
2
11
9 8
(8) Align holes in three intermediate bearings 5
(12) on right and left camshafts (1 and 3)
with tapped holes in engine block (2).
(9) Install six lock screws (13). Torque to
240 lb--in. (27.1 N.m). 13
12 12
1 3
19--109
TM 9--2320--360--34--2
(10) Coat camshaft front end bearing

14
journal (14) with clean engine oil.
15
NOTE
Gasket is on left side bearing
only. 16
(11) Install new gasket (15) and end 17

bearing (16) on journal (14) with
three screws (17). Torque to 40 lb--ft
(54 N.m). 20
(12) Coat camshaft front end bearing
journal (18) with clean engine oil. 22 18
21 19
(13) Install end bearing (19) on journal (18)
with three screws (20). Torque to
40 lb--ft (54 N.m).
NOTE
Spacers have polished outside
diameters.
(14) Install new oil seal (21) and spacer

(22) on end bearing (19).
23
(15) Install woodruff key (23) in

camshaft (1).
(16) Install pulley (24) on camshaft (1) 24
with new lockwasher (25) and
nut (26). Tighten finger tight.
25
26
19--110
TM 9--2320--360--34--2
4
NOTE
Shop cloth is used between 27
camshaft gears to prevent
turning. 1
(17) Place clean shop cloth between teeth of

camshaft gears (4 and 5).
(18) Tighten nut (27) on rear end of camshaft (1) 5

to 300 lb--ft (407 N.m).
28
3
(19) Tighten screw (28) on rear end of camshaft
(3) to 180--190 lb--ft (244--258 N.m).
26
(20) Tighten nut (26) on front end of

camshaft (1) to 300 lb--ft (407 N.m).
31 30 29 4
(21) Install retainer (29) in mounting position

on left camshaft gear (4).
(22) Install adapter (30) in mounting position

with four screws (31). Torque to 40 lb--ft 33
(54 N.m).
5
32
(23) Install adapter (32) on right camshaft
gear (5) with four screws (33). Torque to
40 lb--ft (54 N.m).
19--111
TM 9--2320--360--34--2
34 35
1
NOTE
Camshaft may have to be gently
pulled toward front of engine to
check clearance.
(24) Check clearance between thrust washer

(34) and shoulder (35) of camshaft (1). If
clearance is less than 0.003 in. (0.076 mm)
or greater than 0.018 in. (0.46 mm), replace
camshaft.
(25) Check backlash between gears (4 and 5) 36

using dial indicator (36). Minimum backlash
is 0.002 in. (0.05 mm). Maximum backlash
is 0.010 in. (0.0254 mm).
4 5
19--112
TM 9--2320--360--34--2
f. Follow--On Maintenance (Cont)

(13) Install secondary fuel filter housing (para 4--13).
(16) Adjust valve clearance, engine brake retarder, and fuel injector
timing (para 3--27).
(25) Install fan (TM 9--2320--360--20).
19--113
TM 9--2320--360--34--2
19--13. IDLER GEAR REPAIR
This task covers:

INITIAL SETUP

(TM 9--2320--360--20). Caps, Vise Jaw (Item 17, Appendix E)
Starter removed (TM 9--2320--360--20). Dial Indicator, Magnetic (Item 32, Appendix E)
150 amp circuit breakers removed Holding Fixture, Idler Gear (Item 41,
(TM 9--2320--360--20). Appendix E)
24--volt (front) alternator/bracket removed Scale, Spring (Item 145, Appendix E)
(TM 9--2320--360--20). Vise, Machinist’s (Item 207, Appendix E)
Exhaust manifolds removed (para 3--23). Wrench, Torque, 0--175 Lb--Ft (Item 236,
Air box drains removed (para 3--9). Appendix E)
Air box covers removed (para 3--8).
Engine mounted on engine stand (para 19--3). Materials/Parts
DDEC oil pressure sensor removed Oil, Lubricating (Item 45, Appendix B)
(TM 9--2320--360--20). Cleaning Compound, Solvent (Item 54, Appendix B)
12--volt (rear) alternator/bracket removed Ties, Cable, Plastic (Item 60, Appendix B)
(TM 9--2320--360--20). Screws, Nylon Patch (6) (Item 282, Appendix F)
Blower accessory drive hub removed
(para 4--9).
Oil pan removed (para 3--20).
Flexplate assembly removed (para 3--17).
Flywheel housing removed (para 19--9).
a. Removal
(1) Remove screw (1) and special washer (2)
from idler gear (3).
(2) Remove idler gear assembly (3) from engine 4
block (4).
19--114
TM 9--2320--360--34--2
2
b. Disassembly 3
(1) Remove six screws (1) from idler gear

assembly (2). Discard screws.
(2) Remove retainer (3) from idler gear
assembly (2).
NOTE 6
· Mark parts of idler gear
bearings if they will be used
again. Do not scratch or
damage bearings. 2
· Support idler gear by

bearing cone while in press.
(3) Place idler gear assembly (2) in press with

hollow pin (4) facing down.
CAUTION 8
Idler gear assembly must be
rotated during removal to 4
prevent damage to bearing
cones. 5
(4) Rotate idler gear assembly (2) while

pressing idler gear hub (5) out of bearing 6 7
cones (6 and 7).
(5) Remove idler gear assembly (2) as one unit
from the press.
(6) Remove outer bearing cone (7), inner
spacer ring (8), and inner bearing cone (6)
from idler gear assembly (2). 2
9 10 11
(7) Remove outer bearing cup (9), outer spacer

ring (10), and inner bearing cup (11) from
idler gear assembly (2).
19--115
TM 9--2320--360--34--2
19--13. IDLER GEAR REPAIR (CONT)

5
(8) Remove hollow pin (4) from idler gear 4
hub (5).
WARNING
Solvent cleaning compound MIL-PRF-680 Type II and III may be irritating to the eyes and skin. Use protective gloves
and goggles. Use in well-ventilated areas. Use respirator as needed. Accidental ingestion can cause irritation of
digestive tract and respiratory tract, may cause lung and central nervous system damage. Can be fatal if swallowed.
Inhalation of high/massive concentrations can cause coma or be fatal. First aid for ingestion: do not induce vomiting.
Seek immediate medical attention. First aid for skin contact: remove contaminated clothing. Wash skin thoroughly
with soap and water. If symptoms persist, seek medical attention. First aid for eye contact: flush with water for 15
minutes or until irritation subsides. If symptoms persist, seek medical attention. First aid for inhalation: move to fresh
air. If not breathing, provide artificial respiration. If symptoms persist, seek medical attention. Keep away from open
flames and other sources of ignition. Failure to follow this warning may result in injury or death to personnel.
(1) Clean idler gear and bearing parts with solvent cleaning compound.
(2) Inspect bearing for scoring, pitting, or flat spots on rollers or cones.
(3) Inspect bearing cups for scoring, pitting, and dents in bearing surface.
(4) Examine gear teeth for scoring, pitting, and chips.
(5) Replace all damaged parts. 2
(6) Coat all parts with lubricating oil.
1
d. Assembly
(1) Install hollow pin (1) on idler gear hub (2).
NOTE 6
Bearing cones and cups are
matched sets. If any part is
unusable, all parts must be 5
replaced.
(2) Support idler gear (3), shoulder down, on
bed of press. 4
(3) Coat inner bearing cup (4) with lubricating
oil. Insert inner bearing cup (4), numbered
side up, in bore of gear (3).
3
(4) Press inner bearing cup (4) to seat against
shoulder of gear (3).
(5) Install outer spacer ring (5) on inner bearing
cup (4).
(6) Coat bearing cup (6) with lubricating oil.
Insert outer bearing cup (6), numbered side
down, in bore of gear (3).
(7) Press outer bearing cup (6) to seat against
shoulder of gear (3).
19--116
TM 9--2320--360--34--2

(9) Position outer bearing cone (7), numbered 9
side down, on bed of press.
(10) Press idler gear hub (2) in outer bearing
cone (7) until bottom of hub (2) is flush with
bottom of cone (7). 3
(11) Install inner spacer ring (8) on idler gear
hub (2).
(12) Position gap in spacer ring (8) on side
opposite of oil hole in idler gear hub (2).
(13) Support outer bearing cone (7) and idler
gear hub (2). 8
(14) Position idler gear assembly (3) on idler
gear hub (2).
(15) Position inner bearing cone (9) on idler gear 2
assembly (3).
CAUTION 7
Turn gear while installing bear-
ing cone on idler gear hub to
prevent damage to bearing
cups.
(16) Turn idler gear assembly (3) while pressing

inner bearing cone (9), numbered side up,
over hub (2). 13
(17) Hold hub (2) and turn gear assembly (3) to 11

see if binding occurs.
10
NOTE
To check idler gear preload, do 3
(18) Mount idler gear (3) in soft--jawed vise.
CAUTION
Hollow pin on idler gear hub
must be aligned with hole in test
fixture plate. Failure to comply
may press pin into idler gear 12
hub.
14
(19) Mount two test fixture plates (10 and 11) on
idler gear (3) with screw (12) and nut (13).
(20) Mount test fixture plate (14) on idler gear (3) 16
with three washers (15), lockwashers (16),
and screws (17). Torque to 40 lb--ft 17
(54 N.m).
19--117
TM 9--2320--360--34--2
19--13. IDLER GEAR REPAIR (CONT) 3

19
18
(21) Place plate (11) in jaws of vise.
(22) Install two plastic ties (18) around outside
edge of idler gear (3) and tighten.
(23) Position spring gage (19) hook between tie
strap and idler gear (3).
11
NOTE
· Pull to start gear moving
must not be less than 0.5 lb
(0.23 kg) or more than 4.0
lb (1.8 kg).
· If scale reading is more than
specified maximum, rollers 13
are binding or improperly
installed. 11
· If scale reading is less than
specified minimum, 10
bearings are worn.
(24) Pull spring gage (19) several times and

record pull required to start gear (3) moving. 3
Maximum difference between pulls is 2 lb,
11 oz (1.22 kg).
(25) Remove spring gage (19) and plastic ties
(18) from idler gear (3).
(26) Remove three screws (17), lockwashers

(16), washers (15), and test fixture 12
plate (14).
14
(27) Place idler gear assembly (3) in soft--jawed
vise.
15
(28) Remove nut (13), screw (12), and two test
fixture plates (10 and 11). 16
(29) Remove idler gear assembly (3) from vise.
17
3 20
(30) Install retainer (20) on idler gear assembly

(3) with six new nylon patch screws (21).
21
19--118
TM 9--2320--360--34--2
e. Installation
(1) Align timing marks on camshaft gear (1) and
crankshaft gear (2) with timing marks on
idler gear (3).
A
(2) Slide idler gear (3) in place until crankshaft
A
gear (2) and camshaft gear (1) are fully
meshed.
(3) Rotate gear hub (4) so dowel in hub aligns
5
with hole in end plate (5).
(4) Tap hub (4) until it seats against end
plate (5).
1
(5) Check timing marks again to ensure gears
(1, 2, and 3) are aligned as shown. 3
R
4
VR
R
(6) Install special washer (6) and screw (7) in A
idler gear (3). Torque to 90 lb--ft (122 N.m).
R
2
R
(7) Mount dial indicator (8) on end plate (5) and
check backlash between gears (1, 2, and 3).
Minimum backlash is 0.002 in. (0.05 mm).
Maximum backlash is 0.010 in. (0.25 mm).
(8) Coat bearing (9) and idler gear (3) with 8
1
lubricating oil. 6
7
(4) Install blower accessory drive hub
(para 4--9).
(5) Install 12--volt (rear) alternator/bracket 4 3
(TM 9--2320--360--20).
(6) Install DDEC oil pressure sensor 9
(TM 9--2320--360--20). 2
(7) Remove engine from engine stand
(para 19--3).
19--119
TM 9--2320--360--34--2
19--14. CRANKSHAFT COVER, FRONT OIL SEAL, AND OIL PUMP REPAIR
This task covers:

INITIAL SETUP

Sending units and attachments removed Press, Hydraulic (Item 116, Appendix E)
(TM 9--2320--360--20). Seal Installer, Front Crankshaft (Item 156,
Starter removed (TM 9--2320--360--20). Appendix E)
150 amp circuit breakers removed Wrench Set, Socket, 3/8 In. Drive (Item 232,
(TM 9--2320--360--20). Appendix E)
24--volt (front) alternator/bracket removed Wrench, Torque, 0--300 Lb--In. (Item 235,
(TM 9--2320--360--20). Appendix E)
Exhaust manifolds removed (para 3--23). Wrench, Torque, 0--175 Lb--Ft (Item 236,
Air box drains removed (para 3--9). Appendix E)
Air box covers removed (para 3--8).
Engine mounted on engine stand (para 19--3). Materials/Parts
Fan removed (TM 9--2320--360--20). Grease, Automotive and Artillery (Item 32,
Fan belts removed (TM 9--2320--360--20). Appendix B)
Fan clutch removed (TM 9--2320--360--20). Oil, Lubricating (Item 45, Appendix B)
24--volt (front) alternator adjusting strap Gasket (Item 41, Appendix F)
removed (TM 9--2320--360--20). Gasket (Item 56, Appendix F)
Crankshaft pulley removed (para 3--12). Gasket (Item 32, Appendix F)
Crankshaft vibration damper removed Key (Item 72, Appendix F)
(para 3--14). Locknuts (2) (Item 97, Appendix F)
Oil pan removed (para 3--20). Lockwashers (6) (Item 122, Appendix F)
Lockwashers (4) (Item 127, Appendix F)
Tools and Special Tools Lockwashers (2) (Item 121, Appendix F)
Tool Kit, Genl Mech (Item 202, Appendix E) Screws, Self--Locking (8) (Item 280, Appendix F)
Caliper Set, Micrometer, 0--6 In. (Item 15, Seal (Item 292, Appendix F)
Appendix E)
Caliper, Vernier, 0--6 In. (Item 16, Appendix E)
a. Removal
WARNING
Hold support when removing
screws to prevent it from
dropping. Failure to comply
may result in injury to
personnel.

from support (3). Discard lockwashers.
19--120
TM 9--2320--360--34--2
(2) Remove support (3) and ring (4) from

trunnion (5).

(7) from trunnion (5). Discard lockwashers.
from trunnion (5). Discard lockwashers.
(5) Remove two screws (10) and lockwashers
(11) from trunnion (5). Discard lockwashers.
(6) Remove trunnion (5) from crankshaft
cover (12).
(7) Remove two screws (13), washers (14), and

gasket (15) from oil inlet pipe (16) on bottom
of crankshaft cover (12). Discard gasket.
(18) from inside crankshaft cover (12).
(9) Remove crankshaft cover (12) and gasket
(19) from engine block (20) and set on flat
work surface with flat side facing up.
Discard gasket.
(10) Remove oil pump drive hub (21) and key
(22) from crankshaft (23). Discard key.
19--121
TM 9--2320--360--34--2
19--14. CRANKSHAFT COVER, FRONT OIL SEAL, AND OIL PUMP REPAIR (CONT)
25
26
(11) Remove two nuts (24), screws (25), four
27
washers (26), strainer (27), cover (28), and
gasket (29) from oil inlet pipe assembly (30).
Discard gasket.
28
(12) Remove two spacers (31) from screen (27).
31 29
26
24
27
30
(13) Remove two locknuts (32), screws (33), six

35
washers (34), and two brackets (35) from 37
bracket (36). Discard locknuts.
38
washers (39), and bracket (36) from cylinder 39
block (40). Discard lockwashers. 33
34
36
b. Disassembly
NOTE 34
Oil pump is inside crankshaft 32
cover. 40
(1) Remove eight screws (1) and gear retaining 7

plate (2) from rear of crankshaft cover (3).
Discard screws. 3
NOTE 4
Shaft is removed only if it fails 2
inspection.
(2) Remove drive gear (4) and driven gear (5)

from rear of crankshaft cover (3).
(3) Remove shaft (6) from crankshaft cover (3).
6
(4) Support outer face of crankshaft cover (3)
on two wooden blocks. 5
1
(5) Remove front seal (7) from front side of
crankshaft cover (3). Discard seal.
19--122
TM 9--2320--360--34--2
1
(1) Remove old sealant from crankshaft cover
(1) and engine block (2).
(2) Clean gasket material from mounting

surface of oil inlet pipe assembly (3).
(3) Clean drive and driven gears (4 and 5),

screen (6), and cover (7) with diesel fuel.
3
WARNING
purposes will not exceed 30 4
personal protective equip- 5
etc.).

8
(5) Inspect bushing (8) of driven gear (5) for 6 7
wear. Replace bushing if clearance
between bushing and shaft is more
than 0.0035 in. (0.089 mm). If bushing
is replaced, new clearance should be
0.001--0.0025 in. (0.25--0.064 mm).
CAUTION
Failure to replace excessively 1
worn gears will result in low oil
pressure which may cause
serious damage to engine.
NOTE
The drive and driven gear
should be replaced as a set.
(6) Inspect shaft (9), drive gear (4), driven gear 9

(5), oil inlet pipe (3), cover (7), screen (6)
and crankshaft cover (1) for damage or
wear. Replace damaged parts.
19--123
TM 9--2320--360--34--2
d. Assembly 8
(1) Lubricate shaft (1) and drive and driven
gears (2 and 3) with oil. 7
4
NOTE
· If installing new shaft, do
step (2). 2
5
· Shaft must be flush to 0.020
in. (0.51 mm) below finished
face of crankshaft cover.
(2) Press shaft (1) in crankshaft cover (4).

(3) Install drive and driven gears (2 and 3) in rear 1
side of crankshaft cover (4).
3
NOTE 6
Self--locking screws must be
used due to closeness of
crankshaft.
(4) Install gear retaining plate (5) on rear of

crankshaft cover (4) with eight new screws
(6). Torque to 156--204 lb--in. (18--23 N.m).
(5) Coat sealing lip of new front seal (7) with oil.
NOTE
Sealing lips must face outside of
front cover.
(6) Install front seal (7) in front side of

crankshaft cover (4) using seal installer (8).
5
e. Installation 4
3
NOTE 2
Bevel edge of oil pump drive
hub faces rear of crankshaft.
1
(1) Install new key (1) and oil pump drive hub
(2) on crankshaft (3).
(2) Coat new gasket (4) with grease and install
on engine block (5).
19--124
TM 9--2320--360--34--2
(3) Install crankshaft cover (6) on engine

block (5) and dowels (7). 5
(4) Install two new lockwashers (8) and 6
screws (9) in crankshaft cover (6).
Torque to 80--90 lb--ft (108--122 N.m).
(5) Install new gasket (10), two washers
(11), and screws (12) to oil inlet pipe
assembly (13) on bottom of crankshaft 7
cover (6). Torque to 180--240 lb--in. 13
(20.3--27.1 N.m). 8
9
11 12
10
18
17
(6) Install bracket (14) on engine block (5) 16

with two washers (15), new lockwashers
(16), and screws (17). Torque to 35 lb--ft 15
(47 N.m). 20
19
(7) Install two brackets (18) on bracket (14) 14
with six washers (19), two screws (20),
and new locknuts (21). Do not tighten.
19
(8) Install two spacers (22) in strainer (23). 21
5
22 26
27
23
23
25
(9) Install gasket (24), cover (25), and
strainer (23) on oil inlet pipe assembly 24
(13) and two brackets (18) with two 27 18
screws (26), four washers (27), and nuts
28
(28). Torque to 35 lb--ft (47 N.m). 21
(10) Tighten two locknuts (21) to 35 lb--ft 13
(47 N.m).
19--125
TM 9--2320--360--34--2
(11) Install trunnion (29) on crankshaft cover (6)

with four new lockwashers (30), screws (31), 6 29
two new lockwashers (32), screws (33), two
new lockwashers (34) and screws (35). 34
35
(12) Tighten screws (33 and 35) to 30--35 lb--ft
(41--47 N.m).
(13) Tighten screws (31) to 70--75 lb--ft
(94--102 N.m).
30
31
32
(14) Coat ring (36) with light coat of grease. 30
33
Slide over trunnion (29). 31
(15) Install top half of support (37) on support 40
(38) with two new lockwashers (39) and 29
screws (40). Torque to 45--50 lb--ft 39
(61--67 N.m).
37
(1.1) Install crankshaft vibration damper
(para 3--14). 36
(3) Install 24--volt (front) alternator adjusting
strap (TM 9--2320--360--20).
38
(6) Install fan (TM 9--2320--360--20).
19--126
TM 9--2320--360--34--2
19--15. ENGINE BRAKE RETARDER REPAIR
This task covers

a. Disassembly c. Assembly
INITIAL SETUP

Engine brake retarder on clean work surface. Compound, Sealing and Lubricating (Item 27,
Appendix B)
Tools and Special Tools Connector, Electrical, Butt (Item 29, Appendix B)
Tool Kit, Genl Mech (Item 202, Appendix E) Oil, Lubricating (Item 45, Appendix B)
Compressor Unit, Air (Item 24, Appendix E) Tags, Identification (Item 56, Appendix B)
Appendix E)
NOTE
Supply housing and drone housing are repaired in a similar manner. Solenoid is
installed on supply housing and not on drone housing. Supply housing is shown.
a. Disassembly
(1) Remove screw (1) and cover (2) from
housing (3).
(2) Remove two springs (4 and 5) and spool (6)
from housing (3).
NOTE
Do steps (3) thru (5) for supply
housing only.
(3) Remove solenoid valve (7) from housing (3).

(4) Remove two seals (8 and 9) from solenoid
valve (7).
(5) Remove seal (10) from housing (3).
19--127
TM 9--2320--360--34--2
19--15. ENGINE BRAKE RETARDER REPAIR (CONT)
13
WARNING
Slave piston is retained by
12
spring under compression.
Spring may be discharged
and cause personal injury. 11
(6) Turn housing (3) over. Use press to hold
slave piston spring (11) and spring retainer
(12) in place. 14
WARNING
Wear eye protection and use
care when removing retaining
rings. Retaining rings are
under spring tension and can 3
act as projectiles when
released causing severe eye
injury.
(7) Remove retaining ring (13). 15

(8) Slowly release force from spring retainer 16
(12) and release slave piston spring (11).
(9) Remove spring retainer (12), spring (11), 17
and slave piston (14) from housing (3). 18
19
(10) Remove screw (15), spring retainer (16),
piston spring (17), and fork assembly (18)
from housing (3). 3
(11) Remove master piston (19).
20
NOTE
Mark location of pipe plugs
before removal.
(12) Remove two pipe plugs (20). 21

22 20
(13) Turn housing over. Remove nut (21) and

setscrew (22) from housing (3).
19--128
TM 9--2320--360--34--2
WARNING
Fuel is very flammable and can explode easily. To avoid serious injury or
death, keep flame away from fuel and keep fire extinguisher within easy
reach when working with fuel. Do not work on fuel system when engine is
hot. Fuel can be ignited by hot engine. When working with fuel, post signs
that read NO SMOKING WITHIN 50 FEET of vehicle.
(1) Clean housings and parts with diesel fuel.
WARNING

(3) Inspect all parts for damage. Replace damaged parts.
c. Assembly
(1) Install two pipe plugs (1) in housing (2) in locations marked during removal.
(2) Coat master piston (3) with lubricating oil.
(3) Install master piston (3) and fork assembly (4) in bottom of housing (2).
WARNING
Sealing compound can burn easily, can give off harmful vapors, and is
harmful to skin and clothing. To avoid injury or death, keep away from
open fire and use in well--ventilated area. If sealing compound gets on skin
or clothing, wash immediately with soap and water.
5
(4) Coat screw (5) with sealing and lubricating
compound. Install piston spring (6) with 7
spring retainer (7) and screw (5).
(5) Coat slave piston (8) and slave piston spring 6
(9) with lubricating oil. 12
(6) Install slave piston (8) and slave piston 10

spring (9) in housing (2). 4
(7) Align tab on spring retainer (10) with slot in 9
housing (2).
WARNING 3
Wear eye protection and use 8
care when installing retaining
11
under spring tension and can
act as projectiles when 1 2
injury.
(8) Press spring (9) and spring retainer (10) into

housing (2), to just below retaining ring
groove (11), and install retaining ring (12). 1
19--129
TM 9--2320--360--34--2
19--15. ENGINE BRAKE RETARDER REPAIR (CONT)
18
NOTE
Do steps (9) thru (11) for supply 17
housing only.
(9) Coat seal (13) with oil and install in 2

housing (2). 14
15
(10) Coat two seals (14 and 15) with lubricating
oil and install on solenoid valve (16). 16
(11) Install solenoid valve (16) in supply housing
(2). Torque to 50 lb--in. (5.5 N.m).
13
(12) Install setscrew (17) in housing (2) with
nut (18).
22
23
20
(13) Coat spool (19) with lubricating oil. Install
spool (19) and two springs (20 and 21) in
housing (2). 21
WARNING
Sealing and lubricating com- 19
pound can burn easily, can give
off harmful vapors, and is
harmful to skin and clothing.
To avoid injury or death, keep
away from open fire and use in
well--ventilated area. If sealing
2
clothing, wash immediately
(14) Coat screw (22) with sealing and lubricating 16

compound. Install cover (23) on housing (2)
with screw (22).
18
17
19--130
TM 9--2320--360--34--2
CHAPTER 20
FUEL SYSTEM MAINTENANCE
Contents Para Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20--1 20--1
Blower Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20--2 20--2
Turbocharger Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20--3 20--17
20--1. INTRODUCTION
This chapter contains instructions for repair of fuel system components at the General Support maintenance level.
These components must be removed from the HET Tractor before they can be repaired. The removal procedures
are referenced to chapter 4.
Section II. MAINTENANCE PROCEDURES
20--1
TM 9--2320--360--34--2
20--2. BLOWER REPAIR
This task covers:

INITIAL SETUP

Blower on clean work surface. Cloth, Crocus (Item 16, Appendix B)
Compound, Gasket Forming (Item 19,
Tools and Special Tools Appendix B)
Tool Kit, Genl Mech (Item 202, Appendix E) Grease, Automotive and Artillery (Item 32,
Tool Set, Blower Service (Item 204, Appendix E) Appendix B)
Blocks, Wooden (Figure C--3, Appendix C) Oil, Lubricating (Item 47, Appendix B)
Compressor Unit, Air (Item 24, Appendix E) Rags (Item 51, Appendix B)
Gage, Feeler (Item 50, Appendix E) Cleaning Compound, Solvent (Item 54, Appendix B)
Goggles, Industrial (Item 57, Appendix E) Tags, Identification (Item 56, Appendix B)
Press, Hydraulic (Item 116, Appendix E) Gasket (Item 46, Appendix F)
Screws, Cap, Hex, 5/16--18 x 2 In. (4) Gasket (Item 66, Appendix F)
(Item 147, Appendix E) Lockwashers (19) (Item 119, Appendix F)
Screws, Cap, Hex, 1/4--20 x 1--1/4 In. (5) Overhaul Kit, Blower (Item 153, Appendix F)
(Item 151, Appendix E) Packing, Preformed (Item 195, Appendix F)
Screws, 5/16--18 x 2--1/4 In. (4) (Item 148, Washer, Key (Item 335, Appendix F)
Appendix E)
Washers, Flat, 5/16 In. (8) (Item 210,
Appendix E)
Wrench Set, Impact (Item 228, Appendix E)
Appendix E)
Appendix E)
9 6 1
2
7
a. Disassembly 1
3
(1) Remove two clamps (1) and hose (2) from
8
blower bypass valve (3) and elbow (4). 4
(2) Remove elbow (4) from rear end plate (5).
(3) Remove two screws (6), clamp (7), blower 5
bypass valve (3), and preformed packing (8)
from blower (9). Discard preformed packing.
(4) Remove nine screws (10), lockwashers (11),
rear end plate cover (12), and gasket (13)
from rear end plate (5). Discard
lockwashers and gasket.
13 12
11 10
20--2
TM 9--2320--360--34--2
NOTE
Clean shop towel should be
placed between blower rotors to
keep gears from turning.
17
(5) Remove three screws (14), coupling
assembly (15), and three spacers (16) from 16 15
timing gear (17).
14
20
19
(6) Place coupling assembly (15) in soft--jawed

vise.
(7) Remove three screws (18) and two spring
plates (19) from coupling (20).
(8) Remove coupling (20) from vise.
18
(9) Remove screw (21) and spacer (22) from 17

left timing gear (23).
(10) Remove screw (24) and spacer (25) from
right timing gear (17). 25
24
23
22
21
20--3
TM 9--2320--360--34--2
20--2. BLOWER REPAIR (CONT)
NOTE
· Five 5/16 in.--24 x 1--1/2 in. (38
30
mm) screws can be used to
align tapped holes in gears on 17
rear end plate.
26
· Matchmarks on rotor and timing 27
gear must be aligned for proper
operation.
(11) Install puller tool (26) on left timing gear (23)

with two screws (27).
29
(12) Install puller tool (26) on right timing gear 23
(17) with three screws (27). 26 28
CAUTION 27
Puller screws must be tightened
evenly during removal of timing
gears. Failure to comply may
result in damage to gears.
30
(13) Tighten two screws (28) evenly and remove
gears (17 and 23) from rotors (29 and 30).
31
(14) Remove screws (27) and puller tools (26)
from gears (17 and 23).
NOTE
Spacers should be tagged and 29
marked before removal.
31
(15) Remove two spacers (31) from two
rotors (29 and 30).
34
33
32
(16) Remove six screws (32) and two flat bearing
retainers (33) from rear end plate (5).
32
(17) Remove two screws (34) from rear end
plate (5).
5 34
33
20--4
TM 9--2320--360--34--2
CAUTION
Screws should be threaded all
the way into tapped holes of end 8
plate. Failure to comply may 5
result in damage to end plate.
NOTE
Six puller screws must be 1/4 26
in.--20 x 1--1/4 in. (32 mm) or
35
longer.
(18) Install six screws (35) and align two puller

tools (26) on rear end plate (5).
(19) Turn both puller tools (26) evenly and
remove rear end plate (5) from blower (8). 26
(20) Remove puller tools from rear end 35
plate (5).
41
40
39
(21) Remove 10 screws (36), lockwashers (37), 38

and washers (38) from front end cover (39).
(22) Remove front end cover (39) and gasket
(40) from front end plate (41). Discard
gasket. 37
36
45
44
(23) Bend tangs of key washer (42) flat. 42
(24) Remove screw (43), key washer (42), fuel 43
pump disk (44), and coupling spacer (45) 30
from rotor (30). Discard lockwasher.
20--5
TM 9--2320--360--34--2
48
NOTE
Front and rear end plates
should be matchmarked with 41
blower housing before removal.
47
(25) Remove six screws (46) and two deflectors
(47) from front end plate (41).
(26) Remove two screws (48) from front end
plate (41).
(27) Repeat steps (17) thru (19) to remove front
46
end plate (41).
48 47
CAUTION 46
Rotors should be handled with
care to avoid scratching
surfaces. Failure to comply may 8
result in damage to rotors.
NOTE
· Shop towel must be removed
before removing rotors from 30
blower.
· Tag and mark left and right
rotors before removal.
(28) Matchmark rotors (29 and 30) before

removing.
(29) Remove rotors (29 and 30) from blower (8).
29
53
29
(30) Clamp lobe of left rotor (29) in soft--jawed

vise. 54
(31) Install adapter (49) on left rotor (29).
(32) Install puller tool (50) on adapter (49) with
two screws (51). 51 50
(33) Turn puller screw (52) and remove bearing
collar (53) from left rotor (29).
(34) Remove and discard oil seal (54) from left
rotor (29).
49
52
20--6
TM 9--2320--360--34--2
(35) Place front end plate (41) on wooden blocks

with seal (55) up.
56
(36) Place long end of remover and installer tool
41
(56) in right bore (57), through seal (55), and 59
into roller bearing (58).
(37) Remove roller bearing (58), collar (59), and 61
57
seal (55) from right bore (57). Discard seal.
(38) Install collar (59) in left roller bearing (60) for
support.
(39) Install long end of remover and installer tool
(56) in left bore (61) of front end plate (41) 62
through roller bearing (60).
(40) Remove roller bearing (60) from left 55 60
bore (61).
59
(41) Remove two plugs (62) from front end
plate (41).
58 56
(42) Place rear end plate (5) on wooden blocks
with seal (63) up.
(43) Install long end of remover and installer tool
(56) in bore (64), through seal (63), and into
ball bearing (65).
(44) Remove ball bearing (65) and seal (63) from 66
64
bore (64).
bore (66).
b. Cleaning/Inspection 5
(1) Inspect dowel pins (1) for breakage or
damage. Replace if broken or damaged. 63
WARNING 65
Solvent cleaning compound MIL-PRF-680 Type II and III may be
irritating to the eyes and skin. Use protective gloves and goggles.
Use in well-ventilated areas. Use respirator as needed. Accidental 1
ingestion can cause irritation of digestive tract and respiratory tract,
may cause lung and central nervous system damage. Can be fatal if
swallowed. Inhalation of high/massive concentrations can cause
coma or be fatal. First aid for ingestion: do not induce vomiting.
Seek immediate medical attention. First aid for skin contact: remove
contaminated clothing. Wash skin thoroughly with soap and water.
If symptoms persist, seek medical attention. First aid for eye contact:
flush with water for 15 minutes or until irritation subsides. If symptoms
persist, seek medical attention. First aid for inhalation: move to fresh air.
If not breathing, provide artificial respiration. If symptoms persist, seek
medical attention. Keep away from open flames and other sources of ignition.
•Improper cleaning methods and use of unauthorized cleaning solvents may injure personnel and
damage equipment.
•Fire extinguishers should be placed nearby when using solvent cleaning compound. Failure to follow this
warning may result in injury or death.
•Cloths or rags saturated with solvent cleaning compound must be disposed of IAW authorized facilities'
procedures. Failure to follow this warning may result in injury.
(2) Clean metal parts in solvent cleaning compound.
20--7
TM 9--2320--360--34--2
WARNING
(3) Dry all metal parts, except bearings, with

compressed air. Allow bearings to air dry.
(4) Inspect roller and ball bearings for corrosion,
scoring, pitting, or other damage.
(5) Inspect both timing gears at teeth and bore
splines for chips or nicks.
(6) Inspect oil holes. If clogged, clean with
(7) Inspect all finished surfaces for burrs and
scoring. Clean with crocus cloth.
3
c. Assembly
(1) Place rear end plate (1) on wooden blocks 2
with inner surface up.
(2) Install seal protector (2) on remover and
installer tool (3). 1 4
CAUTION
Double--lipped oil seal must be
installed dry. Do not apply oil to
seal when installing. Oil will
damage protective coating of
seal.
(3) Install new double--lipped oil seal (4), num- 5

ber side up, on tool. Press new oil seal (4)
in bore (5) until tool contacts rear end
plate (1).
(4) Repeat steps (1) thru (3) to install remaining

seal in rear end plate (1) and two seals (4)
in front end plate (6).
(5) Install two pipe plugs (7) on front end
plate (6). 7
20--8
TM 9--2320--360--34--2
(6) Place front end plate (6) on wooden blocks

with inner surface up.
(7) Install seal protectors (2), tapered edge
down, on rotors (8 and 9).
NOTE
· Seal protectors will drive out
plastic sleeve in seal. Discard
sleeve. 10
· When properly installed,
externally splined ends of rotors
will be up, and rotor end with
internal spline will be in right
side of front end plate.
(8) Align matchmarks made during removal and

install rotors (8 and 9) in bores (5). Work
rotors (8 and 9) until they contact front end
plate (6).
CAUTION
Do not let gasket forming com-
pound protrude into blower
housing. Failure to comply may 9 8
result in engine damage.
(9) Lightly coat mating surfaces of blower (10)

and front end plate (6) with gasket forming 11
compound. 2
6
NOTE 5
Matchmarks made during 11
removal should be aligned.
(10) Install blower (10) over rotors (8 and 9) until

it contacts dowel pins (11) in front end
plate (6).
(11) Align dowel pins (11) with holes in blower
(10) and push blower tight against front end 10
plate (6). Tap blower (10) with soft--faced 6
hammer if necessary.
(12) Move blower (10) to work surface while

firmly holding front end plate (6) against
blower (10). Position bottom down.
(13) Install two screws (12) through front end
plate (6) and blower (10).
12
20--9
TM 9--2320--360--34--2
13
(14) Stand blower (10) up on wooden blocks.
CAUTION
Do not apply oil to seals or rotor 9 8
shafts. Damage to seals will
result.
NOTE
Seal protectors will drive out
plastic sleeve in seal. Discard
sleeve.
10
(15) Align matchmarks and install rear end plate
(1) on blower (10).
(16) Install two screws (13) through rear end
plate (1) and blower (10).
16
16
15
(17) Coat two ball bearings (14) with lubricating 15
oil.
CAUTION 14 14
Bearings must rest flat on
rotors. Failure to comply may
result in damage to splines.
9 8
(18) Install ball bearings (14), numbered end up, 1
on rotors (8 and 9) and in rear plate (1).
NOTE
· Bearing retainers should be in-
stalled with chamfered side of
holes up.
· Rear bearing retainers are flat.
(19) Install two bearing retainers (15) on rear end

plate (1) with six screws (16). Torque to
84--108 lb--in. (9.5--12.2 N.m).
20--10
TM 9--2320--360--34--2
(20) Turn blower (10) over on wooden blocks so

front end plate (6) faces up.
20 19
(21) Install two bearing collars (17) on 20
rotors (8 and 9).
18
(22) Coat two roller bearings (18) with lubricating oil. 19
(23) Install roller bearings (18) over rotors (8 and 18 17

9) and in front end plate (6).
NOTE
17
Flanges on reflectors face front
end plate. 8 9
(24) Install two reflectors (19) on front end plate
(6) with six screws (20). Torque to 84--108 6
lb--in. (9.5--12.2 N.m).
WARNING
Do not place fingers between
rotors. Turning rotors may
cause serious injury.
10
(25) Position blower (10) bottom down with rear
end plate (1) facing you.
NOTE
Timing mark (located at flat spot)
in end of each rotor shaft will aid
in aligning rotors and gears.
(26) Set rotors (8 and 9) so that flat spots on

splines are in line with each other and facing
left.
NOTE
Folded shop towel should be
placed between rotor lobes to
keep rotors from turning.
1
(27) Install two spacers (21) on two rotors (8 and 9).
(28) Coat splines of rotors (8 and 9) with 9
lubricating oil. 21
(29) Install both timing gears (22 and 23) on 23

rotors (8 and 9) at the same time so that flat
spots in gear splines align with flat spots in 26
rotor splines.
24
(30) Coat screws (24 and 25) with lubricating oil.
(31) Install two spacers (26) and screws (24 and
25) in timing gears (22 and 23). 8
21
NOTE 22
26
Screws must be tightened 25
evenly to draw both timing gears
tight.
(32) Tighten screws (24 and 25) to 110 lb--ft (149 N.m).
20--11
TM 9--2320--360--34--2

(33) Install four washers (27) and four 5/16 x 2 in. 6
screws (28) in front end plate (6). Torque to
180 lb--in. (20.3 N.m). 27
(34) Install four washers (29) and four 5/16 x
2--1/4 in. screws (30) in rear end plate (1).
Torque to 180 lb--in. (20.3 N.m).
(35) Position blower (10) on side.
NOTE 28
· Shop cloth must be removed
before timing rotors and setting
clearances.
· Clearance between rotor lobes
should be 0.013 in. (3.3 mm).
Clearance is adjusted by install-
ing shims between gears and
bearings to move timing gears
in or out.
1
· Minimum clearances are listed
for feeler gage measurements.
29
· Six checks must be made on
both air inlet and air outlet sides
to determine clearance between
rotors.
· Checks are made 1 in. (25.4
mm) from end of blower. Both
ends must be checked. 30
(36) Place 0.013 in. (3.3 mm) feeler gage

between rotor lobes (31 and 32).
CAUTION
Do not force feeler gage
between rotors. Failure to
comply may result in damage to 10
equipment.
NOTE
If feeler gage cannot be inserted
between rotors, go to step (40).
(37) Rotate rotors (8 and 9) to position feeler

gage between rotor lobes (31 and 32).
8 9
(38) Remove feeler gage from between rotor
lobes (31 and 32).
32
(39) Repeat steps (36) thru (38) until checks 31
have been made on each lobe of rotors (8
and 9) from both inlet and outlet sides of
blower (10).
20--12
TM 9--2320--360--34--2
NOTE
· If clearance is correct, go to
step (45).
· To change gap between rotor
lobes by 0.001 in. (0.025 mm),
add or remove 0.003 in. (0.076 9
mm) shim. 21
· Placing shims behind right--side 33
gear on gear end will turn right-- 23
hand rotor counterclockwise.
· Placing shims behind left--side
8
gear on gear end will turn
left--hand rotor clockwise. 21
(40) If clearance is not correct, determine amount

of movement required to obtain correct 33
clearance.
22
(41) Remove gears (para 20--2a, steps
(9) thru (14)).
(42) Add shims (33) between gears (22 or 23)
and spacers (21) to obtain correct
clearance.
(43) Repeat steps (29) thru (32) and
9 1
(36) thru (40).
(44) If correct clearance cannot be obtained
using shims, replace rotor (8 or 9). 8
NOTE
There are 12 measurements for
checking clearance between ro-
tor lobes and end plates, 6 for
front end plate and 6 for rear
end plate.

between one lobe of rotor (9) and rear end
plate (1).
(46) Repeat step (45) for other two lobes of rotor
(9) and three lobes of rotor (8).
8 6
(47) If clearance is not correct, replace rear end
plate (1).
(48) Place 0.019 in. (0.48 mm) feeler gage 9
between one lobe of rotor (8) and front end
plate (6).
(49) Repeat step (48) for other two lobes of rotor
(8) and three lobes of rotor (9).
(50) If clearance is not correct, replace front end
plate (6).
20--13
TM 9--2320--360--34--2
NOTE
There are 12 measurements for
checking clearance between ro-
tor lobes and housing, 6 from air
inlet side and 6 from air outlet 10
side.

31
between one lobe of rotor (8) and housing of
blower (10).
(52) Rotate rotors and position gage between
one rotor lobe (31) and housing of
blower (10).
9 8
(53) Remove feeler gage from between rotor (8)
and housing of blower (10).
(54) Repeat steps (51) thru (53) for other two
lobes of rotor (8) and three lobes of rotor (9).
(55) If clearance is not correct, replace housing
of blower (10).
10
(56) Position blower (10) so air outlet side is 31

facing up.
(57) Place 0.005 in. (0.13 mm) feeler gage 8
between one lobe of rotor (8) and housing of
blower (10).
(58) Rotate rotors to position feeler gage
between one rotor lobe (31) and housing of 9
blower (10).
(59) Remove feeler gage from between rotor (8)
and housing of blower (10).
(60) Repeat steps (56) thru (59) for other two
lobes of rotor (8) and three lobes of rotor (9). 10
(61) If clearance is not correct, replace basic

blower (10). 29
30
(62) Position blower (10) with air inlet side up.

(63) Remove four screws (30) and washers (29)
from rear end plate (1).
1
20--14
TM 9--2320--360--34--2

from front end plate (6). 6
(65) Install coupling spacer (34) on rotor (9) at 27
front end plate (6). 28
(66) Position fuel pump disk (35), new keywasher
(36), and screw (37) on rotor (9).
(67) Bend one tang of keywasher (36) into slot 34
on fuel pump disk (35). 35
(68) Tighten screw (37) on rotor (9) to 65 lb--ft 36
(88 N.m). 37
9
(69) Bend two tangs of keywasher (36) around
head of screw (37).
6
NOTE 38
Front cover screws are shorter 39
than rear cover screws.
40
(70) Install new gasket (38) and front cover (39)
on front end plate (6) with 10 washers (40),
new lockwashers (41), and screws (42).
Torque to 156--204 lb--in. (17.6--23.0 N.m).
41
42
44
43
NOTE
When properly positioned,
spring plates will mount on
machined side of coupling.
(71) Position two spring plates (43) on coupling

(44) with three screws (45). Do not tighten.
45
(72) Place coupling (44) in soft--jawed vise.
Tighten screws (45) to 30 lb--ft (41 N.m).
20--15
TM 9--2320--360--34--2
(73) Install three spacers (46) and coupling (44)

on timing gear (23) with three screws (47).
23
46 44
47
NOTE
Shop cloth must be removed 55 58
before installing rear cover.
57
1 52
(74) Install new gasket (48) and rear cover (49)
on rear end plate (1) with nine new 54 58
lockwashers (50) and screws (51). Torque
to 180 lb--in. (20.3 N.m). 53 56
(75) Install bracket (52), preformed packing (53),
and blower bypass valve (54) on rear end
plate (1) with two screws (55).
(76) Install elbow (56) on rear end plate (1).
(77) Install hose (57) on blower bypass valve
(54) and elbow (56) with two clamps (58).
48
49
50
51
20--16
TM 9--2320--360--34--2
20--3. TURBOCHARGER REPAIR
This task covers:

INITIAL SETUP

Turbocharger on clean work surface. Compound, Antiseize (Item 18, Appendix B)
Grease, Automotive and Artillery (Item 32,
Caliper Set, Micrometer (Item 15, Appendix E) Cleaning Compound, Solvent (Item 54, Appendix B)
Compressor Unit, Air (Item 24, Appendix E) Locknut (Item 99, Appendix F)
Dial Indicator, Magnetic (Item 32, Appendix E) Rings, Retaining (3) (Item 242, Appendix F)
Gage Set, Telescoping (Item 56, Appendix E) Ring, Retaining (Item 241, Appendix F)
Goggles, Industrial (Item 57, Appendix E) Rings, Seal, Metal (2) (Item 259, Appendix F)
Hammer, Soft--Faced (Item 63, Appendix E) Ring, Seal (Item 260, Appendix F)
Holding Fixture, Turbocharger (Item 71,
Appendix E) Personnel Required
Pliers, Retaining Ring (Item 105, Appendix E) Two
Pliers, Retaining Ring (Item 108, Appendix E)
Appendix E)
Appendix E)
a. Disassembly
4
CAUTION
Do not attempt to remove guard
assembly from compressor 3
housing. Damage to guard or 6
housing will result. 1
(1) Mark compressor housing (1), coupling (2),
and compressor backplate (3) before
removing.
(2) Mark turbine housing (4), coupling (5), and 5
center housing (6) before removing.
WARNING
Fins on impeller and shaft are
very sharp. Use care when
removing. Failure to comply
may result in injury to 2
personnel.
(3) Loosen coupling (2) and remove
compressor housing (1) and coupling (2)
from center housing (6).
(4) Loosen coupling (5) and remove center
housing (6) and coupling (5) from turbine
housing (4).
20--17
TM 9--2320--360--34--2
20--3. TURBOCHARGER REPAIR (CONT)

9
(5) Install turbine wheel (7) in holding fixture (8).

11
(6) Remove locknut (9) from shaft (10) with aid
of assistant. Discard locknut. 10
(7) Tap shaft (10) with soft--faced hammer while
assistant holds center housing (6) up
6
approximately 1 in. (25.4 mm) above holding
fixture (8) to loosen impeller (11).
CAUTION
Do not pry off impeller. Damage 7
to impeller may result.
(8) Remove impeller (11) from shaft (10).

(9) Remove center housing (6) from shaft (10).
8
WARNING
act as projectiles when 13
injury.
10
(10) Remove retaining ring (12) from shaft (10).
Discard retaining ring. 17
(11) Remove turbine wheel shroud (13) from
turbo wheel shaft (10). 14
16
(12) Remove four screws (14) and backplate (3)

from center housing (6).
(13) Remove seal ring (15) from center housing
(6). Discard seal ring.
(14) Remove thrust spacer (16) from 3
backplate (3).
(15) Remove two metal seal rings (17) from 15 6
thrust spacer (16). Discard seal rings.
20--18
TM 9--2320--360--34--2
18 19
(16) Remove three screws (18) from center 20

housing (6).
(17) Remove thrust collar (19) and thrust collar
retainer (20) from center housing (6). 6
(18) Remove bearing (21) and washer (22) from

center housing (6). 21 24
WARNING 22
care when removing retaining 23
injury.
(19) Remove retaining ring (23) from center

housing (6) using retaining ring pliers (Item
105, Appendix E) (24). Discard retaining 6
ring.
24
(20) Remove retaining ring (25) and bearing (26)

from center housing (6) using retaining ring
pliers (24). Discard retaining ring. 28
(21) Remove thrust washer (27) from center
housing (6).
(22) Remove retaining ring (28) from center
housing (6) using retaining ring pliers (24). 27
Discard retaining ring. 26
25
20--19
TM 9--2320--360--34--2

WARNING
minutes or until irritation subsides. If symptoms persist, seek medical attention. First aid for inhalation: move to
fresh air. If not breathing, provide artificial respiration. If symptoms persist, seek medical attention. Keep away from
open flames and other sources of ignition. Failure to follow this warning may result in injury or death to personnel.
3
(1) Soak metal parts in solvent cleaning compound
for 25 minutes. 2
CAUTION
Do not clean turbocharger parts
with steel bristle brush.
Damage to equipment may
result.
4
(2) Clean parts with stiff bristle brush. 1
(3) Clean oil passages (1, 2, and 3) in center
housing (4) and oil passages (5 and 6) in
backplate (7).
WARNING
psi (207 kPa). Use only with 6
ment (goggles/shield, gloves, 5
etc.).
CAUTION
Do not use compressed air on
bearings. Allow bearings to air 7
dry. Compressed air may cause
damage to bearings.
(4) Dry metal parts, except bearings, with
compressed air. Allow bearings to dry.
(5) Inspect turbocharger for nicks, cuts,
scratches, scoring, or other damage.
(6) Inspect screw threads for stripping or
crossthreading.
20--20
TM 9--2320--360--34--2
(7) Measure diameters of turbo wheel shaft

journals (8 and 9) on shaft (10). Journal
diameters must be 0.6250--0.6254 in. 10
(15.875--15.885 mm).
(8) Measure inside diameter of bore (11). 8
Inside diameter of bore (11) must not be
greater than 0.3749 in. (9.522 mm). 9
11
(9) Measure inside diameter of center housing

(12). Inside diameter of center housing (12)
must not be greater than 0.9842 in.
(24.999 mm).
(10) Measure seal bore (13). Seal bore (13)
must not be greater than 0.6895 in.
(17.513 mm). 12
13
14
(11) Measure inside diameter of bearing (14).

Bearing (14) inside diameter must not be
greater than 0.9842 in. (24.999 mm).
15
(12) Measure thrust collar thickness (15). Thrust

collar (15) thickness must not be less than
0.2970 in. (7.543 mm). Thrust collar bore
inside diameter must not be greater than
0.3778 in. (9.596 mm).
16
(13) Measure ring groove width. Ring groove
width will not be greater than 0.0715 in.
(1.816 mm). Thrust spacer (16) outside
diameter must not be less than 0.6705 in.
(17.030 mm).
(14) Replace damaged parts or parts that do not

meet specifications.
20--21
TM 9--2320--360--34--2
3
c. Assembly
WARNING
Wear protective goggles and
use care when installing
retaining rings. Retaining
rings are under spring
tension and can act as
4
projectiles when released
causing severe eye injury. 6
(1) Install retaining ring (1) in center housing (2)

using retaining ring pliers (Item 105, 1
Appendix E) (3).
5 2
(2) Install thrust washer (4), bearing (5), and
retaining ring (6) in turbine side of center
housing (2) using retaining ring pliers (3).
(3) Install retaining ring (7), thrust washer (8), 12 11
and bearing (9) in center housing (2) using
retaining ring pliers (3).
3 9
10 13
8
(4) Install thrust collar retainer (10) on thrust

14
collar (11) with oil groove facing housing (2).
(5) Install thrust collar retainer (10) and thrust
collar (11) in center housing (2) with three 15
screws (12). Torque to 80--100 lb--in.
(9.0--11.3 N.m). 16
(6) Install new seal ring (13) in center
housing (2).
(7) Install two new metal seal rings (14) on
thrust spacer (15).
(8) Install thrust spacer (15) in backplate (16).
20--22
TM 9--2320--360--34--2
17
(9) Install backplate (16) on center housing (2),

aligning marks made during disassembly.
(10) Install four screws (17) in backplate (16).
16
Torque to 80--100 lb--in. (9.0--11.3 N.m).
(11) Position turbo wheel shaft (18) in holding

fixture (19).
(12) Install turbine wheel shroud (20) on turbo
wheel shaft (18).
21
WARNING
injury. 19
(13) Coat lower piston ring groove with grease.

Install new retaining ring (21) in groove.
(14) Install center housing (2) on turbo wheel
shaft (18).
23
(15) Install impeller (22) on shaft (18).
(16) Position new locknut (23) on shaft (18). 22
(17) Tighten locknut (23) to 135 lb--in. (14.9 N.m)

with aid of assistant.
18
(18) Remove locknut (23) from shaft (18) with aid
of assistant.
(19) Inspect locknut (23) and impeller (22) for
scratches. Ensure both contact surfaces are
clean and smooth. Replace damaged parts.
(20) Coat threads of shaft (18) and base of 2
locknut (23) with lubricating oil.
(21) Position locknut (23) on shaft (18). Torque
to 35--55 lb--in. (4.0--6.2 N.m) with aid of
assistant. Tighten 1/4 turn more.
20--23
TM 9--2320--360--34--2
16
(22) Place backplate (16) in soft--jawed vise. 24
NOTE
If reading is not 0.003--0.010 in.
(0.08--0.25 mm), remove
indicator and repeat steps
(17) thru (23).
2
(23) Check thrust float with dial indicator (24).
18
Move shaft (18) back and forth in center
housing (2). Reading should be
0.003--0.010 in. (0.08--0.25 mm).
(24) Remove backplate (16) from soft--jawed
vise.
NOTE
Matchmarks on center housing,
coupling, and turbine housing
should be aligned.
(25) Install turbine wheel assembly (25) and 30

coupling (26) on turbine housing (27).
(26) Coat threads of coupling screw (28) with
antiseize compound.
31
CAUTION
Do not tighten coupling until
aligned with turbine housing. If 33
parts are not aligned, 32
turbocharger will be damaged.
(27) Install new locknut (29) on coupling screw

(28). Torque to 160 lb--in. (18.1 N.m). 16
(28) Loosen locknut (29) to 50 lb--in. (6 N.m).
(29) Tighten locknut (29) to 165 lb--in. (18.9 N.m). 25
27
NOTE
Matchmarks on compressor
housing, coupling, and turbine 29 26
housing should be aligned.
(30) Install compressor housing (30) and

coupling (31) on backplate (16).
(31) Coat threads of coupling screw (32) with 28
lubricating oil.
(32) Install new locknut (33) on coupling screw
(32). Torque to 110--130 lb--in.
(12.4--14.7 N.m).
20--24
TM 9--2320--360--34--2
(33) Position dial indicator (23) on compressor

housing (30).
18
CAUTION
Do not allow sides of extension
rod to touch sides of center
housing. Inaccurate reading 23
may result in poor fit and
damage to turbocharger.
(34) Install extension rod of dial indicator (23) in

oil drain hole in center housing (2) so that 2
rod is against turbo wheel shaft (18).
NOTE
If fit of shaft is not within limits,
disassemble and inspect
turbocharger.
(35) Move shaft (18) up and down. Shaft must

not move more than 0.0070 in. (0.178 mm) 30
or less than 0.003 in. (0.076 mm).
20--25
20--25/(20--26 blank)
TM 9--2320--360--34--2
20--26
TM 9--2320--360--34--2
CHAPTER 21
COOLING SYSTEM MAINTENANCE
Contents Para Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21--1 21--1
Water Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21--2 21--2
21--1. INTRODUCTION
This chapter contains instructions for repair of the water pump at the General Support maintenance level.
21--1
TM 9--2320--360--34--2
21--2. WATER PUMP REPAIR
This task covers

INITIAL SETUP
Equipment Conditions Tools and Specials Tools (Cont)

Water pump on clean work surface. Vise, Machinist’s (Item 207, Appendix E)
Tools and Specials Tools Appendix E)
Adapter, Impeller, Slip Test (Item 1, Materials/Parts
Appendix E) Adhesive--Sealant (Item 7, Appendix B)
Gage, Feeler (Item 50, Appendix E) Compound, International No. 2 (Item 21,
Goggles, Industrial (Item 57, Appendix E) Appendix B)
Handle, Drive (Item 65, Appendix E) Compound, Sealing, Pipe Thread (Item 28,
Installer, Oil Seal (Item 80, Appendix E) Appendix B)
Installer, Water Pump Drive Gear (Item 88, Oil, Lubricating (Item 45, Appendix B)
Appendix E) Cleaning Compound, Solvent (Item 54, Appendix B)
Installer, Water Pump Seal (Item 89, Tags, Identification (Item 56, Appendix B)
Appendix E) Repair Kit, Water Pump (Item 230, Appendix F)
Pliers, Retaining Ring (Item 108, Appendix E) Ring, Retaining (Item 244, Appendix F)
Press, Hydraulic (Item 116, Appendix E) Personnel Required
Puller Kit, Mechanical, Gear and Brg Two
(Item 124, Appendix E)
a. Disassembly
2
(1) Place water pump (1) gear--side down in
soft--jawed vise.
3
WARNING
rings. Retaining rings are 4
act as projectiles when re-
leased and may cause severe 1
eye injury.
Due to size and tension of
retaining ring in step (2),
ensure suitable retaining ring
pliers are used for safety.
Press a hammer against
pump cover to help prevent
injury should retaining ring
slip off pliers.
(2) Remove retaining ring (2), access cover (3),
and seal ring (4) using retaining ring pliers.
Discard retaining ring and seal ring.
21--2
TM 9--2320--360--34--2
(3) Remove locknut (5) and washer (6) from

impeller (7). Discard locknut.
(4) Remove impeller (7) from water pump (1)

with puller (8).
9
(5) Rotate water pump (1) so gear side faces up.
11
(6) Remove elbow (9) from water pump (1). 10
(7) Turn gear (10) until ends of lock ring (11)
can be seen.
1
WARNING
leased and may cause severe
eye injury.
(8) Remove lock ring (11) from groove in water

pump (1).
21--3
TM 9--2320--360--34--2
21--2. WATER PUMP REPAIR (CONT)

1
(9) Press gear (10) and shaft assembly (12)
from water pump (1).
NOTE
Do steps (10) and (11) if gear
fails inspection.
(10) Press shaft (12) from gear (10).
(11) Remove lock ring (11) from shaft (12).
NOTE
Do steps (12) and (13) if
bearings fail inspection. 12
(12) Press shaft (12) from bearing (13).
(13) Press shaft (12) from bearing (14). 10
14
12 10
13
11
(14) Tap water seal (15) from water pump (1).

(15) Tap oil seal (16) from water pump (1).
(16) Remove plug (17) from water pump (1). 16
17
15
WARNING
•Fire extinguishers should be placed nearby when using solvent cleaning compound. Failure to follow this warning may result
in injury or death.
•Cloths or rags saturated with solvent cleaning compound must be disposed of IAW authorized facilities' procedures. Failure to
follow this warning may result in injury.
(1) Clean all metal parts with solvent cleaning compound.

(2) Inspect passages of housing for obstructions, deposits, and cracks.
Clean out any obstructions or deposits. Replace housing if cracked.
(3) Inspect bearings for damage and rough turning. Replace both
bearings if either bearing is damaged.
(4) Inspect gear for worn, chipped, or missing teeth.
21--4
TM 9--2320--360--34--2
c. Assembly
NOTE
· Do steps (1) thru (3) if bearings
were removed during disassem- 4 1 3 2
bly.
· Bearings are installed with
numbered side of one bearing
facing numbered side of other
bearing.
8
(1) Lubricate bearings (1 and 2) and shaft (3)
with oil.
CAUTION
Apply pressure to inside bearing 7
races only. Failure to comply
may damage bearings. 6
(2) Press shaft (3), threaded end down, into
small bearing (2) using water pump drive 5
gear installer (4) to support bearing.
(3) Press shaft (3), threaded end up, into large
bearing (1) using water pump drive gear
installer (4) to support bearing.
(4) Place water pump (5) gear--side down on
clean work surface.
(5) Install new oil seal (6), lip facing down, in
water pump (5) using oil seal installer (7)
and drive handle (8).
WARNING
Adhesive--sealant can burn easily, can give off harmful vapors, and is
harmful to skin and clothing. To avoid injury or death, keep away from
open fire and use in well--ventilated area. If adhesive--sealant gets on skin
10
(6) Coat outside of new water seal (9) with
adhesive--sealant.
9
(7) Position new water seal (9), small side
facing up, in water pump (5). 5
CAUTION
Water pump seal installer must
be used to install water seal to
correct height. Failure to
comply may result in damage to
equipment.
NOTE
Excess sealant should be wiped
from water seal.
(8) Install new water seal (9) in water pump (5)
using water pump seal installer (10).
21--5
TM 9--2320--360--34--2
21--2. WATER PUMP REPAIR (CONT)
WARNING 13
When installing shaft assem-
bly, ensure shaft assembly is
installed straight into pump
body or damage to shaft as- 11
sembly and pump body may
result.
1
(9) Install shaft assembly (3) into water pump
(5) by pressing on outer race of larger 3
bearing (1).
(10) Install lock ring (11) in water pump (5) to
secure shaft assembly (3).
WARNING 5
Gear must be installed
straight onto shaft or gear will
be damaged.
NOTE
Do step (11) if gear was
removed during disassembly.
(11) Press gear (13) onto shaft assembly (3)

using water pump drive gear installer (12) to
support shaft assembly from beneath.
12
WARNING
soap and water. 5
(12) Coat threads of elbow (14) with pipe thread

sealing compound and install elbow (14) in
water pump (5).
(13) Coat threads of plug (15) with pipe thread
sealing compound and install plug (15) on
water pump (5).
15
21--6
TM 9--2320--360--34--2
(14) Coat threads of shaft (3) with compound

no. 2.
(15) Place gear (13) in soft--jawed vise.
18
(16) Install impeller (16) on shaft (3) with washer
(17) and new locknut (18). Torque to 35--40 17
lb--ft (47--54 N∙m).
NOTE 16
Steps (17) thru (21) measure
slip torque of gear. 3
(17) Scribe a line across gear (13) and shaft (3). 5
(18) Scribe a second line across impeller (16),
locknut (18), and shaft (3).
(19) Install adapter (19) on torque wrench (20).

(20) Insert adapter dowel pins (21) in impeller
puller holes (22) and apply torque of 80 lb--ft
(108 N∙m). Check assembly for slippage
while applying torque. 13
NOTE
If slippage was felt, examine
scribed marks to determine if
gear or impeller slipped and do
step (21). Otherwise go to
step (22).
20
(21) Replace shaft (3) and component that
slipped (13 or 16). Repeat steps
(17) thru (20).
(22) Insert 0.015 in. (0.38 mm) feeler gage (23) 22
through water outlet opening between
impeller (16) and inside wall (24) of water 19
16
pump (5).
21
NOTE 24
If clearance in step (23) is
wrong, repeat para 21--2a and 23
21--2b. 5
3
(23) Turn impeller (16) while holding feeler gage
(23) in position to check clearance between 22
all blades of impeller (16) and inside wall of
water pump (5).
(24) Remove gear (13) from vise.
13
NOTE
Retaining ring, access cover,
and seal ring are installed in
para 5--5.
21--7/(21--8 blank)
TM 9--2320--360--34--2
21--8
TM 9--2320--360--34--2
CHAPTER 22
TRANSMISSION MAINTENANCE
Contents Para Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--1 22--1
General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--2 22--1
Transmission to Transmission Stand Installation/Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--3 22--3
Flywheel Assembly/Lockup Clutch Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--4 22--9
Torque Converter Stator Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--5 22--17
Torque Converter Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--6 22--20
Torque Converter Housing/Front Support Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--7 22--24
Forward Clutch and Turbine Shaft Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--8 22--37
Fifth Clutch Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--9 22--47
Fourth Clutch Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--10 22--53
Lockup Cutoff Valve Body Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--11 22--56
Trimmer Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--12 22--58
First Shift Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--13 22--60
Main Control Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--14 22--63
Center Support Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--15 22--76
Planetary Gearing, Shafts, and Third Clutch Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--16 22--83
Rear Cover and First Clutch Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--17 22--97
Adapter Housing and Second Clutch Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--18 22--107
Transmission Housing Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--19 22--112
22--1. INTRODUCTION
This chapter contains instructions for replacement and repair of transmission components at the General Support
maintenance level. Some parts must be removed before transmission parts can be accessed. They are
referenced to other paragraphs of this manual or TM 9--2320--360--20.
Section II. SERVICE AND INSPECTION

22--2. GENERAL MAINTENANCE INSTRUCTIONS
a. Maintenance. Follow these basic instructions when working on the transmission.
(1) Handle transmission parts carefully to prevent nicking, scratching, or denting. Internal parts
of transmission have close operating tolerances. They may bind if parts are damaged. Some
parts rely upon a smooth surface to create a seal. They may leak if surfaces are scratched.
(2) Do not use metal tools when working on internal parts of transmission or when removing
gaskets or packing. Use a pointed wooden dowel to remove packing from grooves. Use
wooden or plastic scrapers on gasket surfaces.
b. Cleaning. Follow these cleaning instructions when working on the transmission.
(1) All parts must be clean to permit proper inspection of subassemblies and parts. Ensure that
no debris or foreign material enters the transmission when working on internal parts.
22--1
TM 9--2320--360--34--2
22--2. GENERAL MAINTENANCE INSTRUCTIONS (CONT)

WARNING
CAUTION
DO NOT use caustic soda solution in place of steam cleaning method. Use only
dry cleaning solvent to clean friction--faced clutch plates.
(2) Thoroughly clean metal transmission parts, except bearings and friction--faced clutch plates,
with solvent cleaning compound (Item 54, Appendix B) or by steam cleaning method.
WARNING
Compressed air for cleaning purposes will not exceed 30 psi (207 kPa). Use only with
effective chip guarding and personal protective equipment (goggles/shield, gloves, etc.).
(3) Drip--dry and air--dry bearings, then oil (Item 44, Appendix B). Dry other parts with
compressed air. Oil steam--cleaned parts immediately after drying to prevent rust.
(4) Clean oil passages by working a piece of soft wire back and forth through them. Flush with solvent
cleaning compound (Item 54, Appendix B). Dry with compressed air.
c. Inspection. Follow these inspection instructions when working on the transmission.
(1) Inspect surfaces which contact gaskets, packing, or seals. Ensure there are no nicks, burrs,
or scratches. Remove or correct any defect with crocus cloth (Item 16, Appendix B) before
assembly.
(2) Inspect bores for wear, scratches, grooves, burrs, or dirt. Remove scratches and burrs with
crocus cloth (Item 16, Appendix B) and clean. Remove foreign matter from bores and clean.
Replace deeply scratched, grooved, and excessively worn parts.
(3) Inspect housing and other cast metal parts for cracks. Replace cracked parts as necessary.
(4) Inspect gears for scuffed, nicked, burred, worn, or broken teeth. If defect cannot be corrected with
soft stone, replace damaged gear.
(5) Inspect thrust face of gears for scoring, scratches, or burrs. If defects are found, remove
with soft stone. If defects cannot be removed, replace gears as necessary.
(6) Inspect splined parts for stripped, twisted, chipped, or burred splines. Remove burrs with soft
stone and replace parts if other defects are found. Spline wear is not considered defective
except when it affects tightness of the assembly.
(7) Inspect retaining rings for nicks, distortion, or looseness. Replace retaining rings if loose or
damaged.
(8) Inspect springs for signs of overheating, permanent set, or wear due to rubbing of adjacent
parts. Replace springs if damage is found.
(9) Inspect friction--faced clutch plates and steel clutch plates for burrs, scoring, excessive wear,
distortion, embedded metal, galling, cracks, and damaged teeth or tangs. Remove burrs and
minor surface defects with soft stone. If other than minor surface defects are found, replace
clutch plates.
22--2
TM 9--2320--360--34--2
Section III. MAINTENANCE PROCEDURES
22--3. TRANSMISSION TO TRANSMISSION STAND INSTALLATION/REMOVAL
This task covers:

a. Installation c. Follow--On Maintenance
b. Removal
INITIAL SETUP

Transmission removed from container Compound, Sealing, Pipe Thread (Item 28,
(para 7--3). Appendix B)
Tags, Identification (Item 56, Appendix B)
Tools and Special Tools Gasket (Item 25, Appendix F)
Tool Kit, Genl Mech (Item 202, Appendix E) Kit, Mounting Parts (Item 145, Appendix F)
Fixture, Transmission Holding (Item 45, Locknuts (7) (Item 86, Appendix F)
Sling Assemblies (2) (Item 160, Appendix E) Screws (4) (Item 276, Appendix F)
Stand, Engine (Item 181, Appendix E) Screws (4) (Item 277, Appendix F)
Two
a. Installation
(1) Remove breather (1) from reducer (2).
(2) Remove reducer (2) from transmission (3).
NOTE
Tag and mark hoses before 1
removal.
2
(3) Remove hose no. 2672 (4) from adapter (5). 14
3
11
(4) Remove hose no. 2646 (6) from elbow (7). 13 10
(5) Remove hose no. 2851 (8) from screen
adapter (9).
NOTE
Transmission lockup solenoid 9
and hoses no. 2672, 2646, and 8
12
2851 are removed with bracket. 6
15
(6) Remove locknut (10), screw (11), and 7
bracket (12) from transmission (3). Discard
locknut.
(7) Remove hose no. 2852 (13) from elbow (14)
and elbow (15). 5
4
22--3
TM 9--2320--360--34--2
22--3. TRANSMISSION TO TRANSMISSION STAND INSTALLATION/REMOVAL (CONT)

elbow (17).
(9) Remove hose no. 2934 (18) from 19
elbow (19).
18
NOTE
PTO solenoid and hoses no. 17
2852, 2933, and 2934 are
removed with bracket.
3
(10) Remove locknut (20), screw (21), and
bracket (22) from transmission (3). 16
Discard locknut.
21
20 22
29 26
(11) Remove locknut (23), screw (24), and 27
bracket (25) from transmission (3). Discard 30
locknut. 31
(12) Remove five nuts (26) and copper washers 28
(27) from studs (28). Discard copper 3
washers.
(13) Remove screw (29) from PTO (30) and
transmission (3).
24
(14) Remove PTO (30) and gasket (31) from
transmission (3). Discard gasket.
25 23
22--4
TM 9--2320--360--34--2
33
34 32
(33) from torque converter housing (34) and
transmission (3). Discard lockwashers.
33
3
32
37
(16) Install transmission holding fixture (35) on
engine stand (36) with four screws (37).
35
36
WARNING
Transmission weighs approxi- 38
mately 1125 lb (510 kg). Use 35
caution when lifting transmis-
sion. Failure to comply may
result in serious injury or
death to personnel.
(17) Install lifting device on transmission (3).

(18) Position holding fixture (35) over 3
transmission (3) while assistant supports
transmission with lifting device.
(19) Install holding fixture (35) on transmission
with four screws (38) and locknuts (39).
(20) Remove lifting device from transmission (3).
39
22--5
TM 9--2320--360--34--2
b. Removal 3
4
WARNING
Transmission weighs approxi-
mately 1125 lb (510 kg). Use
caution when lifting transmis-
sion. Failure to comply may
result in serious injury or
death to personnel. 1
(1) Install lifting device on transmission (1).
(2) Remove four locknuts (2) and screws (3)
from holding fixture (4) and transmission (1)
while assistant supports transmission with
lifting device.
(3) Place transmission (1) on hard, level surface
and remove lifting device.
2
4 5
(4) Remove four screws (5) and holding fixture

(4) from engine stand (6).
7
9 8
(5) Install four new lockwashers (7) and screws

(8) in transmission (1) and torque converter
housing (9). Torque to 67--80 lb--ft 7
(91--108 N.m).
1
8
22--6
TM 9--2320--360--34--2
12 14
(6) Install new gasket (10) and PTO (11) on
13
transmission (1).
11
(7) Install screw (12) in PTO (11) and 10
transmission (1).
15
(8) Install five new washers (13) and nuts 1
(14) on studs (15).
(9) Install bracket (16) on transmission (1)
with screw (17) and new locknut (18).
17
16 18
NOTE 23
PTO solenoid and hoses no.
2852, 2933, and 2934 are 22
installed with bracket.
25
(10) Install bracket (19) on transmission (1)
with screw (20) and new locknut (21).
1
(12) Install hose no. 2933 (24) on elbow (25). 24
20
21 19
22--7
TM 9--2320--360--34--2
(13) Install hose no. 2852 (26) on elbow (27) and

elbow (28).
NOTE
Transmission lockup solenoid
and hoses no. 2672, 2646, and
2851 are installed with bracket.
(14) Install bracket (29) on transmission (1) with

screw (30) and new locknut (31). 39

28
1 31
(17) Install hose no. 2672 (36) on adapter (37).
WARNING
29
use in well--ventilated area. If 27 34
35
soap and water.
(18) Coat threads of reducer (38) and breather 37 36

(19) Install reducer (38) on transmission (1).
(20) Install breather (39) on reducer (38).
Install transmission in container (para 7--3).
22--8
TM 9--2320--360--34--2
22--4. FLYWHEEL ASSEMBLY/LOCKUP CLUTCH REPAIR
This task covers:

INITIAL SETUP

Transmission mounted on stand (para 22--3). Oil, Lubricating (Item 44, Appendix B)
Tools and Special Tools Gasket (Item 58, Appendix F)
Bracket, Lifting, Flywheel (Item 12, Appendix E) Ring, Seal (Item 252, Appendix F)
Compressor Unit, Air (Item 24, Appendix E) Ring, Seal (Item 261, Appendix F)
Pan, Oil Drain (Item 102, Appendix E) Ring, Seal (Item 262, Appendix F)
Goggles, Industrial (Item 57, Appendix E) Ring, Seal (Item 269, Appendix F)
Two
a. Removal
(1) Place drain pan under flywheel assembly (1)
to catch draining oil. 4
(2) Install lifting bracket (2) on flywheel
assembly (1) with two screws (3).
(3) Remove two screws (4), access cover (5), 5
and gasket (6) from torque converter
housing (7). Discard gasket.
7
2
22--9
TM 9--2320--360--34--2
22--4. FLYWHEEL ASSEMBLY/LOCKUP CLUTCH REPAIR (CONT)
WARNING
Leave one screw in place behind lifting bracket. Screw is intended to
secure flywheel assembly until lifting device is in place. Failure to comply
may result in serious injury to personnel and damage to equipment.
NOTE
Use flywheel lifting bracket to turn flywheel for access
to screws inside torque converter housing.
(4) Remove 29 of 30 screws (8) and 9

8 10
lockwashers (9) from torque converter pump
(10) and flywheel assembly (1) with aid of 2
assistant. Discard lockwashers.
(5) Install lifting device on lifting bracket (2). 1
(6) Raise lifting device until it supports weight of

flywheel assembly (1).
(7) Remove remaining screw (8) and
lockwasher (9) from flywheel assembly (1).
Discard lockwasher.
CAUTION
Torque converter turbine may be
removed with flywheel or remain
in transmission. Ensure that
torque converter turbine is
supported to prevent it from
falling when removing flywheel.
Failure to comply may result in
damage to converter turbine.
(8) Hold torque converter turbine (11) on 11

flywheel (1) while assistant operates lifting
device. 10
13 12
14
(9) Remove flywheel assembly (1) with torque
converter turbine (11) from torque converter 1
pump (10).
(10) Remove seal ring (12) from turbine shaft
(11) Remove seal ring (14) from torque converter
pump (10). Discard seal ring.
22--10
TM 9--2320--360--34--2
NOTE
11
If torque converter turbine re-
mains in transmission, go to
step (14).
(12) Position flywheel assembly (1) on level

surface so torque converter turbine (11) 15
faces up.
CAUTION
Pry up evenly to remove torque
converter turbine from flywheel. 16
Use shop towels at two pry
points to prevent scoring or oth-
er damage to torque converter
turbine or flywheel.
1
(13) Remove torque converter turbine (11) from
flywheel assembly (1).
(14) Remove backplate (15) and lockup clutch
plate (16) from flywheel (1).
3
1 2
(15) Turn flywheel assembly (1) over so screws

(3) face up.
(16) Remove two screws (3) and lifting bracket
(2) from flywheel assembly (1).
b. Disassembly
(1) Remove two keys (1) from flywheel (2). 2
1
22--11
TM 9--2320--360--34--2
(2) Place wooden blocks on ground.

(3) Position flywheel (2) on blocks with piston
(3) facing down. 3
(4) Lift flywheel (2) 12 in. (30 cm) with aid of
assistant. Drop flywheel (2) on wooden
blocks to free piston (3). Remove piston (3).
(5) Remove seal ring (4) from outer groove in
piston (3). Discard seal ring. 4
(6) Remove seal ring (5) from outer groove in
flywheel hub (6). Discard seal ring.
7
NOTE 5
Do step (7) if pins fail
inspection. 6
(7) Remove six pins (7) from flywheel (2).
(8) Set torque converter turbine (8) on level

surface with bearing shaft (9) facing up.
2
NOTE
Bearing may stay in bore of
flywheel.
(9) Remove bearing (10) from bearing shaft (9)
while assistant holds down torque converter 10
housing (8).
9
8
WARNING
fresh air. If not breathing, provide artificial respiration. If symptoms persist, seek medical attention. Keep away
from open flames and other sources of ignition. Failure to follow this warning may result in injury or death to personnel.
22--12
TM 9--2320--360--34--2
WARNING
effective chip guarding and 1
etc.).
(2) Dry all parts, except for bearings, with

compressed air.
(3) Inspect all parts for damage. Replace all
damaged parts.
(4) Measure thickness of lockup clutch plate (1).
Replace if less than 0.19 in. (4.83 mm) thick.
2
(5) Place straight edge on backplate (2) and

insert feeler gage. Measure gap between
straight edge and backplate. If feeler gage
larger than 0.010 in. (0.25 mm) will fit under
straight edge, replace backplate.
(6) Place straight edge on piston (3) and insert

feeler gage. Measure gap between straight
edge and piston. If feeler gage larger than
0.010 in. (0.25 mm) will fit under straight
edge, replace piston.
d. Assembly
(1) Coat bearing shaft (1) and bearing (2) with 1
lubricating oil.
(2) Position bearing (2) on bearing shaft (1) and
press bearing on shaft.
22--13
TM 9--2320--360--34--2
NOTE 7
· Do step (3) only if pins were
removed.
· Pins should be installed so 9
0.330--0.320 in. (8.38--8.13 mm)
remains above surface.
(3) Install six pins (3) in flywheel (4).

(4) Coat outside of hub (5) and new seal ring (6) 8
with lubricating oil.
(5) Install new seal ring (6) on hub (5). 3
(6) Coat outer groove of piston (7) and new seal 6
ring (8) with lubricating oil.
(7) Install new seal ring (8) on groove of 5
piston (7).
(8) Coat inner hub (9) of piston (7) and piston
seal surface of flywheel (4) with lubricating
oil.
(9) Position piston (7) on flywheel (4) and align 4
six holes with six pins (3) on flywheel (4).
Seat piston (7) firmly on pins.
(10) Install two keys (10) in flywheel (4). 10
3
2
e. Installation 1
(1) Install lifting bracket (1) on flywheel
22--14
TM 9--2320--360--34--2
(2) Turn flywheel assembly (2) over so bracket

(1) faces down.
(3) Soak clutch plate (4) in lubricating oil for 3
minutes and install on flywheel (2). 6
(4) Align notches with keys (5) and install
backplate (6) in flywheel (2).
CAUTION
4
Gear on torque converter tur-
bine must be lined up with teeth
of lockup clutch plate. Damage
to lockup clutch may result. 5
1
2
(5) Install torque converter turbine (7) on
flywheel (2).
(6) Coat new seal ring (8) with lubricating oil

and install on turbine shaft (9).
(7) Coat new seal ring (10) with lubricating oil 7
and install on torque converter pump (11).
11
9 8
CAUTION
Support torque converter turbine 10
during installation. Damage to
equipment may result. 2
(8) Hold torque converter turbine (7) on

flywheel assembly (2) while assistant
operates lifting device. Position flywheel
assembly (2) on torque converter pump (11)
and align holes.
22--15
TM 9--2320--360--34--2
12
13
(9) Install lockwasher (12) and screw (13) on
1
flywheel assembly (2) and remove lifting
device from lifting bracket (1).
2
NOTE
Lifting bracket is used to turn fly-
wheel for access to screw holes
inside torque converter housing.
(10) Loosely install 29 new lockwashers (12) and

screws (13) on flywheel assembly (2).
(11) Tighten 30 screws (13) to 41--49 lb--ft
(56--66 N.m).
(12) Remove two screws (3) and lifting bracket 3

(1) from flywheel assembly (2).
(13) Install new gasket (14) and access cover 17

(15) on torque converter housing (16) with
two screws (17). Torque to 25--30 lb--ft
(34--41 N.m). 15
14
16
Remove transmission from stand (para 22--3).
22--16
TM 9--2320--360--34--2
22--5. TORQUE CONVERTER STATOR REPAIR
This task covers:

INITIAL SETUP

Flywheel assembly removed (para 22--4). Oil, Lubricating (Item 44, Appendix B)
Holder, Stator Roller (Item 70, Appendix E)
a. Removal
NOTE
Bearings, springs, and roller
race may fall out when stator is
removed.
Remove stator (1) from torque converter pump

(2) and shaft (3). 2
b. Disassembly
(1) Hold rim of stator (1) on work surface.
3
(2) Turning roller race (2) clockwise, slowly
remove from stator (1). 4
(3) Remove 10 roller springs (3) and 10 rollers

(4) from stator (1).
(4) Remove thrust bearing (5) and thrust
bearing race (6) from stator (1).
1 6 5 2
22--17
TM 9--2320--360--34--2
22--5. TORQUE CONVERTER STATOR REPAIR (CONT)

WARNING
(1) Clean parts in solvent cleaning compound.
WARNING
Compressed air used for cleaning purposes will not exceed 30 psi (207
kPa). Use only with effective chip guarding and personal protective
equipment (goggles, shield, and gloves).
(2) Dry parts, except bearings, with compressed

air.
(3) Inspect parts for cracks, chipping, and 7
warping. If damage is found, replace parts.
(4) Coat parts with oil prior to assembly.
6
d. Assembly
(1) Position stator (1) on work surface rear side 4
up.
(2) Install thrust bearing race (2) in rear side of
stator (1). 4 5
(3) Insert roller holder tool (3) in stator (1)
against thrust bearing race (2) with string 3
hanging out bottom.
(4) Install 10 roller springs (4) and rollers (5) in 2
cam pockets on stator (1).
(5) Install thrust bearing (6) on roller holder
tool (3).
(6) Install roller race (7) in stator (1) until it
contacts thrust bearing (6).
(7) Remove roller holder tool (3) from stator (1)
by pulling attached string.
1
(8) Push roller race (7) in while turning
clockwise until thrust bearing (6) seats on
thrust bearing race (2).
22--18
TM 9--2320--360--34--2
e. Installation
CAUTION
· Keep outer face of stator down
to prevent roller race, bearings,
and springs from falling out.
· Stator must turn freely in
clockwise direction and lockup
in counterclockwise direction.
Failure to ensure this may result
in improper operation and
damage to equipment.
(1) Hold stator (1) with thrust pads (2) away

from transmission (3).
(2) Install stator (1) on shaft (4). Check that
stator turns freely in clockwise direction and
locks up in counterclockwise direction.
3 4
Install flywheel assembly (para 22--4).
22--19
TM 9--2320--360--34--2
22--6. TORQUE CONVERTER PUMP REPAIR
This task covers:

INITIAL SETUP

Torque converter stator removed (para 22--5). Oil, Lubricating (Item 44, Appendix B)
Tools and Special Tools Lockstrips (6) (Item 105, Appendix F)
Tool Kit, Genl Mech (Item 202, Appendix E) Ring, Retaining (Item 243, Appendix F)
Puller, Bridge (Item 122, Appendix E) Rings, Seal (Item 252, Appendix F)
Bolts, Puller (2) (Item 10, Appendix E) Rings, Seal (Item 254, Appendix F)
Handle, Driver (Item 67, Appendix E) Personnel Required
Goggles, Industrial (Item 57, Appendix E) Two
Remover/Installer, Converter Pump Snap
Ring (Item 132, Appendix E)
Screw, Forcing (Item 152, Appendix E)
Sleeve, Puller (Item 159, Appendix E)
Appendix E)
2
a. Removal
5
(1) Turn transmission assembly so torque
converter housing (1) faces up. 7 7
WARNING 6 6
injury.
(2) Remove retaining ring (2) from ground

sleeve (3) with snap ring remover/installer
(4). Remove spacer (5). Discard retaining
ring.
(3) Bend corners of two lockstrips (6) away from
heads of two opposing screws (7). Remove
two screws with aid of assistant.
22--20
TM 9--2320--360--34--2
CAUTION
11
Failure to use sleeve when 9
9
tightening puller may damage
transmission assembly. 12 8
(4) Install sleeve (8), two puller bolts (9), puller 10
bridge (10), and forcing screw (11) on
pump (12). 1
(5) Tighten forcing screw (11) to separate pump
(12) from ground sleeve (3).
(6) Remove forcing screw (11), puller bridge
(10), two puller bolts (9), and sleeve (8) from
pump (12).
(7) Remove pump (12) from torque converter 3
housing (1) and set on level surface.
2
b. Disassembly
1
(1) Bend remaining corners of 6 lockstrips (1) 3
away from heads of 10 screws (2).
(2) Remove 10 screws (2), 6 lockstrips (1), and
2 bearing retainers (3) from torque converter 8
pump (4). Discard lockstrips.
(3) Remove torque converter hub (5) from 9
pump (4).
(4) Remove two seal rings (6 and 7) from hub
(5). Discard seal rings. 4
(5) Remove outer race (8) and bearing (9) from

pump (4).
(6) Remove inner race (10) from pump (4). 10
6
5
7
WARNING
•Cloths or rags saturated with solvent cleaning compound must be disposed of IAW authorized facilities' procedures. Failure
to follow this warning may result in injury.
22--21
TM 9--2320--360--34--2
22--6. TORQUE CONVERTER PUMP REPAIR (CONT)
WARNING
kPa). Use only with effective chip guarding and personal protective
equipment (goggles, shield, and gloves).
(2) Dry metal parts, except bearings, with compressed air.

(3) Inspect parts for damage.
(4) Replace damaged parts.
(5) Coat parts with lubricating oil.
d. Assembly
(1) Coat new seal ring (1) with lubricating oil
and install on torque converter pump
hub (2).
CAUTION
Ensure that two bearing races
have the same serial number. 9
(2) Install inner race (3) on hub (2). 8
(3) Install hub (2) on torque converter pump (4). 7
CAUTION
Bearing must be kept clean dur- 6
ing installation. Keep bearing
wrapped until bearing is in-
5
stalled. Set bearing on clean,
lint--free paper and never on
dirty surface.
4
(4) Install bearing (5) in inner race (3).
(5) Install outer race (6) over bearing (5).
(6) Install two bearing retainers (7) in groove on
3
outer race (6).
(7) Position 6 new lockstrips (8) and 12 screws 1
(9). Snug the screws at 12, 6, 3, and 9
o’clock positions. Snug the remaining 2
screws finger tight.
(8) Tighten the four screws in the same manner
(12, 6, 3, and 9 o’clock) 35--40 lb ft (47--54
N.m). Tighten the remaining eight screws
35--40 lb ft (47--54 N.m) with aid of assistant.
(9) Bend corners of lockstrips (8) against heads
of screws (9).
22--22
TM 9--2320--360--34--2
e. Installation
CAUTION 2
Keep seal ring sealed in pack-
age until ready to use so seal
ring does not change shape. 1
(1) Compress new seal ring (1) to one--half

diameter and hold for at least 10 seconds.
(2) Install new seal ring (1) in groove on torque

converter pump hub (2).
CAUTION
Make sure tangs of converter
hub engage properly in trans-
mission pump. Failure to com-
ply may result in damage to
9
equipment. 8
(3) Install torque converter pump (3) in torque 7

converter housing (4).
(4) Position driver handle tool (5) around ground

sleeve (6) and on pump (3). Drive pump 5
down until seated. 3
(5) Remove driver handle tool (5).
(6) Install spacer (7) over ground sleeve (6) and

in pump (3).
WARNING 6 4
rings. Retaining rings are un-
der spring tension and can
leased causing severe eye in-
jury.
(7) Using snap ring remover/installer (8), install

retaining ring (9) on ground sleeve (6).
(8) Coat pump (3) and area around hub (2) with
lubricating oil.
Install torque converter stator (para 22--5).
22--23
TM 9--2320--360--34--2
22--7. TORQUE CONVERTER HOUSING/FRONT SUPPORT REPAIR
This task covers:

INITIAL SETUP

Torque converter pump removed (para 22--6). Compound, Sealing, Pipe, Pipe Thread (Item 28,
Appendix B)
Tools and Special Tools Oil, Lubricating (Item 44, Appendix B)
Tool Kit, Genl Mech (Item 202, Appendix E) Sealant, Adhesive, Silicone (Item 2, Appendix B)
Compressor, Spring (Item 23, Appendix E) Cleaning Compound, Solvent (Item 54, Appendix B)
Compressor Unit, Air (Item 24, Appendix E) Tags, Identification (Item 56, Appendix B)
Eyes, Lifting (Item 40, Appendix E) Gasket (Item 21, Appendix F)
Goggles, Industrial (Item 57, Appendix E) Lockwashers (14) (Item 122, Appendix F)
Hammer, Slide (Item 64.1, Appendix E) Ring, Retaining (Item 247, Appendix F)
Handle, Driver (Item 66, Appendix E) Ring, Retaining (Item 246, Appendix F)
Installer, Front Support Needle Bearing Ring, Retaining (Item 238, Appendix F)
(Item 78, Appendix E) Rings, Seal (2) (Item 273, Appendix F)
Guide Pin Set (Item 60, Appendix E) Ring, Seal (Item 263, Appendix F)
Puller Kit, Mechanical Slide Hammer Seal, Oil (Item 308, Appendix F)
Remover Tool, Bearing (Item 142, Appendix E) Personnel Required
Remover, Valve Pin (Item 143.1, Appendix E) Two
Appendix E)
Appendix E)
1
2 3
4
a. Removal
(1) Loosen two screws (1) inside torque
(2) Remove seven screws (3) and lockwashers
(4) from inside torque converter housing (2).
22--24
TM 9--2320--360--34--2
1
2
(3) Remove seven screws (5) and lockwashers 9
(6) holding torque converter housing (2) to 8
transmission housing (7). Discard
lockwashers.
2
(4) Install two lifting eyes (8) on torque
(5) Install lifting device to lifting eyes (8).
CAUTION
Do step (6) before removing
torque converter housing. Pitot 10
collector will be damaged if step
11
(6) is not performed.
(6) Remove two screws (1) and washers (9) 12

from torque converter housing (2).
(7) Remove torque converter housing (2) while
assistant operates lifting device. 7 13
(8) Remove bearing race (10), roller bearing

(11), and bearing race (12).
(9) Remove pitot collector (13) from 6
transmission housing (7).
5
3 1
5
b. Disassembly
(1) Turn torque converter housing (1) over and
place on wooden blocks with aid of 66
86
assistant.
4
(2) Remove two seal rings (2) from support hub
(3). Discard seal rings.
CAUTION
When screws are removed, oil
pump will fall. Ensure that as-
sistant supports oil pump to pre-
vent damage.
1
(3) Remove six screws (4) and oil pump (5)
from torque converter housing (1) while
assistant supports oil pump.
66
86
22--25
TM 9--2320--360--34--2
22--7. TORQUE CONVERTER HOUSING/FRONT SUPPORT REPAIR (CONT)
(4) Remove outer seal ring (6) from backplate

(5) Remove screw (8) and backplate (7) from oil
6
pump (5).
7
(6) Remove drive gear (9) from oil pump (5). 8
(7) Remove two driven gears (10) from oil pump
shafts (11). 9
12
NOTE 12
Do step (8) only if bearings are 10
damaged. 10
(8) Remove bearings (12) from driven

gears (10).
(9) Set oil pump (5) on rim and remove oil seal 5
(13). Discard seal. 11
(10) Remove three plugs (14) from oil pump (5).
13
14
(11) Remove elbow (15) from torque converter

housing (1).
WARNING
act as projectiles when re- 18 19 20
16 17
leased causing severe eye
injury.
NOTE
Tag and mark all parts.
(12) Slowly remove retaining ring (16) while

15
assistant pushes support assembly (17).
Discard retaining ring.
(13) Remove support assembly (17), valve seat
(18), converter bypass valve (19), and
spring (20).
22--26
TM 9--2320--360--34--2
(14) Remove two screws (21). Install spring

compressor tool (22). 22 21
WARNING
injury.
(15) Push in washer (23) and remove retaining
ring (24). Discard retaining ring.
CAUTION
Keep valve clean and free from
nicks and burrs. Failure to
comply will result in difficulty in 27
assembly. 24 23 25 26
(16) Remove washer (23), valve stop (25), valve

spring (26), and lockup shift valve (27).
22
28
(17) Remove two screws (28). Install spring

compressor tool (22).
(18) Push in washer (29) and remove retaining
ring (30). Discard retaining ring.
CAUTION
comply will result in difficulty in
assembly.
36
(19) Remove washer (29), valve stop (31), valve 37 34
spring (32), and main pressure regulator
valve (33).
(20) Remove 11 screws (34) from front support 35
assembly (35).
(21) Remove three screws (36) and screw (37)
from front support assembly (35).
33
31 32
30 29
22--27
TM 9--2320--360--34--2

42.1
(22) Remove front support assembly (35) from
torque converter housing (1).
(23) Remove gasket (38) from torque converter
(24) Remove bearing (39) from ground sleeve
bore (40) using bearing remover tool (41).
(25) Remove pin (43), shifter valve (44), and 41
spring (45) from torque converter
housing (1) using valve pin remover (42) 38
and slide hammer (42.1).
39
40
42 1
43
44 1
45
35
WARNING
Use in well-ventilated areas. Use respirator as needed. Accidental ingestion can cause irritation of digestive tract and respiratory tract,
may cause lung and central nervous system damage. Can be fatal if swallowed. Inhalation of high/massive concentrations can cause
coma or be fatal. First aid for ingestion: do not induce vomiting. Seek immediate medical attention. First aid for skin contact: remove
contaminated clothing. Wash skin thoroughly with soap and water. If symptoms persist, seek medical attention. First aid for eye
contact: flush with water for 15 minutes or until irritation subsides. If symptoms persist, seek medical attention. First aid for inhalation:
move to fresh air. If not breathing, provide artificial respiration. If symptoms persist, seek medical attention. Keep away from open
•Cloths or rags saturated with solvent cleaning compound must be disposed of IAW authorized facilities' procedures. Failure
to follow this warning may result in injury.
(1) Clean metal parts with solvent cleaning compound and inspect for damage.
WARNING
22--28
TM 9--2320--360--34--2
(3) Measure spring lengths using spring tester

(1). Converter bypass valve spring, lockup
shift valve spring, and main pressure
regulator valve spring must be replaced if
load--height specifications, listed in table
22--1, are not met. 1
(4) Inspect two oil pump shafts (2). Replace oil

pump assembly if shafts are worn or
damaged. 2
Table 22--1. Valve Spring Load--Height Specifications
Spring Length Without Load Length Under Load Load
Converter 2.65 in. 1.62 in. 21 to 23 lb

bypass valve (67.3 mm) (41.2 mm) (9.6 to 10.4 kg)
Lockup shift 3.33 in. 1.8 in. 24 to 25.5 lb

valve (84.6 mm) (45.7 mm) (10 to 10.9 kg)
Main regulator 3.94 in. 2.64 in. 82 to 87 lb

valve (100.1 mm) (67.1 mm) (37.2 to 39.4 kg)
d. Assembly 1
(1) Install bearing (1) in ground sleeve bore (2) 2

using bearing installer tool (3) and driver
handle (4).
22--29
TM 9--2320--360--34--2
8 5
(2) Set torque converter housing (5) on wooden

blocks. 6
NOTE
Pin is properly installed when its
head is 0.300 in. (7.62 mm)
above housing surface.
(3) Install spring (6), shifter valve (7), and pin
(8) on torque converter housing (5).
9
(4) Install new gasket (9) on torque converter
housing (5).
10
(5) Align holes and install front support
assembly (10) on torque converter 5
housing (5).
(6) Install three screws (11) in front support

assembly (10). Torque to 36--43 lb--ft
(49--58 N.m).
11
(7) Install 11 screws (12) in front support 13 12
(49--58 N.m).
(8) Install screw (13) in front support assembly
(10). Torque to 36--43 lb--ft (49--58 N.m). 10
CAUTION
assembly.
(9) Install main pressure regulator valve (14) 16
small end first in front support 15 14
assembly (10).
(10) Install main pressure regulator valve spring
(15) and valve stop (16) in front support
assembly (10).
22--30
TM 9--2320--360--34--2
(11) Install spring compressor tool (17) on front 17

support assembly (10).
10
WARNING
injury.
(12) Install washer (18) and retaining ring (19) on
main pressure regulator valve spring (15). 18 15
(13) Remove spring compressor tool (17) from 19
front support assembly (10).
CAUTION
assembly. 10
(14) Install lockup shift valve (20) small end first

in front support assembly (10).
(15) Install valve spring (21) and valve stop (22)
in front support assembly (10).
22 21 20
24 23
10
(16) Install spring compressor tool (17) on front
support assembly (10). 17
(17) Install washer (23) and new retaining ring
(24) on valve spring (21).
(18) Remove spring compressor tool (17) from
front support assembly (10).
22--31
TM 9--2320--360--34--2
(19) Install spring (25), converter bypass valve 31

(26), valve seat (27), and support assembly 10
(28) in front support assembly (10).
26
WARNING 27 25
care when installing retaining 29
injury. 30
(20) Install new retaining ring (29) while assistant

pushes against front support assembly (10). 5
(21) Install elbow (30) on torque converter

housing (5).
(22) Install four remaining screws (31) in front
support assembly (10). Torque to 36--43
lb--ft (49--58 N.m).
WARNING
34
soap and water. 37
(23) Coat threads of three plugs (32) with pipe 35

(24) Install three plugs (32) on pump (33). 36
NOTE
35
Do step (25) only if bearings
were removed.
(25) Install two new bearings (34) in two driven

gears (35).
(26) Install two driven gears (35) on shafts (36). 33
36
(27) Install drive gear (37) in oil pump (33).
(28) Install backplate (38) on pump (33) with 32
screw (39). Torque to 120--180 lb--in.
(13.6--20.3 N.m).
22--32
TM 9--2320--360--34--2
38 35
(29) Check clearance between backplate (38),
drive gear (37), and two driven gears (35) 37
using feeler gages (40). Maximum
clearance is 0.006 in. (0.15 mm). If 40
clearance is more than 0.006 in. (0.15 mm),
replace oil pump.
35
(30) Turn oil pump (33) over.

(31) Coat rubber lip of new seal (41) with
lubricating oil and install seal in pump (33). 41
(32) Coat new outer seal ring (42) with lubricating

oil and install on backplate (38). 33
42
38
5
10
33
43
(33) Turn torque converter housing (5) on side

(34) Install oil pump (33) on torque converter
housing (5) while assistant holds torque
(35) Align screw holes in oil pump (33) with holes
on front support (10).
(36) Install six screws (43) in front support (10)
and oil pump (33) with aid of assistant.
22--33
TM 9--2320--360--34--2
43 43 5
10
(37) Set torque converter (5) on wooden blocks

with front support (10) facing up with aid of
assistant.
(38) Tighten six screws (43) to 35--45 lb--ft
(47--61 N.m).
66
86
e. Installation 1 2
CAUTION
Keep seal rings sealed in pack-
age until ready to use to keep
from being damaged.
(1) Compress two new seal rings (1) to one--half

diameter and hold for 10 seconds.
(2) Install two new seal rings (1) in grooves of
support hub (2).
3
(3) Install bearing race (3), roller bearing (4), 6
and bearing race (5) on inner bore (6).
22--34
TM 9--2320--360--34--2
(4) Turn torque converter housing (7) over so

support hub (2) faces down.
12
NOTE
Guide screws are installed in
side of pitot collector with one
hole in center.
7
(5) Install two guide screws (8) in pitot
collector (9).
(6) Position pitot collector (9) on forward clutch
housing (10) with tube under pitot collector
ring (11).
2
(7) Install lifting eyes (12) and lifting device on 13
torque converter housing (7).
(8) Position torque converter housing (7) over
transmission housing (13) while assistant
8
(9) Align two pitot collector guide screws (8)
11
with two small holes in torque converter
housing (7) while assistant operates lifting
device. 10
CAUTION
Take care not to damage pitot
tube and seal rings when
installing torque converter
housing.
9
(10) Install torque converter housing (7) on
(11) Remove lifting device and lifting eyes (12).
15
14
NOTE
Move pitot collector guide
screws up and down to check
that pitot tube is free.
(12) Install seven new lockwashers (14) and

screws (15). Torque to 67--80 lb--ft
(90--108 N.m)
22--35
TM 9--2320--360--34--2
NOTE
If transmission is mounted in
stand, it may only be possible to 7
install 7 of 11 washers (16) and
screws (17). The remaining four
screws will be installed when 13
transmission is removed from
stand.
(13) Install seven new lockwashers (16) and

screws (17) holding torque converter 16
housing (7) to transmission housing (13).
Torque to 67--80 lb--ft (90--108 N.m). 17
WARNING
open fire and use in well-- 8
ventilated area. If adhesive-- 18
soap and water.
(14) Apply small amount of silicone adhesive--

sealant to two washers (18) and
screws (19).
(15) Remove one pitot collector guide screw (8)

and pull up on other pitot collector guide
screw (8); position washer (18) and screw
(19). Tighten screw until snug.
(16) Remove other pitot collector guide screw (8)

and position washer (18) and screw (19).
Tighten screw until snug.
(17) Tighten two screws (19) to 38--48 lb--in.

(4.3--5.4 N.m).
Install torque converter pump (para 22--6).
22--36
TM 9--2320--360--34--2
22--8. FORWARD CLUTCH AND TURBINE SHAFT REPAIR
This task covers:

INITIAL SETUP

Torque converter housing removed Installer and Staking Set, Collector Ring (Item 84,
Main control valve removed (para 22--14). Press, Hydraulic (Item 116, Appendix E)
Protector, Forward Clutch Piston Inner Seal
Tools and Special Tools (Item 118, Appendix E)
Tool Kit, Genl Mech (Item 202, Appendix E) Stock, Shim (Figure C--7, Appendix C)
Caliper Set, Micrometer (Item 15, Appendix E) Tool, Lifting (Item 198, Appendix E)
Compressor Set, Clutch Spring (Item 22,
Appendix E) Materials/Parts
Compressor Unit, Air (Item 24, Appendix E) Compound, Retaining (Item 22, Appendix B)
Alignment Tool, Fifth Clutch (Item 9, Oil, Lubricating (Item 44, Appendix B)
Appendix E) Cleaning Compound, Solvent (Item 54, Appendix B)
Fixture, PTO Gear Removal (Item 43, Tape, Insulation, Electrical (Item 57, Appendix B)
Appendix E) Rings, Seal (2) (Item 253, Appendix F)
Gage, Depth, Micrometer (Item 48, Ring, Seal (Item 264, Appendix F)
Appendix E) Ring, Seal (Item 267, Appendix F)
Goggles, Industrials (Item 57, Appendix E)
Heater, Gun Type (2) (Item 68, Appendix E) Personnel Required
Two
a. Removal
3
(1) Turn transmission (1) in stand so that turbine
shaft (2) is pointing up.
4
(2) Remove turbine shaft (2) and forward clutch
assembly (3) using lifting tool (4).
(3) Remove outer race (5), roller bearing (6), 5
and inner race (7).
(4) Place forward clutch assembly (3) in clean 6
area.
7
22--37
TM 9--2320--360--34--2
22--8. FORWARD CLUTCH AND TURBINE SHAFT REPAIR (CONT)
b. Disassembly
(1) Remove two seal rings (1) from turbine shaft 5
(2). Discard seal rings.
(2) Place collector ring installer (3) on forward
clutch assembly (4).
6
1 7
3
10
8
4
(3) Place forward clutch assembly (4) and

collector ring installer (3) in hydraulic press
with shaft down. 12 11
CAUTION
Use wooden or plastic dowels to
remove retaining rings. Using
screwdrivers may damage
transmission housing.
4
(4) Remove large inner retaining ring (5) from
forward clutch assembly (4).
(5) Remove fifth clutch driving hub (6) from
3
(6) Remove forward clutch driving hub (7), inner
race (8), bearing (9), and outer race (10)
from forward clutch assembly (4).
(7) Remove five steel plates (11) and five
friction plates (12) from forward clutch
assembly (4).
22--38
TM 9--2320--360--34--2
NOTE
Ensure gap in retaining ring
faces you.
(8) Install clutch spring compressor (13) on

spring retainer (14). 15
WARNING
injury.
14
(9) Compress spring retainer (14) with clutch
spring compressor (13). Remove retaining
ring (15).
(10) Release pressure from spring retainer (14)
and remove clutch spring compressor (13).
14
(11) Remove spring retainer (14) from forward
clutch piston (16). 17
(12) Remove 20 piston return springs (17) from 16
forward clutch piston (16).
4
(13) Remove forward clutch assembly (4) from

press.
(14) Remove collector ring installer (3) from
22--39
TM 9--2320--360--34--2
(15) Place wooden blocks on ground. 2
(16) Position forward clutch assembly (4) on

blocks with turbine shaft (2) facing up.
(17) Lift forward clutch assembly (4) 12 in. (30
4
cm) with aid of assistant. Drop clutch
assembly (4) on wooden blocks to free
forward clutch piston (16). Remove piston
(16) from clutch assembly (4).
(18) Remove inner seal ring (18) and outer seal
ring (19) from forward clutch piston (16).
Discard seal rings. 18
19
NOTE 16
Do steps (19) thru (22) if PTO
gear has missing or damaged
teeth or if pitot collector ring is
damaged or distorted. Other-
wise, go to para 22--8c.
(19) Install shim stock (20) in gap between

retaining ring (21) and teeth of PTO gear
(22). Push retaining ring in forward clutch
assembly (4) and put shim stock every 3 in.
(76 mm) around forward clutch assembly.
(20) Secure shim stock (20) in place with
electrical tape.
(21) Place PTO gear removal fixture (23) in
press. Install forward clutch assembly (4) on
PTO gear removal fixture (23) with shaft 24
pointing up.
(22) Press forward clutch assembly (4) out of 22
PTO gear (22). Remove PTO gear (22),
forward clutch assembly (4), pitot collector
ring (24), and PTO gear removal fixture (23) 4
from press.
20 22
21
23
22--40
TM 9--2320--360--34--2
WARNING
do not induce vomiting. Seek immediate medical attention. First aid for skin contact: remove contaminated clothing.
Wash skin thoroughly with soap and water. If symptoms persist, seek medical attention. First aid for eye contact:
flush with water for 15 minutes or until irritation subsides. If symptoms persist, seek medical attention. First aid for
inhalation: move to fresh air. If not breathing, provide artificial respiration. If symptoms persist, seek medical
attention. Keep away from open flames and other sources of ignition. Failure to follow this warning may result in
(1) Clean metal parts with solvent cleaning compound and

inspect for damage. Replace damaged parts.
(2) Turbine shaft is pressed in forward clutch housing
and should be tight. Replace forward clutch housing 1
if there is any up and down movement.
(3) Measure piston release spring lengths using
spring tester (1). Replace all 20 piston release
springs if any 3 do not meet the following
load--height requirements:
(a) Length without load: 1.25 in. (31.8 mm)
(b) Length under load: 0.88 in. (22.4 mm) 2
with load of 17.9--18.9 lb (8.13--8.58 kg).
(4) Clean ball pockets (2) with solvent cleaning compound.
WARNING
Compressed air for cleaning purposes
will not exceed 30 psi (207 kPa). Use
only with effective chip guarding and
personal protective equipment
(5) Inspect balls for freedom of movement and
proper staking. Replace balls if damaged.
(6) Dry pockets with compressed air. Apply
lubricating oil around area of ball pockets (2).
(7) Measure individual clutch plate thickness by
measuring amount of cone. The amount of
LEVEL SURFACE CLUTCH PLATE
cone is the distance between the inside
diameter and level surface.
(a) Steel clutch plate:
Minimum thickness 0.0993 in. (2.522 mm)
(b) Friction plate:
(c) Clutch driving hub (plate contact area): MEASURE HERE FOR CONE
22--41
TM 9--2320--360--34--2

d. Assembly
NOTE
Do step (1) only if balls were
removed.
(1) Install eight balls (1) in ball pockets (2).

Stake forward clutch assembly (3) housing 6
to retain balls.
NOTE
If collector ring and PTO gear were
not removed, go to step (10). 4
(2) Position forward clutch assembly (3) on
work table with shaft pointing down.
1
WARNING
3
rings. Retaining rings are under
spring tension and can act as
projectiles when released 2
causing severe eye injury.
(3) Install retaining ring (4) in groove (5) on

outside of forward clutch assembly (3).
WARNING 5
Wear heat--resistant gloves to
prevent burning hands when
handling hot PTO gear. Failure to
comply may result in severe
injury.
CAUTION
PTO gear must be heated for 20--30
minutes to allow it to fit over forward
clutch assembly. Failure to heat
PTO gear will result in damage to
components.
(4) Heat PTO gear (6) with two heater guns with
7
aid of assistant.
NOTE
· PTO gear must be installed with
chamfered inside diameter first.
· When properly installed, retaining
ring should move freely in groove. 3
(5) Carefully place PTO gear (6) on forward
clutch assembly (3) until retaining ring (4)
expands into PTO gear (6) groove.
(6) Coat collar of oil collector ring (7) with
retaining compound and place on forward
22--42
TM 9--2320--360--34--2
(7) Install collector ring installer (8) on oil

collector ring (7). 7
(8) Using staking tool (9), bend edge of oil 3

collector ring (7) in groove in forward clutch
assembly (3) while assistant supports
forward clutch assembly on edge. Ensure
oil collector ring (7) does not touch work
surface.
(9) Remove collector ring installer (8) from oil
collector ring (7).
(10) Look at bottom of forward clutch piston (10); 9
note whether forward clutch piston is labeled 7
X, Y, or Z.
10
(11) Stack 10 clutch plates (11 and 12) on flat

surface of press starting with steel plate (11)
and alternating with friction plate (12).
(12) Place fifth clutch driving hub (13) on clutch
plates (11 and 12).
13
12
11
22--43
TM 9--2320--360--34--2

(13) Apply pressure to clutch pack (14) to steady
it.
(14) Press evenly on fifth clutch driving hub (13) 13
with 100 psi (689.5 kPa).
15
NOTE
Forward clutch piston (10) must
14
be a Z piston if clutch pack
clearance is 1.4152--1.4415 in.
(35.956--36.614 mm). Forward
clutch piston must be a Y piston
if clutch pack clearance is
1.3882--1.4148 in.
(35.260--35.935 mm). Forward
clutch piston must be an X
piston if clutch pack clearance is
1.3615--1.3878 in.
(34.582--35.230 mm).
20
(15) Measure distance from base of clutch pack 19
(14) to machined surface (15) of hub (13) to
get clutch pack clearance. 10
(16) Replace clutch plates (11 and 12) as needed

to ensure proper clutch pack thickness.
(17) Remove clutch pack (14) and fifth clutch 17
driving hub (13) from press.
16
(18) Install collector ring installer (8) on forward
(19) Position forward clutch assembly (3) with 18
shaft down on hydraulic press.
(20) Coat two new seal rings (16 and 17) with 3
lubricating oil.
NOTE
Lip of piston seal rings face
down on piston.
(21) Install seal ring (16) and seal ring (17) on
forward clutch piston (10).
(22) Install inner hub seal protector (18) over
inner hub of forward clutch assembly (3).
(23) Install forward clutch piston (10) over seal
protector (18). Carefully work forward clutch
piston (10) completely down until seated.
(24) Remove inner hub seal protector (18).
(25) Install 20 piston release springs (19) on
forward clutch piston (10). 8
(26) Install piston release spring retainer (20) on
piston release springs (19).
22--44
TM 9--2320--360--34--2
WARNING
injury.
(27) Compress spring retainer (20) with clutch

spring compressor tool (21) and hydraulic
20
press. Install retaining ring (22).
(28) Release pressure from spring retainer (20) 21
and remove clutch spring compressor
tool (21). 29
13
NOTE
Install bearing race with cupped
side down.
(29) Install outer race (23) on small hub of

forward clutch assembly (3). 26
(30) Install thrust bearing (24) on outer race (23).

28
(31) Coat inner race (25) with lubricating oil and
install on thrust bearing (24).
(32) Soak five friction plates (26) in clean 27
lubricating oil for 2 minutes.
25
(33) Install forward clutch driving hub (27) on
forward clutch assembly (3). 24
(34) Install five steel plates (28) and five friction
23
plates (26), starting with steel plate (28) and
alternating with friction plate (26).
(35) Install fifth clutch driving hub (13) on forward 3
(36) Install large inner retaining ring (29) on
(37) Remove forward clutch assembly (3) from
press.
22--45
TM 9--2320--360--34--2
e. Installation
(1) Install two new seal rings (1) on turbine
shaft (2). 1
(2) Install outer race (3), roller bearing (4), and
inner race (5) on fifth clutch assembly (6) in
2 8
(3) Install fifth clutch alignment fixture (8) on fifth
WARNING 5
Compressed air used to lock-
up fifth clutch plate will not 4
exceed 30 psi (207 kPa). Use
only with effective chip guard-
ing and personal protective 3
gloves, etc.).
(4) Apply air pressure to port (9) to lock up fifth

clutch plates.
(5) Remove fifth clutch alignment fixture (8) and
install forward clutch assembly (6) in 7
transmission housing (7) using lifting tool (10)
while assistant holds air pressure in fifth
(6) Have assistant stop air pressure when
forward clutch assembly (2) is fully seated in
8
10
2
7
7
6
(1) Install torque converter housing (para 22--7). 9
(2) Install main control valve body (para 22--14).
22--46
TM 9--2320--360--34--2
22--9. FIFTH CLUTCH REPAIR
This task covers:

INITIAL SETUP

Forward clutch and turbine shaft removed Oil, Lubricating (Item 44, Appendix B)
Ring, Seal (Item 264, Appendix F)
Tools and Special Tools Ring, Seal (Item 267, Appendix F)
Bracket, Lifting (Item 11, Appendix E)
Compressor, Clutch Spring (Item 22,
Appendix E)
Gage, Clearance (Item 46, Appendix E)
Spring Tester (Item 190, Appendix E)
a. Removal
2
Attach lifting bracket (1) to fifth clutch assembly
(2) and remove clutch from transmission
housing (3).
22--47
TM 9--2320--360--34--2
22--9. FIFTH CLUTCH REPAIR (CONT)
1
b. Disassembly
(1) Remove thrust bearing race (1) from rear
hub of clutch housing (2).
3
WARNING
care when removing snap
rings. Snap rings are under 4
5
(2) Remove snap ring (3) and backplate (4)
from clutch housing (2). 6
(3) Remove five friction plates (5) and five steel
plates (6) from clutch housing (2).
2 9
(4) Compress spring retainer (7) with clutch 10

spring compressor tool (8) until it is clear of 11
snap ring (9). Remove snap ring.
(5) Remove spring compressor tool (8) from
clutch housing (2). 2
(6) Remove spring retainer (7) and 20 piston

return springs (10) from piston (11).
(7) Remove piston (11) from clutch housing (2).
22--48
TM 9--2320--360--34--2
(8) Turn piston (11) over. Remove seal rings

(12 and 13) from piston (11). Discard seal 12
rings.
(9) Record piston identification letter (X, Y, or Z)
found on bottom side of piston (11).
13
11
Y
WARNING
(1) Clean metal parts with solvent cleaning compound and inspect for damage.
Replace damaged parts.
WARNING
spring tester (1). Replace piston release
springs if any 3 of each set of 20 do not
meet the following load--height requirements:
(a) Length without load must be at least 1
1.25 in. (31.8 mm).
(b) Length under load must be at least
0.88 in. (22.4 mm) with a load of
17.9--18.9 lb (8.1--8.6 kg)
cone is the distance between the inside LEVEL SURFACE CLUTCH PLATE
(a) Friction plate: Minimum thickness
0.0993 in. (2.522 mm)
(b) Steel clutch plate: Minimum thick-
ness 0.090 in. (2.29 mm)
(c) Backplate: Minimum thickness
0.390 in. (9.91 mm) MEASURE HERE FOR CONE
22--49
TM 9--2320--360--34--2
22--9. FIFTH CLUTCH REPAIR (CONT)

NOTE 2
Staking must withstand a 30 lb (133 N)
load applied through the bleed hole.
(5) Inspect eight balls (2) for freedom of
movement and proper staking. Replace
balls if damaged.
WARNING
flush with water for 15 minutes or until irritation subsides. If symptoms persist, seek medical attention. First aid
for inhalation: move to fresh air. If not breathing, provide artificial respiration. If symptoms persist, seek medical
attention. Keep away from open flames and other sources of ignition. Failure to follow this warning may result
in injury or death to personnel.
•The flashpoint for type II solvent cleaning compound is 141-198°F (61-92C) and type III is
200-241°F (93-116C).
damage equipment.
•Fire extinguishers should be placed nearby when using solvent cleaning compound. Failure to
follow this warning may result in injury or death.
•Cloths or rags saturated with solvent cleaning compound must be disposed of IAW authorized
facilities' procedures. Failure to follow this warning may result in injury.
•Eye shields must be worn when cleaning with a wire brush. Flying rust and metal particles may
cause injury.
(6) Clean eight ball pockets (3) with

WARNING
Compressed air for cleaning purposes
will not exceed 30 psi (207 kPa).
Use only with effective chip
guarding and personal protective
equip ment (goggles/shield, gloves, etc.). 1
(7) Dry ball pockets (3) with compressed air.

3
(8) Apply lubricating oil around area of ball
pockets (3).
d. Assembly
NOTE 2
Do step (1) only if balls were removed.
(1) Install eight balls (1) in ball pockets (2).
Stake clutch housing (3) to retain balls.
22--50
TM 9--2320--360--34--2
NOTE 6
Lip of piston seal rings faces
bottom of piston cavity.
(2) Lubricate and install new seal rings (4 and 4

5) in grooves in piston (6).
5
10
(3) Install piston (6), spring bosses up, in clutch
housing (3).
(4) Soak five friction plates (7) in clean 9
lubricating oil for 2 minutes.
NOTE
If new piston is used, make sure
identification letter (X, Y, or Z)
matches letter on old piston.
(5) Install five steel plates (8) and five friction

plates (7) starting with steel plate (8) and
7
WARNING
care when removing snap 8
rings. Snap rings are under
(6) Install backplate (9) and snap ring (10) in

clutch housing (3).
3
22--51
TM 9--2320--360--34--2
22--9. FIFTH CLUTCH REPAIR (CONT) 12
NOTE
Clearance is satisfactory when
15
thinner portion of gage will pass
between backplate and clutch
14
plates; the thicker portion of the
gage will not.
13
(7) Hold backplate (9) firmly against snap ring 6
(10). Insert gage and check clearance 3
between backplate and clutch pack (11).
Clearance should be 0.80--0.120 in.
(2.03--3.04 mm). If measurement is
incorrect, replace clutch plates as needed. 11 9
(8) Install bottom half of clutch spring
compressor tool (12) under clutch 10
housing (3).
(9) Install 20 piston return springs (13) on
piston (6).
(10) Install spring retainer (14) outer lip down on
20 piston return springs (13).
WARNING
Wear eye protection and use 12 16
care when installing snap
(11) Install clutch spring compressor tool (12)
and press on spring retainer (14) until snap
ring groove on clutch hub is visible. Install
snap ring (15).
(12) Lubricate and install thrust bearing race (16)

on rear hub of clutch housing (3).
3
e. Installation 2
(1) Ensure thrust bearing race (1) is in place on 1
the rear hub of clutch housing (2).
(2) Attach lifting bracket (3) to fifth clutch 4
assembly (4) and install fifth clutch into
transmission (5). 6
(3) Engage internal splines with splines on
center sun gear shaft (6). 5
Install fourth clutch (para 22--10).
22--52
TM 9--2320--360--34--2
22--10. FOURTH CLUTCH REPAIR
This task covers:

INITIAL SETUP

Fifth clutch removed (para 22--9). Oil, Lubricating (Item 44, Appendix B)
Caliper Set, Micrometer (Item 15, Appendix E)
Gage, Depth, Micrometer (Item 48, Appendix E)
a. Removal
1
WARNING
3
4
injury.
5
(1) Remove retaining ring (1) from transmission
housing (2).
(2) Remove backplate (3) from transmission
housing (2).
(3) Remove four friction plates (4) and four steel 2
plates (5) from transmission housing (2).
22--53
TM 9--2320--360--34--2
22--10. FOURTH CLUTCH REPAIR (CONT)

WARNING
(1) Clean metal parts with solvent cleaning compound and inspect for damage. Replace damaged parts.
WARNING
Compressed air for cleaning purposes will not exceed 30 psi (207 kPa). Use only
with effective chip guarding and personal protective equipment (goggles/shield, gloves, etc.).
(3) Inspect friction clutch plates (internal splined
plates) for embedded metal particles,
severely pitted faces, loose fittings,
excessive wear, cracks, distortion, and
damaged spline teeth. Replace clutch
plates if any other defects are found.
LEVEL SURFACE CLUTCH PLATE
(4) Inspect steel clutch plates (external--tanged
plates) for burrs, scoring, embedded metal
particles, severely pitted faces, galling,
excessive wear, cracks, and distortion.
Remove burrs and minor surface defects
using soft stone. Replace clutch plates
which have any other defects.
MEASURE HERE FOR CONE
cone is the distance between the inside
(a) Steel clutch plate (color--coded red):
Maximum cone 0.013 in. (0.33 mm)
(b) Steel clutch plate (color--coded green):
(c) Friction plate:
Maximum depth of oil grooves 0.008 in. (0.20 mm)
(d) Backplate minimum thickness 0.490 in. (12.45 mm)
22--54
TM 9--2320--360--34--2
(6) Stack backplate (1), four fiction plates (2),

three steel plates (3) and one steel plate (4)
on flat surface of suitable hydraulic press,
starting with the backplate and alternating
with friction plates.
(7) Place fourth clutch piston (5) on top of clutch
plates (2), (3), and (4).
(8) Press evenly on fourth clutch piston (5) with 5
100 PSI load.
(9) Measure distance from base of backplate (1) 4
to top of fourth clutch piston (5). A 2
(10) From Table 22--1.1, select the proper steel
plate combination to obtain 3.0712 -- 3.0426 3
in. (78.01 -- 77.28 mm) height. Tie these
parts together and tag for subsequent 1
assembly.
TABLE 22--1.1 Fourth Clutch Pack Height
DIM A PLATE PLATE

FROM 6834488 6834720
TO
3.0932 3.0845 ADD 2 REMOVE 2
3.0845 3.0712 ADD 1 REMOVE 1
3.0712 3.0426 -- --
3.0426 3.0293 REMOVE 1 ADD 1
22--54.1/(22--54.2 blank)
TM 9--2320--360--34--2
c. Installation
NOTE
Do step (1) only if center
support was not removed. 5
(1) Install fifth clutch assembly (para 22--9).

(2) Soak friction plates (1) in clean lubricating oil 4
for 2 minutes.
NOTE
Thick steel plates (color--coded
green) must be installed on
bottom of stack.
(3) Install steel plate (2) (color--coded green)

with gap (3) facing as shown.
7
6
NOTE
All steel plates and backplate
must align with gap noted in
step (3).
(4) Install four friction plates (1) and three steel

2
plates (2), starting with friction plate (1) and
alternating with steel plate (2).
(5) Install backplate (4).
3
WARNING
injury.
(6) Install retaining ring (5) with gap opposite oil

pan side (6) of transmission housing (7).
Install forward clutch assembly and turbine shaft
(para 22--8).
22--55
TM 9--2320--360--34--2
22--11. LOCKUP CUTOFF VALVE BODY REPAIR
This task covers:

INITIAL SETUP

Internal filter element removed (para 7--7). Cloth, Crocus (Item 16, Appendix B)
Transmission installed on stand (para 22--3). Oil, Lubricating (Item 44, Appendix B)
Tools and Special Tools Tags, Identification (Item 56, Appendix B)
Appendix E)
a. Removal 2
Remove eight screws (1) and lockup cutoff 3
valve (2) from main control valve (3).
b. Disassembly
5
6
NOTE 1
Tag and mark all parts.
(1) Remove retainer pin (1) from lockup cutoff

valve (2).
(2) Remove valve plug (3) and valve (4) from
lockup cutoff valve (2). 4
(3) Remove two retainer pins (5) from lockup 3 7
cutoff valve (2).
2
(4) Remove two valve plugs (6) and valves (7)
from lockup cutoff valve (2).
22--56
TM 9--2320--360--34--2
WARNING
Solvent cleaning compound MIL-PRF-680 Type II and III may be irritating to the eyes and skin. Use
protectivegloves and goggles. Use in well-ventilated areas. Use respirator as needed. Accidental
ingestion can cause irritation of digestive tract and respiratory tract, may cause lung and central
nervous system damage. Can be fatal if swallowed. Inhalation of high/massive concentrations can
cause coma or be fatal. First aid for ingestion: do not induce vomiting. Seek immediate medical
attention. First aid for skin contact: remove contaminated clothing. Wash skin thoroughly with
soap and water. If symptoms persist, seek medical attention. First aid for eye contact: flush with
water for 15 minutes or until irritation subsides. If symptoms persist, seek medical attention. First
aid for inhalation: move to fresh air. If not breathing, provide artificial respiration. If symptoms persist,
seek medical attention. Keep away from open flames and other sources of ignition. Failure to follow
this warning may result in injury or death to personnel.

WARNING 4
2
Compressed air for cleaning purposes will
7
not exceed 30 psi (207 kPa). Use only with effective
chip guarding and personal protective equipment

(3) Inspect valve body and valves for nicks, burrs,
and scratches. If defects are found, remove 5
with crocus cloth. 6 1
3
d. Assembly
(1) Install two valves (1) and valve plugs (2) in
lockup cutoff valve (3). 3
CAUTION 1
Retaining pins must be flush
with bottom of lockup cutoff 2
valve. Failure to comply may
result in damage to equipment.
(2) Install two retaining pins (4) in lockup cutoff
valve (3).
(3) Install valve (5), valve plug (6), and retaining
pin (7) in lockup cutoff valve (3).
e. Installation
Position lockup cutoff valve (1) on main control
valve (2) and install eight screws (3). Torque to
96--144 lb--in. (10.8--16.3 N.m).
Install internal filter element (para 7--7).
22--57
TM 9--2320--360--34--2
22--12. TRIMMER VALVE REPAIR
This task covers:

INITIAL SETUP

Internal filter element removed (para 7--7). Cloth, Crocus (Item 16, Appendix B)
Oil, Lubricating (Item 44, Appendix B)
Tools and Special Tools Cleaning Compound, Solvent (Item 54, Appendix B)
Appendix E)
a. Removal 2
Remove six screws (1) and trimmer valve (2)
from main control valve (3).
3
b. Disassembly
WARNING
Spring behind stop is under 3
tension. To prevent injury,
use care when removing
retaining pin.
1
(1) Remove retaining pin (1) from trimmer
valve (2). 4
(2) Remove valve plug (3), stop (4), spring (5), 5

plug (6), and valve (7) from trimmer
6
valve (2).
7
2
22--58
TM 9--2320--360--34--2
WARNING
flush with water for 15 minutes or until irritation subsides. If symptoms persist, seek medical attention. First aid.
for inhalation: move to fresh air. If not breathing, provide artificial respiration. If symptoms persist, seek medical
attention. Keep away from open flames and other sources of ignition. Failure to follow this warning may result in
•Eye shields must be worn when cleaning with a wire brush. 5
Flying rust and metal particles may cause injury.
(1) Clean metal parts with solvent cleaning compound. 7
WARNING 4
Compressed air for cleaning purposes 3
will not exceed 30 psi (207 kPa).
Use only with effective chip guarding 2
and personal protective equipment 1 3
(goggles/shield, gloves, etc.). 6
(2) Dry metal parts with compressed air . 1
(3) Inspect valve body and valve for nicks,
burrs, and scratches. If defects are found, 2
remove with crocus cloth.
(4) Coat parts with lubricating oil after cleaning.
d. Assembly
(1) Install valve (1), plug (2), spring (3), stop (4),
and valve plug (5) in trimmer valve (6). 3
CAUTION
Retaining pin must be flush with
bottom of trimmer valve. Failure
to equipment.
(2) Install retaining pin (7) in trimmer valve (6).
e. Installation
4
(1) Install trimmer valve (1) on main control
valve (2) with six screws (3).
(2) Tighten six screws (3) and screw (4) to
96--144 lb--in. (10.8--16.3 N.m).
Install internal filter element (para 7--7).
22--59
TM 9--2320--360--34--2
22--13. FIRST SHIFT VALVE REPAIR
This task covers:

INITIAL SETUP

Trimmer valve removed (para 22--12). Cloth, Crocus (Item 16, Appendix B)
Transmission installed on stand (para 22--3). Oil, Lubricating (Item 44, Appendix B)
1
a. Removal
Remove screw (1) and first shift valve (2) from 2
main control valve (3).
3
b. Disassembly
WARNING
Springs are under tension. To
prevent injury, use care when
removing retaining pin.
(1) Remove retaining pin (1) from first shift
valve (2). 4 3
(2) Remove valve plug (3), spring (4), and valve 6 5
(5) from first shift valve (2).
CAUTION
Mark position of adjusting ring
before removal. Damage to 1
transmission may result if not
7
assembled to same notch. 8
9
(3) Remove retaining pin (6) from first shift
10
valve (2).
(4) Remove adjusting ring (7), washer (8), stop 11
(9), spring (10), and valve (11) from first shift 2
valve (2).
22--60
TM 9--2320--360--34--2
WARNING
irritation of digestive tract and respiratory tract, may cause lung and central nervous system damage. Can
be fatal if swallowed. Inhalation of high/massive concentrations can cause coma or be fatal. First aid for
ingestion: do not induce vomiting. Seek immediate medical attention. First aid for skin contact: remove
contaminated clothing. Wash skin thoroughly with soap and water. If symptoms persist, seek medical
attention. First aid for eye contact: flush with water for 15 minutes or until irritation subsides. If symptoms
persist, seek medical attention. First aid for inhalation: move to fresh air. If not breathing, provide artificial
respiration. If symptoms persist, seek medical attention. Keep away from open flames and other sources
of ignition. Failure to follow this warning may result in injury or death to personnel.
WARNING
(2) Dry metal parts with compressed air .
(3) Inspect valve body and valve for nicks, burrs, and scratches. If
defects are found, remove with crocus cloth.
d. Assembly
CAUTION
Install adjusting ring in position
marked during removal. Dam-
age to transmission may result if
not assembled to same notch. 9 10
8
(1) Install valve (1), spring (2), stop (3), washer 7
(4), and adjusting ring (5) in first shift valve (6). 11
CAUTION
Retaining pins must be flush 6
with bottom of first shift valve. 5
Failure to comply may result in 4
damage to equipment. 3
2
(2) Install retaining pin (7) far enough in first
shift valve (6) to hold adjusting ring (5) in 1
place.
(3) Position stop (3) in first shift valve (6) and
fully seat retaining pin (7).
(4) Install valve (8), spring (9), and valve plug
(10) in first shift valve (6).
(5) Install retaining pin (11) in first shift valve (6).
22--61
TM 9--2320--360--34--2
22--13. FIRST SHIFT VALVE REPAIR (CONT)
2
e. Installation
Position first shift valve (1) on main control valve
(2) and install screw (3). Do not tighten.
Install trimmer valve (para 22--12).
22--62
TM 9--2320--360--34--2
22--14. MAIN CONTROL VALVE REPAIR
This task covers:

INITIAL SETUP

Transmission installed on stand Tool Kit, Genl Mech (Item 202, Appendix E)
(para 22--3). Spring Tester (Item 190, Appendix E)
Transmission external modulator Wrench, Torque, 0--300 Lb--In. (Item 235,
removed (TM 9--2320--360--20). Appendix E)
Lockup cutoff valve body removed
(para 22--11). Materials/Parts
Trimmer valve removed (para 22--12). Cleaning Compound, Solvent (Item 54, Appendix B)
First shift valve removed (para 22--13). Tags, Identification (Item 56, Appendix B)
Personnel Required
Two
a. Removal
CAUTION
Ensure forward clutch is
secured before turning
transmission in stand. Clutch
may fall out and become
damaged.
(1) Turn transmission (1) to access main control

valve (2).
(2) Remove two screws (3) and oil baffle (4)
from separator plate (5).
2 7
(3) Remove 15 screws (6) and 3 long screws
(7) from main control valve (2). 3
1
6
4
22--63
TM 9--2320--360--34--2
22--14. MAIN CONTROL VALVE REPAIR (CONT)
(4) Remove screw (8) and selector detent 8

assembly (9) from main control valve (2). 9
12
(5) Remove two screws (10) and washers (11)
from main control valve (2). 2
CAUTION
Ensure selector valve is secured 10
before removing control valve,
otherwise it could fall out and
become damaged. 11
(6) Remove main control valve (2) from

transmission (1) while holding selector
valve (12).
(7) Place main control valve (2) on flat work
surface bottom up.
2
b. Disassembly
(1) Remove three screws (1) from modulator 10
valve body (2).
(2) Remove modulator valve body (2) while 11
1
holding oil transfer plate (3) and separator
plate (4) together on control valve body (5). 2
WARNING
All valves are under spring
tension. Release springs
slowly to avoid personal
injury.
3
CAUTION
· Do not use magnets to remove
valve bodies. Magnetized 4
valve bodies may not work
properly. 5
· Mark positions of adjusting rings

before removal. Improper 6
shifting and possible damage to
assembled to same notch.
NOTE 8
Tag and mark all parts after
removing. 9
(3) Press adjusting ring (6) inward and remove 10

retaining pin (7) from modulator valve
body (2). 2
(4) Remove adjusting ring (6), spring (8),
modulator valve (9), and valve actuator pin 7
(10) from modulator valve body (2).
22--64
TM 9--2320--360--34--2
(5) Hold oil transfer plate (3) and separator

plate (4) together and remove from control
valve body (5). 3
CAUTION
Ensure transfer plate and sepa-
rator plate do not separate
before turning over.
(6) Turn oil transfer plate (3) and separator plate 4

(4) over with separator plate up. Place on
flat work surface.
CAUTION 5
Ensure transfer plate is face up
on work surface before separa-
tor plate is removed. Failure to
do so will allow check balls to
fall from control valve.
(7) Lift separator plate (4) from oil transfer

plate (3).
5
CAUTION
Do not drop selector valve. Tip
may break off and valve will
become unserviceable.
(8) Remove selector valve (11) from control

valve body (5).
11 15
CAUTION 17
Record and identify check balls
by size, color, and location. 18
equipment damage. 19
(9) Remove four 1/4 in. check balls (12) from oil 16 13
12 14
transfer plate (3). 3
(10) Remove 3/8 in. check ball (13) and 5/16 in.
check ball (14) from oil transfer plate (3). 12
(11) Remove retaining pin (15) from check valve
pin (16) while assistant presses down on
cup washer (17).
(12) Remove cup washer (17), spring (18), and
lubrication check valve (19) from oil transfer
plate (3).
22--65
TM 9--2320--360--34--2
(13) Remove check valve pin (16) from bottom of

oil transfer plate (3).
16
(14) Remove priority valve (20), spring (21), and 20

valve stop (22) from port (23).
(15) Remove plug (24) and governor screen 21
assembly (25) from control valve body (5).
(16) Remove six of eight screws (26) from 22
trimmer valve cover (27).
WARNING
All valves are under spring
tension. Release springs
slowly to avoid personal 27
injury.
(17) Slowly remove last two screws (26) evenly

while holding down trimmer valve cover (27).
Remove trimmer valve cover. 26
23
5 24
25
5
(18) Remove spring (28), valve stop (29), 31
trimmer plug (30), and fourth clutch trimmer 30
valve (31) from control valve body (5). 28
(19) Remove spring (32), valve stop (33), plug 29
(34), and third clutch trimmer valve (35) from
control valve body (5).
(20) Remove spring (36), valve stop (37), plug 35
(38), and fifth clutch trimmer valve (39). 39 34
32
38
36 33
37
22--66
TM 9--2320--360--34--2
(21) Remove spring (40), valve stop (41), plug

(42), and second clutch trimmer valve (43) 43
from control valve body (5).
42
(22) Remove spring (44), valve stop (45), and 40
accumulator valve (46) from control valve 41
body (5).
44
5 45
46
51
47
(23) Remove retainer pin (47), spring spacer 5

(48), spring (49), and three--four relay valve
(50) from control valve body (5). 50
(24) Remove retaining pin (51), valve stop (52), 49
spring (53), and two--three relay valve (54) 48
(25) Remove retaining pin (55), spring (56), valve
stop (57), and governor accumulator valve
54
(58) from control valve body (5).
55 53
52
58
56
57
CAUTION
Mark position of adjusting ring
before removal. Improper
shifting and possible damage to
assembled to same notch.
(26) Remove retaining pin (59), adjusting ring

(60), washer (61), valve stop (62), valve
spring (63), and hold regulator valve (64)
5
64
63 59
61 62
60
22--67
TM 9--2320--360--34--2
(27) Remove retaining pin (65), adjusting ring (66),

valve spring (67), valve stop (68), two--three
shift modulator valve (69), and two--three 71 65
77
shift signal valve (70) from control valve body (5).
(28) Remove retaining pin (71), adjusting ring (72),
valve spring (73), valve stop (74), three--four 82
shift modulator valve (75), and three--four
shift signal valve (76) from control valve body (5). 81
79
(29) Remove retaining pin (77), adjusting ring 80
(78), spring (79), valve stop (80), four--five 78
modulator shift valve (81), and four--five shift 5
signal valve (82) from control valve body (5).
76
valve spring (85), and four--five relay valve 73 70
(86) from control valve body (5). 74 69
72 67
valve spring (89), and trimmer regulator 66
valve (90) from control valve body (5).
WARNING
Solvent cleaning compound MIL-PRF-680 Type II and III may be 83
irritating to the eyes and skin. Use protective gloves and goggles. 87 5
Use in well-ventilated areas. Use respirator as needed. Accidental
ingestion can cause irritation of digestive tract and respiratory tract,
90
may cause lung and central nervous system damage. Can be fatal 89
if swallowed. Inhalation of high/massive concentrations can cause
coma or be fatal. First aid for ingestion: do not induce vomiting. 88
Seek immediate medical attention. First aid for skin contact:
remove contaminated clothing. Wash skin thoroughly with soap
and water. If symptoms persist, seek medical attention. First aid
for eye contact: flush with water for 15 minutes or until irritation
86
subsides. If symptoms persist, seek medical attention. First aid 85
for inhalation: move to fresh air. If not breathing, provide artificial 84
respiration. If symptoms persist, seek medical attention. Keep away
from open flames and other sources of ignition. Failure to follow this
•The flashpoint for type II solvent cleaning compound is 141-198°F (61-92C) 1

and type III is 200-241°F (93-116C).
•Improper cleaning methods and use of unauthorized cleaning solvents
may injure personnel and damage equipment.
•Fire extinguishers should be placed nearby when using solvent cleaning
compound. Failure to follow this warning may result in injury or death.
•Cloths or rags saturated with solvent cleaning compound must be disposed
of IAW authorized facilities' procedures. Failure to follow this warning may
result in injury.
•Eye shields must be worn when cleaning with a wire brush. Flying rust
and metal particles may cause injury.

(2) Inspect valves, valve stops, and plugs for
damage. Replace damaged parts.
(3) Inspect bores and surfaces of control valve
body for damage.
(4) Measure spring lengths using spring tester
(1). Replace springs which do not meet
load--length specifications listed in table 22--2.
22--68
TM 9--2320--360--34--2
Table 22--2. Spring Load--Length Specifications
Assembly
Length Length Text Reference
Without Load Under Load Load Step Callout
in. (mm) in. (mm) lb (kg) No. No.
Trimmer regulator valve spring 1.37 (34.8) 0.89 (22.6) 2.43--2.69 (2) (3)
(10.8--11.9)
Four--five shift relay valve spring 2.18 (55.4) 1.20 (30.5) 16.20--19.80 (4) (7)
(72.1--88.1)
Four--five shift signal valve spring 2.69 (68.3) 1.15 (29.2) 8.9--9.6 (6) (12)
(39.6--42.7)
Three--four shift signal valve spring 2.37 (60.2) 1.15 (29.2) 11.0--11.5 (9) (18)
(48.9--51.2)
Two--three shift signal valve spring 2.98 (75.7) 1.15 (29.20 10.6--11.4 (12) (24)
(47.2--50.7)
Hold regulator valve spring 1.91 (48.5) 1.15 (29.2) 7.46--7.76 (16) (30)
(33.2--34.5)
Governor accumulator valve spring 1.83 (46.5) 0.70 (17.8) 11.6--12.8 (19) (36)
(51.6--56.9)
Two--three relay valve spring 1.52 (38.6) 1.10 (27.9) 7.2--8.8 (21) (40)
(32.03--39.14)
Three--four relay valve spring 2.18 (55.4) 1.94 (49.3) 29.0--35.0 (23) (44)
(129.0--155.7)
Accumulator valve spring 2.77 (70.4) 1.49 (37.8) 11.6--12.8 (25) (47)
(51.6--56.9)
Second clutch trimmer valve spring 2.38 (60.5) 1.94 (49.3) 29.0--35.0 (26) (52)
(129.0--155.7)
Fifth clutch trimmer valve spring 2.38 (60.5) 1.94 (49.3) 29.0--35.0 (27) (56)
(129.0--155.7)
Third clutch trimmer valve spring 2.38 (60.5) 1.94 (49.3) 29.0--35.0 (28) (60)
(129.0--155.7)
Fourth clutch trimmer valve spring 2.16 (54.9) 1.94 (49.3) 12.2--14.8 (29) (64)
(54.3--65.8)
Priority valve spring 1.17 (29.7) 0.94 (23.9) 8.15--9.25 (32) (70)
(36.3--41.2)
Lubrication check valve spring 2.45 (62.2) 1.97 (50.0) 39.41--48.21 (33) (76)
(175.3--214.4)
Modulator valve spring 1.47 (37.3) 0.80 (20.3) 11.9--13.1 (40) (86)
(52.9--58.3)
22--69
TM 9--2320--360--34--2
d. Assembly
5 9
(1) Place control valve body (1) on clean work 1
surface flat side up.
(2) Install trimmer regulator valve (2), valve 2
spring (3), and valve stop (4) in control valve 3
body (1). 4
(3) Press valve stop (4) and insert retaining pin
(5) in control valve body (1).
(4) Install four--five shift relay valve (6), valve 6
spring (7), and valve stop (8) in control valve 7
body (1). 8
(5) Press valve stop (8) and insert retaining pin
CAUTION
Install adjusting rings in positions marked during removal. Improper shifting and
possible damage to transmission may result if not assembled to same notch.
(6) Install four--five shift signal valve (10),
four--five shift modulator valve (11), spring
(12), and adjusting ring (13) in control valve
body (1).
(7) Press adjusting ring (13) and insert retaining
pin (14) in control valve body (1) far enough 26
to hold adjusting ring in place. 14 20
(8) Install valve stop (15) in control valve body

(1). Install retaining pin (14) through hole in
valve stop (15). 10
(9) Install three--four shift signal valve (16),
11
three--four shift modulator valve (17), valve 12
spring (18), and adjusting ring (19) in control 15
valve body (1). 13
1
pin (20) in control valve body (1) far enough
to hold adjusting ring in place. 16
17
(11) Install valve stop (21) in control valve body 18 22
(1). Install retaining pin (20) through hole in 21 23
valve stop (21). 19 24
27
(12) Install two--three shift signal valve (22), 25
two--three shift modulator valve (23), valve
spring (24), and adjusting ring (25) in control
valve body (1).
to hold adjusting ring in place.
valve stop (27).
22--70
TM 9--2320--360--34--2
(15) Install hold regulator valve (28), valve spring

(29), washer (30), and adjusting ring (31) in
to hold adjusting ring in place.
(1). Install retaining pin (32) through hole in 1
valve stop (33).
28 32
29
30 33
(18) Install governor accumulator valve (34) and 31

spring (35) in control valve body (1).
(19) Install valve stop (36) in control valve body 41
valve stop (36). 45
(20) Install two--three relay valve (38) and spring
1
(21) Install valve stop (40) in control valve body 42
valve stop (40). 43
44
(22) Install three--four relay valve (42) and spring
(23) Install spring spacer (44) in control valve
body (1). Install retaining pin (45) through 38
hole in spring spacer (44). 39
37
40
34
35
36
49
(24) Install spring (46), valve stop (47), and
accumulator valve (48) in control valve 50
body (1). 51
52
(25) Install second clutch trimmer valve (49), plug
(50), spring (51), and valve stop (52) in
46
control valve body (1). 1
47
48
22--71
TM 9--2320--360--34--2
(26) Install fifth clutch trimmer valve (53), plug 1

(54), spring (55), and valve stop (56) in 61
control valve body (1). 62
63
(27) Install third clutch trimmer valve (57), plug 64
(58), spring (59), and valve stop (60) in
(28) Install fourth clutch trimmer valve (61),
trimmer plug (62), spring (63), and valve 57
stop (64) in control valve body (1). 53 58
59
54 60
55
71 56
70
(29) Install governor screen assembly (65) and
69
plug (66) in control valve body (1).
(30) Install trimmer valve cover (67) and eight
screws (68) in control valve body (1) while
pressing on springs. Torque to 96--144
lb--in. (10.8--16.3 N.m).
67
(31) Install spring (69), valve stop (70), and
priority valve (71) in port (72).
CAUTION
Do not drop selector valve. Tip 68
may break off and valve will be- 72
come nonserviceable. 1 66
65
(32) Install selector valve (73) in control valve
body (1). 77
1 76
75
78 74
73
(33) Install check valve pin (74), lubrication check

valve (75), spring (76), and spring cup
washer (77) in oil transfer plate (78).
22--72
TM 9--2320--360--34--2
(34) Install retaining pin (79) in check valve pin

(74) while assistant presses down on spring
cup washer (77).
(35) Install 5/16 in. check ball (80) and 3/8 in.
check ball (81) in oil transfer plate (78).
(36) Install four 1/4 in. check balls (82) in oil
transfer plate (78).
(37) Slide separator plate (83) on oil transfer

plate (78).
(38) Hold separator plate (83) and oil transfer
plate (78) together, turn plates over, and
place on control valve body (1).
NOTE
Screws are used to align holes
in plates and control valve body.
(39) Insert six screws (84) through oil transfer

plate (78), separator plate (83), and control
valve body (1).
22--73
TM 9--2320--360--34--2
CAUTION
87
Install adjusting ring in position
marked during removal. Dam-
age to transmission may result if 86
not assembled to same notch.
85
(40) Install actuator pin (84), modulator valve 84
(85), spring (86), and adjusting ring (87) in
modulator valve body (88). 88
pin (89) in modulator valve body (88). 89
90
88
84
(42) Place modulator valve body (88) on oil

84
transfer plate (78) and install three screws
(90). Torque to 96--144 lb--in.
(10.8--16.3 N.m).
(43) Remove six screws (84) from oil transfer
78
plate (78) and control valve body (1).
1
7
8
4
e. Installation
(1) Install control valve body (1) in transmission 1
3
housing (2) making sure shift rack pin (3)
engages slot on selector valve (4). 6
(2) Install two washers (5) and screws (6) on 1
2
5
(3) Install selector detent assembly (7) and
screw (8) on control valve body (1).
22--74
TM 9--2320--360--34--2
10
1
(4) Install 3 long screws (9) and 15 screws (10)

on control valve body (1).
(5) Install oil baffle (11) and two screws (12) on
separator plate (13).
12 9
(6) Tighten screws (6, 8, 9, 10, and 12) to
108--132 lb--in. (12.2--14.9 N.m).
11 1 6
8
13
(1) Install first shift clutch valve (para 22--13).
(2) Install trimmer valve (para 22--12).
(3) Install lockup cutoff valve (para 22--11).
22--75
TM 9--2320--360--34--2
22--15. CENTER SUPPORT REPAIR
This task covers:

INITIAL SETUP

Fourth clutch removed (para 22--10). Oil, Lubricating (Item 44, Appendix B)
Control valve removed (para 22--14). Cleaning Compound, Solvent (Item 54, Appendix B)
Ring Kit, Seal, Buttjoint (Item 273, Appendix F)
Tools and Special Tools Rings, Seal (2) (Item 265, Appendix F)
Tool Kit, Genl Mech (Item 202, Appendix E) Rings, Seal (2) (Item 250, Appendix F)
Compressor Unit, Air (Item 24, Appendix E) Screw, Anchor (Item 281, Appendix F)
Compressor Set, Center Support (Item 21, Washers, Retaining (8) (Item 338, Appendix F)
Appendix E) Washer (Item 332, Appendix F)
Gage, Seal Ring Groove (Item 53, Appendix E)
Bracket, Lifting (Item 11, Appendix E)
Heater, Gun Type (Item 68, Appendix E)
Press, Hydraulic (Item 116, Appendix E)
Swaging Tool (Item 186, Appendix E)
Tester, Spring (Item 190, Appendix E)
Appendix E)
a. Removal
3
(1) Remove two seal rings (1) from center
support (2). Discard seal rings. 4
(2) Remove bearing (3) and bottom race (4)
from center support (2).
22--76
TM 9--2320--360--34--2
(3) Remove center support anchor screw (5)

and washer (6) from transmission (7).
Discard screw and washer. 9
WARNING
injury. 2
(4) Remove retaining ring (8) from transmission (7).
(5) Install center support lifting bracket (9) into the
seal ring grooves on the center support
hub (10). 11
NOTE 7
· Center support housing is fitted
to transmission housing with
very little clearance and may
bind if transmission housing is
cold. Heat transmission
housing with heat lamp or warm
current of air.
· If center support housing starts
upward and begins to bind, tap
center support housing
downward and lift again. 6
(6) Lifting straight up, remove center support (2) 5 5
from transmission (7).
(7) Set center support (2) on flat work surface.
6
(8) Remove thrust washer (11) from
transmission (7).
7
(9) Remove lifting bracket (9) from center
support hub (10).
1
b. Disassembly 4
(1) Remove fourth clutch piston (1) from center
3
support housing (2).
(2) Remove outer seal ring (3) and inner seal
ring (4) from fourth clutch piston (1).
(3) Cut and remove four retaining washers (5).
Discard retaining washers. 2
(4) Remove clutch ring (6) from fourth clutch
piston (1).
(5) Remove 20 springs (7) from fourth clutch
piston (1).
22--77
TM 9--2320--360--34--2
22--15. CENTER SUPPORT REPAIR (CONT)

11
(6) Turn center support housing (2) over.
(7) Remove third clutch piston (8) from center
12
support housing (2).
13
ring (10) from third clutch piston (8).
(9) Cut and remove four retaining washers (11).
8
Discard retaining washers.
(10) Remove clutch ring (12) from third clutch
10
piston (8).
(11)Remove 20 springs (13) from third clutch 9
piston (8).
(12) Turn center support housing (2) over.
NOTE
2
Do step (13) only if replacing
bushing.
(13) Collapse bushing (14) at seam and remove

from center support housing (2) using a chisel.
14
WARNING
(1) Clean metal parts with solvent cleaning compound and inspect for damage. Replace damaged parts.
WARNING
(2) Dry metal parts using compressed air.
22--78
TM 9--2320--360--34--2

springs if any three of each set do not meet
the following load--height requirements:
(a) Length without load must be at least 1
1.29 in. (32.7 mm).
0.82 in (20.8 mm) with load of
4.3--5.7 lb (2--2.6 kg).
(c) Measure thrust washer thickness.
Thickness must be no less than
0.091 in. (2.31 mm).
(4) Insert seal ring groove gage (2) into groove

(3) on center support. Rotate gage around 3
hub. If the gage does not rotate freely, the
support is damaged and should be replaced.
Repeat the check on the other seal ring
groove.
d. Assembly
(1) Place center support (1) on press, hub side 3
up. 2
1
NOTE
Oil hole in prebored bushing
must align with oil hole in center
hub.
(2) Install prebored bushing (2) in hub with

installer (3).
2
5
(3) Remove center support (1) from press and 4
place on flat work surface hub side up.
1
(4) Use swaging tool (4) to swage bushing (2)
by staking edges of oil hole (5).
22--79
TM 9--2320--360--34--2
22--15. CENTER SUPPORT REPAIR (CONT) 9
6
(5) Install 20 springs (6) in third clutch
piston (7). 7
(6) Install clutch ring (8) on third clutch
piston (7).
(7) Install four new retaining washers (9) while 10
applying pressure to clutch ring (8).
11
(8) Coat seal rings (10 and 11) with lubricating
oil.
(9) Install inner seal ring (10) and outer seal ring
(11) in third clutch piston (7). 1
(10) Install third clutch piston (7) in center
support (1).
15
14
(11) Turn center support (1) over on opposite 12

side.
(12) Install 20 springs (12) in fourth clutch 13
piston (13).
(13) Install clutch ring (14) in fourth clutch
piston (13). 16
(14) Install four new retaining washers (15) while
applying pressure to clutch ring (14). 17
(15) Apply lubricating oil to seal rings (16 and 17).

(16) Install inner seal ring (16) and outer seal ring
(17) in fourth clutch piston (13). 1
(17) Install fourth clutch piston (13) on center
support (1).
22--80
TM 9--2320--360--34--2
e. Installation
(1) Install thrust washer (1) in transmission (2). 3
(2) Install lifting bracket (3) on center support hub (4). 4
NOTE 5
Ensure tapped hole on center
support housing is aligned with
hole in transmission housing.
(3) Lower center support (5) into transmission (2). 1

(4) Position washer (6) and anchor screw (7) in
transmission (2) and center support (5). Do
not tighten. 2
(5) Remove lifting bracket (3) from center

support hub (4).
6
7
(6) Install compressor sleeve (8) on hub (4) of 12

center support (5). Place compressor bar
13
(9) across transmission (2). Install two
screws (10).
(7) Tighten compressor screw (11) to 60 lb--in.
(6.8 N.m) to compress center support (5).
(8) Using retaining ring gage (12), measure
retaining ring opening with each of four lugs
(13). This will determine retaining ring size.
10
(a) Blue color--coded ring is 0.148--
0.150 in. (3.76 to 3.81 mm thick). 11
2
(b) Yellow color--coded ring is 0.152--
0.154 in. (3.86--3.91 mm) thick. 9
(c) White color--coded ring is 0.155--
0.157 in. (3.94--3.99 mm) thick.
(d) Red color--coded ring is 0.158--
0.160 in. (4.01--4.06 mm) thick.
8 4 5
10
22--81
TM 9--2320--360--34--2
22--15. CENTER SUPPORT REPAIR (CONT)
14
NOTE 15
Ensure split in retaining ring
17
faces opposite oil pan.
(9) Install retaining ring (14) that has same color 16

code as lug on gage.
10
(10) Ease tension on compressor screw (11) and
remove two screws (10) from transmission 11
housing (2). 2
(11) Remove compressor bar (9) and 9
compressor sleeve (8) from transmission
housing (2).
(12) Fold new seal rings (15) in half and hold for
10 seconds.
(13) Install bottom race (16) and bearing (17) on 8 4
hub (4). 10
(14) Install two new seal rings (15) in center

support hub (4).
(15) Tighten center support anchor screw (7) to

45 lb--ft (61 N.m).
Install fifth clutch (para 22--9).
22--82
TM 9--2320--360--34--2
22--16. PLANETARY GEARING, SHAFTS, AND THIRD CLUTCH REPAIR
This task covers:

INITIAL SETUP

Center support removed (para 22--15). Compound, Sealing, Lubricating (Item 23,
Appendix B)
Tool Kit, Genl Mech (Item 202, Appendix E) Cleaning Compound, Solvent (Item 54, Appendix B)
Bracket, Lifting, Main Shaft (Item 13, Tag, Identification (Item 56, Appendix B)
Appendix E) Pin, Spring (2) (Item 227, Appendix F)
Caliper Set, Micrometer (Item 15, Appendix E) Spindles (6) (Item 328, Appendix F)
Compressor Unit, Air (Item 24, Appendix E) Spindles (4) (Item 327, Appendix F)
Drill, Electric, Portable, 1/4 In. (Item 34, Washers, Thrust (12) (Item 339, Appendix F)
Appendix E) Washer, Thrust (Item 340, Appendix F)
Drill, Electric, Portable, 1/2 In. (Item 35, Washers, Thrust (8) (Item 341, Appendix F)
Appendix E) Washer, Thrust (Item 342, Appendix F)
Drill, Twist, 5/8 In. (Item 36, Appendix E) Washer, Thrust (Item 343, Appendix F)
Gage Set, Telescoping (Item 56, Appendix E)
Installer, Bushing (Item 77, Appendix E) Personnel Required
Press, Hydraulic (Item 116, Appendix E) Two
Reamer Set, Sun Gear Bushing
Swaging Tool, Sun Gear (Item 187, Appendix E)
Lifting Tool, Rear Planetary (Item 97,
Appendix E)
2
a. Removal
3
(1) Install lifting bracket (1) on main shaft (2).
(2) Remove front planetary carrier assembly (3) 6
from transmission housing (4) while
assistant operates lifting device. 5
(3) Remove lifting bracket (1) from main

shaft (2). 4
(4) Lift planetary connecting drum (5) and front
planetary ring gear (6) from transmission
housing (4).
22--83
TM 9--2320--360--34--2
22--16. PLANETARY GEARING, SHAFTS, AND THIRD CLUTCH REPAIR (CONT)
WARNING 7
injury. 10
NOTE
Backing plate is color--coded
green and thicker than six steel
plates.
(5) Remove retaining ring (7), backing plate (8),
six friction plates (9), and six steel plates
(10) from transmission housing (4). Tie third
clutch plates together and identify the pack.
(6) Lift center planetary ring gear (11) and rear

sun gear (12) from transmission housing (4).
WARNING
Do not lift the rear planetary
assembly by the ball bearing 11
on the rear end. The bearing
may come off and the heavy
planetary may fall. Failure to
comply with this warning may
result in personal injury or 13 12
CAUTION
Output shaft yoke must be 14
turned while lifting rear plane-
tary carrier assembly out of
transmission housing. Failure to
comply will not allow rear carrier
assembly to be removed and
may cause equipment damage. 4
(7) Install lifting tool (13) on rear planetary

carrier assembly (14) and lift assembly from
transmission housing (4) with suitable lifting
device.
(8) Place rear planetary carrier assembly on flat
work surface. Remove lifting tool (13).
22--84
TM 9--2320--360--34--2
b. Disassembly
3
Gear Unit and Main Shaft
(1) Remove center sun gear shaft (1) and main
shaft (2) from front carrier assembly (3).
1
(2) Remove center sun gear shaft (1) from main
shaft (2). 4
5
(3) Remove thrust washer (4) from base of main
shaft (2). Discard thrust washer. 2
NOTE
Remove lube orifice plug only if
required.
6
(4) Remove lube orifice plug (5) from main 3
7
shaft (2).
(5) Remove front sun gear (6) from front carrier
assembly (3). 7
(6) Remove two thrust washers (7) from front

carrier assembly (3). Discard thrust
washers.
WARNING
injury. 10
(7) Remove retaining ring (8) and front ring gear 12

(9) from planetary connecting drum (10). 14
13
(8) Remove center carrier assembly (11) from
connecting drum (10).
15
(9) Remove snap ring (12) from rear sun gear 16
(13) and center ring gear (14). 17
(10) Remove rear sun gear (13) from center ring 18

gear (14).
19
(11) Remove bearing race (15), bearing (16), and

bearing race (17) from rear carrier
assembly (18).
(12) Remove bearing (19) from rear carrier
assembly (18).
22--85
TM 9--2320--360--34--2

Front Carrier
4
(1) Place front carrier assembly (1) on flat work
surface.
(2) Inspect front carrier assembly (1) for 1
excessive wear, damage, or heavy metal
contamination.
(3) Check end play of pinions (2). With thrust
washer (3) held flat, insert feeler gage (4)
between front carrier assembly (1) and
thrust washer (3). End play must be within
0.008--0.031 in. (0.21--0.78 mm).
NOTE
Do steps (4) thru (10) only if end
play is not within specifications.
3
(4) Drill away staked ends of six spindles (5)
2
using 5/8 in. (16 mm) bit.
(5) Place front carrier assembly (1) in press. 3
1
(6) Press six spindles (5) from from front carrier 5
assembly (1). Discard spindles.
(7) Remove front carrier assembly (1) from
press. 6 7
(8) Remove 6 pinions (2) and 12 thrust washers
(3) from front carrier assembly (1).
(9) Remove six roller bearings (6) from
pinions (2).
NOTE
Do step (10) only if bushing fails
inspection.
(10) Remove bushing (7) from front carrier

assembly (1).
1
Center Carrier 4
(1) Place center carrier assembly (1) on flat
work surface.
(2) Inspect center carrier assembly (1) for
contamination.
(3) Check end play of spur gears (2). With 2 3
thrust washer (3) held flat, insert feeler gage
(4) between center carrier assembly (1) and
thrust washer (3). End play must be within
0.008--0.031 in. (0.21--0.78 mm).
22--86
TM 9--2320--360--34--2
NOTE
3
Do steps (4) thru (10) only if end 6
play is not within specifications. 2
(4) Drill away staked ends of four spindles (5) 7

using 5/8 in. (16 mm) bit. 6
(5) Place center carrier assembly (1) in press.
3
(6) Press four spindles (5) from center carrier
assembly (1). Discard spindles.
(7) Remove front carrier assembly (1) from
press. 5 1
8
NOTE
Some transmissions will have a
single graphite filled polyamide
thrust washer in place of the
combination of bronze and steel
thrust washers.
(8) Remove four spur gears (2), eight bronze

thrust washers (3), and eight steel thrust
washers (6) from center carrier
assembly (1).
(9) Remove eight roller bearings (7) from
pinions (2).
(10) Remove bushing (8) from center carrier
assembly (1). 6
6
2
5
1
3
Rear Carrier 4
(1) Place rear carrier assembly (1) on flat work
surface with splined hub up.
(2) Inspect rear carrier assembly (1) for
contamination.
(3) Check end play of pinions (2 and 3). With
thrust washer (4 and 5) held flat, insert
feeler gage (6) between rear carrier
assembly (1) and thrust washers (4 and 5).
End play must be within 0.008--0.031 in.
(0.21--0.78 mm).
22--87
TM 9--2320--360--34--2
WARNING
NOTE
Do steps (4) thru (16) only if end
play is not within specifications. 2
12 14 13 11
(4) Remove snap ring (7) from rear carrier
assembly (1).
(5) Remove spring pin (8) from rear carrier
assembly (1).
8
(6) Place rear carrier assembly (1) in press with 10
splined hub down.
NOTE
Balls may fall when pressing
spindles. Catch balls to prevent
losing them.
9
(7) Press four spindles (9) with locking balls
(10) from rear carrier assembly (1) using soft
drift.
1 7
(8) Remove four pinions (2), washers (11), and
washers (12) from rear carrier assembly (1).
(9) Remove four bearings (13) and bearings
(14) from pinions (2).
15 16 1
(10) Remove snap ring (15) from rear carrier

assembly (1).
18
(11) Remove spring pin (16) from rear carrier
assembly (1).
(12) Turn rear carrier assembly (1) over in press.
(13) Press four spindles (17) with locking balls
(18) from rear carrier assembly (1) using soft
drift. 17
(14) Remove four pinions (3) and eight washers
(19) from rear carrier assembly (1).
(15) Remove four bearings (20) from pinions (3).
19 20 19
(16) Remove rear carrier assembly (1) from 3
press.
22--88
TM 9--2320--360--34--2
WARNING
massive concentrations can cause coma or be fatal. First aid for ingestion: do not induce vomiting. Seek immediate
medical attention. First aid for skin contact: remove contaminated clothing. Wash skin thoroughly with soap and water.
If symptoms persist, seek medical attention. First aid for eye contact: flush with water for 15 minutes or until irritation
subsides. If symptoms persist, seek medical attention. First aid for inhalation: move to fresh air. If not breathing, provide
artificial respiration. If symptoms persist, seek medical attention. Keep away from open flames and other sources of ignition.
WARNING

NOTE
All planetary gears in a carrier assembly are replaced as a set.
(3) Inspect parts for damage. Replace damaged parts.
(4) Inspect friction clutch plates (internal splined
plates) for embedded metal particles,
severely pitted faces, loose fittings,
excessive wear, cracks, distortion, and
damaged spline teeth. Replace clutch
plates if any other defects are found.
(5) Inspect steel clutch plates (external--tanged
plates) for burrs, scoring, embedded metal
particles, severely pitted faces, galling, LEVEL SURFACE CLUTCH PLATE
excessive wear, cracks, and distortion.
Remove burrs and minor surface defects
using soft stone. Replace clutch plates
which have any other defects.
(6) Measure individual clutch plate thickness
and cone. The amount of cone is the
distance between the inside diameter and MEASURE HERE FOR CONE
level surface.

(c) Friction plate:
Maximum depth of oil grooves 0.008 in. (0.20 mm)
22--89
TM 9--2320--360--34--2
(6.1) Stack eight steel plates (1) and seven

friction plates (2) on flat surface of suitable
hydraulic press, starting with a steel plate
and alternating with a friction plate.
(6.2) Place third clutch piston (3) on top of clutch
plates (1 and 2).
(6.3) Press evenly on third clutch piston (3) with
100 psi load.
(6.4) Measure distance from base of clutch plates
(1 and 2) to top of third clutch piston (3).
(6.5) From Table 22--3, select the proper steel
plate combination to obtain 3.2014 -- 3.1794
in. (81.32 -- 80.76 mm) height. Tie these
parts together and tag for subsequent
assembly.
Table 22--3. Third Clutch Pack Height
PLATE PLATE
FROM TO 6834488 6834720
3.2058 3.1935 ADD 2 REMOVE 2
3.1935 3.1802 ADD 1 REMOVE 1
3.1802 3.1582 -- --
3.1582 3.1449 REMOVE 1 ADD 1
3.1449 3.1316 REMOVE 2 ADD 2
22--90
TM 9--2320--360--34--2
NOTE
Shaft bushing surface measurement
will be used in paragraph 22--17 to find
output shaft bushing clearance.
(7) Measure and note diameter of shaft
bushing surface (1) of main shaft (2).
(8) Measure diameter of front carrier bushing
surface (3). 6
2
(9) Measure inside diameter of bushing (4).
5
(10) If bushing (4) to front carrier bushing surface
(3) clearance is greater than 0.0072 in. (0.18
mm), replace bushing. 1
(10.1) Inspect surface finish of bearing surfaces (5

and 6) on main shaft (2). Replace main
shaft if any defects are found.
(11) Measure diameter of bushing surfaces (5
and 6) on main shaft.
4
(12) Measure inside diameter of bushings (7 and
8) in sun gear shaft (9).
3
NOTE
Bushings can be easily removed once
collapsed. Use of a small punch thru
the swagging hole will collapse the 8
forward bushing. A small chisel
between the shaft and the bushing 9
outside edge can be used to collapse 7
the rear bushing.
(13) If clearance between bushings (7 and 8) and
shaft bushing surfaces (2 and 5) is more than
0.0064 in. (0.16 mm), remove bushings.
(14) Inspect both ends of sun gear shaft (9) for
spline damage and cracks. Inspect shaft
inside diameter for scoring and metal transfer.
Replace sun gear shaft if any defects are
found.
22--90.1
TM 9--2320--360--34--2

d. Assembly
Rear Carrier
(1) Position rear carrier assembly (1) in press.
(2) Install bearing (2) in pinion (3).
(3) Place new thrust washers (4 and 5) on 5
opposite ends of pinion (3).
(4) Place pinion (3) with bearing (2) and 7 2
washers (4 and 5) in slot at splined end of
carrier (1).
(5) Insert spindle (6) with locking ball (7) in bore
through washers, pinion, and bearings. 9 3
Align locking ball with slot in carrier (1) and
press spindle until it seats. 4
(6) Repeat steps (1) thru (5) to install remaining
three spindles and associated parts.
(7) Press new spring pin (8) in hole
0.330--0.370 in. (8.38--9.40 mm) above the
1
face of carrier.
WARNING
(8) Install spindle retaining snap ring (9) in groove in carrier (1).
22--90.2
TM 9--2320--360--34--2
(9) Turn rear carrier assembly (1) over in press.
CAUTION
Short bearing must be toward
front end of carrier to align with
lubrication holes in spindle pin.
NOTE
Bearings (10 and 11) are differ-
ent, thrust washers (13 and 14)
are the same.
(10) Install bearing (10) and bearing (11) in

pinion (12). 13
(11) Place new thrust washers (13 and 14) on 11

ends of pinion (12). 17
10
(12) Place pinion (12) with washers (13 and 14) 15
and bearings (10 and 11) in their location in 12
slot at rear end of carrier (1).
14
(13) Insert spindle (15) with locking ball (16) in 18
bore through washers, pinion, and bearings.
Align locking ball with slot in carrier (1) and 16
press spindle until it seats.
(14) Repeat steps (9) thru (13) to install
remaining three spindles and associated
parts.
(15) Press new spring pin (17) in hole 1
0.330--0.370 in. (8.38--9.40 mm) above the
face of carrier.
WARNING
projectiles when released 19
(16) Install spindle retaining snap ring (18) in

groove in carrier (1).
1
(17) Install bearing (19) on rear carrier
assembly (1).
22--91
TM 9--2320--360--34--2
Front Carrier
(1) Coat four roller bearings (1) and eight new
black thrust washers (2) with lubricating oil. 6
2
(2) Install thrust washer (2) on each end of four
pinions (3).
NOTE 3
Do step (3) only if bushing was
removed.
1
(3) Position front carrier assembly (4) rear end
2
up. Install bushing (5).
(4) Install two thrust washers (2), roller bearing
(1), and pinion (3) in front carrier assembly
(4), aligning loading pins with pin bores in
carrier (4).
(5) Press spindles (6) in carrier until both ends
of spindle are equal. 4
(6) Repeat steps (4) and (5) for other five
pinions.
(7) Remove carrier (4) from press and stake
both ends of spindles (6) in four places. 5
22--92
TM 9--2320--360--34--2
Center Carrier
NOTE
Some transmissions and service parts
will have a single graphite filled poly-
amide thrust washer in place of the com-
bination of bronze and steel thrust
washers.
(1) Coat eight roller bearings (1), new steel 3

thrust washers (2), and new bronze thrust 6
washers (3) with lubricating oil. 2
(2) Install steel thrust washer (2) on each end of

four spur gears (4). 4
(3) Install bronze thrust washer (3) on each
steel thrust washer (2).
(4) Position center carrier (5) front end up.
Install thrust washers (2 and 3), two roller 1
bearings (1), and spur gear (4) in center
carrier assembly, aligning loading pins with 2
pin bores in carrier (5).
5 3
(5) Press spindles (6) in carrier until both ends
of spindle are equal.
(6) Repeat steps (4) and (5) for other three
pinions.
(7) Remove carrier (5) from press and stake
both ends of spindles (6) in four places.
22--92.1/(22--92.2 blank)
TM 9--2320--360--34--2
WARNING
Sealing compound can burn easily,
can give off harmful vapors, and is 16
harmful to skin and clothing. To
avoid injury or death, keep away from 13
open fire and use in well-- ventilated
area. If sealing compound gets on
skin or clothing, wash immediately
15
(8) Coat bushings (13 and 14) with sealing
compound.
(9) Position bushing (13) at bore of small end of
sun gear shaft (15). Align interlock split so
bushing is more than 45 degrees from 14
swaging hole in sun gear shaft. 20
(10) Press in bushing (13) using end of bushing
installer tool (16) marked 0.360.
(11) Install bushing (14) in larger end of sun gear
shaft (15) using end of bushing installer tool 17
(16) marked 0.260. Align interlock split so
bushing is more than 45 degrees from
swaging hole in sun gear shaft. 13 19
(12) Push both bushings (13 and 14) in swaging
holes of sun gear shaft assembly (15) using
15 15
swaging tool (17).
NOTE
Bushing PN 6835323 requires machin-
ing before final assembly, continue with
step (13). Bushing PN 29506041 is
pre--bored and does not require machin- 14
18
ing, continue with Gear Unit and Main
Shaft assembly.
(13) Clamp holding fixture (18) in vise. Set sun

gear shaft (15) in holding fixture with small 23
end up. Position sun gear bushing reamer
(19) and pilot tool (20) in sun gear shaft (15).
CAUTION 24
Keep reamer rotating at full drill speed
when pulling back through bushing. If
22
reamer is not rotating at full drill speed,
bushing could be damaged.
(14) Machine bushing at approximately 75 to 150

rpm while adding oil through either hole on 21
top of pilot tool (20) using 1/2 in. (13 mm)
electric drill.
(15) Clamp pilot tool (20) in vise. Insert bushing
pilot tool (21) in small end of sun gear shaft
(15) and hold with locking pin (22). Position 20
bushing pilot tool (21) in pilot tool (20), and
position reamer and shaft assembly (23) in
sun gear shaft.
22--93
TM 9--2320--360--34--2
(16) Engage shaft of reamer and shaft assembly

(23) with pilot tool (20). 23
(17) Machine bushing at approximately 75 to 150
rpm while adding lubricating oil in bore at
sides of sun gear shaft (15) using 1/2 in. (13
mm) electric drill. 15
(18) Check inner diameter of bushings for runout.
Runout must not exceed 0.002 in. (0.05 mm)
10
total indicator reading. Surface finish should
be 30 microinch (0.762 micrometer). 20 9
(19) Thoroughly clean sun gear shaft (15) of
8
chips and debris.
4
Gear Unit and Main Shaft
(1) Install larger bearing race (1), bearing (2),
and smaller bearing race (3) in connecting 1
drum (4). 2
3 7
WARNING 6
(2) Install rear sun gear (5) on center ring gear

(6) and install snap ring (7). 12
(3) Install center carrier assembly (8) in 13 11
connecting drum (4).
(4) Install front ring gear (9) and retaining ring
(10) in connecting drum (4). 14
(5) Install thrust washer (11) and front sun gear 13

(12) on front carrier assembly (13). 18
(6) Coat thrust washer (14) with grease and 17

install on front carrier assembly (13). 15
(7) Install lube orifice plug (15) on large end of 16
main shaft (16).
(8) Install thrust washer (17) on base of main
shaft (16).
(9) Install center sun gear shaft (18) on main
shaft (16).
(10) Install center sun gear (18) and main shaft
(16) on front carrier assembly (13).
22--94
TM 9--2320--360--34--2
e. Installation
NOTE
Teeth of first clutch planetary
ring gear and second clutch
planetary ring gear must be
aligned. Failure to comply will 2
not allow rear carrier assembly
to be installed completely.
(1) Align teeth of first clutch planetary ring gear

(1) with teeth of second clutch planetary
gear (2).
WARNING
Planetary is heavy. Do not lift
rear planetary assembly by 6
ball bearing on rear end.
Bearing may come off caus-
ing planetary to fall. Failure
to comply may result in per-
sonnel injury or damage to 3 7
equipment.
NOTE
Output shaft yoke must be 4
turned while lowering rear
planetary carrier assembly into
first clutch planetary ring gear.
Failure to comply will not allow
rear carrier assembly to be
installed completely. 5
(2) Install lifting tool (3) on rear carrier assembly

(4) and install in transmission housing (5)
with suitable lifting device. Remove lifting
tool from rear carrier assembly.
(3) Install center planetary ring gear (6) and rear
sun gear (7) in transmission housing (5).
22--95
TM 9--2320--360--34--2
11
(4) Install six steel plates (8) and six friction

plates (9) in transmission housing (5). 10
WARNING 9
injury.
NOTE
Backing plate is color--coded
green and thicker than six steel
plates.
(5) Install backing plate (10) and retaining ring

(11) in transmission housing (5). 5
14
(6) Install planetary connecting drum (12) and
front planetary ring gear (13) in transmission 15
housing (5).
16
(7) Install lifting bracket (14) on main shaft (15).
(8) Install front planetary carrier assembly (16) 13
in transmission housing (5) while assistant
operates lifting device. 12
(9) Remove lifting bracket (14) from main

shaft (15). 5
Install center support (para 22--15).
22--96
TM 9--2320--360--34--2
22--17. REAR COVER AND FIRST CLUTCH REPAIR

This task covers:
INITIAL SETUP

Governor removed (para 7--6). Wrench, Torque, 0--175 Lb--Ft (Item 236,
Planetary gears removed (para 22--16). Appendix E
Tools and Special Tools) Materials/Parts

Tool Kit, Genl Mech (Item 202, Appendix E) Adhesive--Sealant, Silicone, RTV (Item 2
Blocks, Wooden (Figure C--3, Appendix C) Appendix B)
Caliper Set, Micrometer (Item 15, Appendix E)) Compound, Retaining (Item 22, Appendix B
Compressor Set, Clutch Spring (Item 22, Compound, Sealing, Pipe Thread (Item 28,
Goggles, Industrial (Item 57, Appendix E) Grease, High Temperature (Item 34.1,
Handle, Driver (Item 66, Appendix E) Appendix B)
Handle, Driver (Item 67, Appendix E) Oil, Lubricating (Item 44, Appendix B)
Installer, Bearing (Item 75, Appendix E) Cleaning Compound, Solvent (Item 54, Appendix B)
Installer, Oil Seal Output (Item 81, Appendix E) Gasket (Item 59, Appendix F)
Installer, Output Shaft Bearing (Item 82 Lockwashers (24) (Item 122, Appendix F)
Appendix E) Nut (Item 148, Appendix F)
Multiplier, Torque (Item 99, Appendix E), Ring, Seal (Item 266, Appendix F)
Protector, Seal (Item 119, Appendix E) Ring, Seal (Item 268, Appendix F)
Sling, Endless Strap (Item 161, Appendix E) Seal, Oil (Item 315, Appendix F)
Socket, 3--1/8 In. (Item 162, Appendix E
Tester, Spring (Item 190, Appendix E)) Personnel Required
Wrench, Torque, 0--600 Lb--Ft (Item 233, Two
Appendix E)
a. Removal 2
3 4
(1) Position transmission assembly (1) so yoke
(2) is pointing up. 5 5
(2) Remove 21 screws (3), 3 screws (4), and 24
lockwashers (5) from rear cover (6) and 6
adapter housing (7). Discard lockwashers.
(3) Install lifting device on yoke (2).
8
(4) Remove and guide rear cover (6) away from
adapter housing (7) while assistant operates
lifting device. 7
(5) Place rear cover (6) on clean work surface.
1
(6) Remove lifting device from yoke (2).
NOTE
Gasket may stay on rear cover
or adapter housing.
(7) Remove gasket (8) from either rear cover (6)

or adapter housing (7). Discard gasket.
22--97
TM 9--2320--360--34--2
22--17. REAR COVER AND FIRST CLUTCH REPAIR (CONT)
10 7
11
(8) Remove ring gear (9) with four steel plates

(10) and four friction plates (11) from
adapter housing (7).
(9) Remove five steel plates (12) and four 9
friction plates (13) from adapter housing (7).
13
12
b. Disassembly 6
(1) Position rear cover (1) on wooden blocks so
output shaft (2) is pointing up. 2
(2) Remove nut (3) and yoke (4) from output 1
shaft (2). Discard nut.
(3) Remove dust shield (5) and oil seal (6) from
rear cover (1). Discard oil seal.
22--98
TM 9--2320--360--34--2
7
WARNING
injury.
(4) Remove retaining ring (7) from rear

cover (1).
1
(5) Remove output shaft (2) from rear cover (1). 8
NOTE
Do step (6) only if governor
support pin is damaged.
(6) Remove governor support pin (8) from rear

cover (1).
13
(7) Press output shaft (2) from bearing (9). 14
12
(8) Remove spacer (10) and speedometer drive
gear (11) from output shaft (2). 2
NOTE 11
Transmissions with a serial 10
number lower than 251017042
have a roller bearing; serial
numbers of 251017042 or
higher have a bushing. Both
shaft assemblies are completely
interchangeable.
(9) Remove roller bearing (12) from output

shaft (2). 9
(10) Thread long screw (13) into small orifice
plug (14). Pry up on screw to remove plug.
22--99
TM 9--2320--360--34--2

(11) Position rear cover (1) flange side up. Use
wooden block for support. 16
(12) Install clutch spring compressor tool (15) in
rear cover (1).
WARNING
15
injury.
(13) Compress clutch spring compressor tool and

remove large external retaining ring (16)
from rear cover (1).
(14) Remove clutch spring compressor tool (15)
from rear cover (1).
15
(15) Remove piston spring retainer (17) from first

clutch piston (18).
(16) Remove vent tube (19) from rear cover (1).
(17) Remove 30 piston release springs (20) from
first clutch piston (18).
(18) Remove first clutch piston (18) from rear 17
cover (1).
(19) Remove inner seal ring (21) and outer seal 20
ring (22) from rear cover (1). Discard seal
rings. 18
NOTE
are damaged. 21
(20) Remove dowel pins (23 and 24) from rear
cover (1).
(21) Remove two small plugs (25) and large plug 22
(26) from rear cover (1).
23
1 1
26
19
24
19
22--100
TM 9--2320--360--34--2
WARNING
eye contact: flush with water for 15 minutes or until irritation subsides. If symptoms persist, seek medical
attention. First aid for inhalation: move to fresh air. If not breathing, provide artificial respiration. If symptoms
persist, seek medical attention. Keep away from open flames and other sources of ignition. Failure to follow
(1) Clean metal parts with solvent cleaning compound

and inspect for damage. Replace damaged parts.
(2) Inspect all parts for burrs, scratches, and
pitting. Remove defects.
(3) Inspect all parts for missing or broken
splines or teeth. Replace all damaged parts.
NOTE
Do step (4) for piston release
springs coded light blue. Do
step (5) for piston release
springs coded light green.

spring tester (1). Replace piston release 1
(a) Length without load must be at least
1.31 in. (33.3 mm).
26--28 lb (11.8--12.7 kg).

(a) Length without load must be
at least 1.29 in. (32.7 mm).
(b) Length under load must be
at least 0.82 in. (20.8 mm)
with a load of 4.3--5.7 lb (2--2.6 kg).
22--101
TM 9--2320--360--34--2
(5.1) Measure individual clutch plate thickness

distance between the inside diameter and a
level surface.
Minimum thickness 0.0933 in. (2.522 mm) LEVEL SURFACE CLUTCH PLATE
(c) Friction plate:
Minimum thickness 0.1347 in. (3.420 mm) MEASURE HERE FOR CONE
Maximum depth of oil grooves 0.008 in.
(0.20 mm)
22--102
TM 9--2320--360--34--2
(6) Stack nine steel plates (2) and eight friction

plates (3) on flat surface of suitable
hydraulic press, starting with steel plate and
alternating with friction plate.
(7) Place first clutch piston (4) on top of clutch
plates (2 and 3).
(8) Press evenly on first clutch piston (4) with
100 psi load.
(9) Measure distance from base of clutch plates
(2 and 3) to thrust pad (5).
(10) From Table 22--4, select the proper steel
plate combination to obtain 3.0964--3.0744
in. (78.65--78.09 mm) height (6). Tie these
assembly.
NOTE
There are two thicknesses of
steel plates.
(11) Measure thickness of one tang (7) on each

of seven steel plates (2). Thin plates should
measure 0.096--0.103 in. (2.44--2.62 mm).
Thick plates should measure 0.116--0.123
in. (2.95--3.12 mm).
(12) Replace friction plate if thickness is less
than 0.1347 in. (3.421 mm).
(13) Repeat steps (4) thru (10) to recheck first
clutch thickness.
(14) Check friction plate for presence of oil
grooves.
(15) Remove first clutch piston (4), steel plates
(2), and friction plates (3) from press.
Table 22--4. First Clutch Pack Height
PLATE PLATE
FROM TO 23047771 23047772
3.1363 3.1230 ADD 3 REMOVE 3
3.1230 3.1097 ADD 2 REMOVE 2
3.1097 3.0964 ADD 1 REMOVE 1
3.0964 3.0744 -- --
3.0744 3.0611 REMOVE 1 ADD 1
3.0611 3.0478 REMOVE 2 ADD 2
3.0478 3.0345 REMOVE 3 ADD 3
22--102.1/(22--102.2 blank)
TM 9--2320--360--34--2
d. Assembly
(1) Position rear cover (1) flange side up. Use 5
(2) Coat new inner seal ring (2) and new outer
9
seal ring (3) with lubricating oil.
(3) Install new inner seal ring (2) and new outer 4
seal ring (3) on first clutch piston (4) with lips
facing down.
(4) Install first clutch piston (4) in rear cover (1)
using seal protector (5).
NOTE 2
were removed.
3
(5) Install two dowel pins (6 and 7) in rear
cover (1).
(6) Install vent tube (8) on rear cover (1).
6
1
(7) Install 30 piston release springs (9) in first

clutch piston (4).
(8) Install piston spring retainer (10) on piston
release springs (9). 12
11
(9) Push down on piston spring retainer (10)
and piston release springs (9) using clutch
spring compressor tool (11). Press until
retaining ring groove in rear cover (1) is 10
cleared.
WARNING
injury. 11
(10) Install retaining ring (12). Remove clutch
spring compressor tool (11).
22--103
TM 9--2320--360--34--2

(11) Position rear cover (1) on side with governor
support pin access hole facing down. Use
(12) Install orifice plug (13) in output shaft (14).
17
CAUTION
A roller bearing must be pressed back
into a shaft that had a bearing, and a
bushing must be pressed back into a
shaft that had a bushing. 14
16
(13) Coat output shaft roller bearing (15) with
retaining compound.
(14) Install output shaft roller bearing (15) in
output shaft (14) using output shaft roller
bearing installer tool (16) and driver
handle (Item 66, Appendix E) (17).
(15) Install speedometer drive gear (18) and 1
spacer (19) on output shaft (14).
(16) Press bearing (20) on output shaft (14). 15
NOTE 14
Do step (17) only if governor 18
support pin was removed. 19 20
(17) Install governor support pin (21) in rear
cover (1) if removed.
21 24
14
1
(18) Coat threads of two small plugs (22) and
install in rear cover (1). 23
(19) Install large plug (23) in rear cover (1).
WARNING
injury.
(20) Install output shaft (14) and retaining ring
(24) in rear cover (1). 22
22--104
TM 9--2320--360--34--2
30
29
27
(21) Position rear cover (1) flange side down.
(22) Install new oil seal (25) with seal lip facing 26 28
rear cover (1) using oil seal installer (26) and
driver handle (Item 67, Appendix E) (27). 25
(23) Install dust shield (28) in rear cover (1), flat
side first, so rear edge of shield is flush with
14
surface of rear cover. 1
(23.1) Coat inner surface of oil seal (25) with high
temperature grease.
(24) Install yoke (29) on output shaft (14).
(25) Coat threads of output shaft (14) and new
retainer nut (30) with lubricating oil.
WARNING
Adhesive--sealants and
sealing compounds can burn
vapors, and are harmful to
skin and clothing. To avoid
injury or death, keep away
from open fire and use in
well--ventilated area. If sealing
with soap and water. 2 3
(25.1) Apply adhesive to the splines of output shaft
(14) between yoke (20) and new retainer nut 1
(30).
(26) Install new retainer nut (30) on output
shaft (14). Torque to 600--800 lb--ft
(814--1085 N.m).
e. Installation
(1) Soak eight friction plates (1) in clean
lubricating oil for at least 2 minutes.
(2) Install nine clutch plates (1 and 2) in adapter
housing (3), starting with steel plate (2) and 1
(3) Install rear planetary ring gear (4) in adapter 2
housing (3).
(4) Install remaining clutch plates starting with
friction plates (1).
22--105
TM 9--2320--360--34--2
10 7 11
(5) Position new gasket (5) on transmission
9 9
assembly (6) and align holes.
(6) Install lifting device to yoke (7). 8
NOTE 5
There are two different size
dowel pins on screw flange face
of rear cover to help align cover 6
with transmission.
(7) Lift rear cover (8) and position over

transmission assembly (6) while assistant
operate lifting device. Align holes in
transmission assembly and rear cover.
(8) Install 24 new lockwashers (9), 21 screws
(10), and 3 screws (11). Torque to 67--80
lb--ft (91--108 N.m).
(1) Install planetary gears (para 22--16).
(2) Install governor (para 7--6).
22--106
TM 9--2320--360--34--2
22--18. ADAPTER HOUSING AND SECOND CLUTCH REPAIR
This task covers:

INITIAL SETUP

Rear cover and first clutch removed Oil, Lubricating (Item 44, Appendix B)
Gasket (Item 59, Appendix F)
Tools and Special Tools Ring, Seal (Item 251, Appendix F)
Tool Kit, Genl Mech (Item 202, Appendix E) Ring, Seal (Item 265, Appendix F)
Caliper Set, Micrometer (Item 15, Appendix E)
Spring Tester (Item 190, Appendix E)
a. Removal
(1) Remove adapter housing (1) from 7
(2) Place adapter housing (1) on flat work 3
surface with piston side up.
(3) Remove gasket (3) from transmission
housing (2). 8
(4) Remove rear planetary ring gear (4) with

four steel plates (5) and four friction plates 5
(6) from transmission housing (2).
(5) Remove four steel plates (5), four friction
2
plates (6) from rear planetary ring gear (4).
(6) Remove five steel plates (7) and four friction 6
plates (8) from transmission housing (2).
(7) Tie the second clutch plates together and
identify the pack.
4
22--107
TM 9--2320--360--34--2
22--18. ADAPTER HOUSING AND SECOND CLUTCH REPAIR (CONT)
5
6
b. Disassembly
7 1
(1) Remove second clutch piston (1) from
bottom of adapter housing (2).
ring (4) from second clutch piston (1). 4
(3) Cut and remove four retaining washers (5). 3
Discard retaining washers.
(4) Remove clutch ring (6) from second clutch 2
assembly (1).
(5) Remove 28 springs (7) from second clutch
piston (1).
10
NOTE
· Remove dowel pins and lube 8
plugs only if required.
· Dowel pins may have remained
in transmission housing during
removal of adapter housing. If
so, go to step (6). If not, go to
step (7).
(6) Remove dowel pins (8 and 9) from 9

9
11
(7) Remove lube plug (11) from adapter

housing (2).
(8) Remove dowel pins (8 and 9) from adapter
housing (2).
22--108
TM 9--2320--360--34--2
WARNING
(1) Clean metal parts with dry cleaning solvent

and inspect for damage. Replace damaged parts.
(2) Inspect all parts for burrs, scratches, and
pitting. Remove defects.
(3) Inspect all parts for missing or broken
splines or teeth. Replace all damaged parts.
(a) Length without load must be at least
1.29 in. (32.7 mm).
4.3--5.7 lb (2--2.6 kg).
(4.1) Measure individual clutch plate thickness
distance between the inside diameter and a
level surface.
(a) Steel clutch plate (color--coded red): LEVEL SURFACE CLUTCH PLATE
(c) Friction plate: MEASURE HERE FOR CONE
Maximum depth of oil grooves 0.008 in.(0.20 mm)
22--109
TM 9--2320--360--34--2
22--18. ADAPTER HOUSING AND SECOND CLUTCH REPAIR (CONT)

(5) Stack nine steel plates (2) and eight friction
plates (3) on flat surface of suitable
hydraulic press, starting with steel plate (2)
and alternating with friction plate (3).
(6) Place second clutch piston (4) on top of
clutch plates (2 and 3).
(7) Press evenly on second clutch piston (4)
with 100 psi load.
(8) Measure distance from base of clutch plates
(2 and 3) to top of piston (4).
(9) From Table 22--5, select the proper steel
plate combination to obtain 3.6064--3.5844
in. (91.60--91.04 mm) height. Tie these
assembly.
Table 22--5. Second Clutch Pack Height
PLATE PLATE
FROM TO 23047771 23047772
3.6463 3.6330 ADD 3 REMOVE 3
3.6330 3.6197 ADD 2 REMOVE 2
3.6197 3.6064 ADD 1 REMOVE 1
3.6064 3.5844 -- --
3.5844 3.5711 REMOVE 1 ADD 1
3.5711 3.5578 REMOVE 2 ADD 2
3.5578 3.5445 REMOVE 3 ADD 3
22--110
TM 9--2320--360--34--2
NOTE
There are two thicknesses of
steel plates.
(10) Measure thickness of one tang (6) on each 4

of seven steel plates (2). Thin plates should
measure 0.096--0.103 in. (2.44--2.62 mm).
Thick plates should measure 0.116--0.123
in. (2.95--3.12 mm). 6
(11) Replace friction plate if thickness is less
than 0.1347 in. (3.420 mm) 2
(12) Repeat steps (6) thru (8) to recheck second
clutch thickness. 3
(13) Check friction plate for presence of oil
grooves.
(14) Remove second clutch piston (4), steel
plates (2), and friction plates (3) from press.
d. Assembly 8
7
(1) Install dowel pins (1 and 2) and lube plug (3)
in adapter housing (4).
5 6
(2) Install 28 springs (5) in clutch piston (6).
(3) Install clutch ring (7) on clutch piston (6).
(4) Install four new retaining washers (8) while
9
applying pressure to clutch ring (7).
(5) Coat seal rings (9 and 10) with lubricating 10
oil.
(6) Install inner seal ring (9) and outer seal ring 1
(10) in clutch piston (6).
3
(7) Install clutch piston (6) in adapter 4
housing (4).
2
22--110.1/(22--110.2 blank)
TM 9--2320--360--34--2
e. Installation
(1) Soak eight friction plates (1) in oil for 2 6
minutes.
NOTE
Aligning the splines in the fric-
tion plates during installation will 1
allow for simple installation of
the rear planetary ring gear.
5
(2) Install nine clutch plates (1 and 2) in
transmission housing (3), starting with steel
plate (2) and alternating with friction plate 2
(1). Align the splines on the friction plates.
(3) Install rear planetary ring gear (4) in clutch 2
plates (2).
(4) Install remaining clutch plates (1 and 2) in
transmission housing, starting with friction 3
plate (1) and alternating with steel plate (2).
1
(5) Lightly coat one side of gasket (5) with
grease and set gasket on transmission
housing (3) with greased side of gasket
down.
4
NOTE
Adapter housing is installed with
clutch piston side facing
transmission housing.
(6) Position adapter housing (6) on transmission

housing (3).
Install rear cover and first clutch (para 22--17).
22--111
TM 9--2320--360--34--2
22--19. TRANSMISSION HOUSING REPAIR
This task covers:

a. Removal c. Assembly
INITIAL SETUP

Adapter housing and second clutch Cleaning Compound, Solvent (Item 54, Appendix B)
removed (para 22--18). Compound, Sealing, Lubricating (Item 23,
Appendix B)
Tools and Special Tools Locknut (Item 90, Appendix F)
Tool Kit, Genl Mech (Item 202, Appendix E) Pin, Retaining (Item 225, Appendix F)
Installer, Manual Shaft Oil Seal (Item 79, Seal, Oil (Item 307, Appendix F)
Appendix E) Washer (Item 333, Appendix F)
Remover/Setter, Stud (Item 138,
Appendix E)
Wrench, Torque, 0--300 Lb--In (Item 235,
Appendix E)
7
8
12
a. Removal
(1) Remove retainer pin (1) and loosen locknut
(2) from manual shaft (3). Discard cotter
pin.
(2) Hold lever (4) and locknut (2) with one hand 6
and remove manual shaft (3) by pulling shaft
through oil seal (5).
(3) Remove lever (4) and locknut (2) from 5
transmission housing (6). Discard locknut.
(4) Remove manual shaft oil seal (5) from
transmission housing (6). Discard seal.
10
(5) Remove fifth clutch pressure tap plug (7) 11
3 9
from transmission housing (6).
(6) Remove plugs (8, 9, and 10) and washer
(11) from transmission housing (6).
(7) Remove five studs (12) from transmission
housing (6).
3
6 2 1
22--112
TM 9--2320--360--34--2
WARNING
7
4
1
(1) Clean transmission housing and metal parts
with solvent cleaning compound.
(2) Inspect parts for damage. Replace
damaged parts.
2
(3) If signs of damage to transmission housing
are noted, replace transmission housing. 9 8
c. Assembly
(1) Install five studs (1) on transmission

housing (2). 6
3
(2) Install washer (3) and plugs (4, 5, and 6) on 10 5
(3) Install fifth clutch pressure tap plug (7) from
(4) Coat outside of new oil seal (8) with sealing
and lubricating compound and install oil seal 10
in transmission using manual shaft oil seal
installer (9). 11
(5) Insert manual shaft (10) halfway by pushing
shaft through oil seal (8) in transmission 2 12 13
housing (2).
(6) Position lever (11) in transmission housing
(2) and install new locknut (12) on manual
shaft (10). Fully seat shaft (10) and tighten
locknut to 180--240 lb--in. (21--27 N.m).
(7) Install new retainer pin (13) on manual shaft
(10) by inserting straight side of pin in hole
and curve over shaft.
Install adapter housing and second clutch (para 22--18).
22--113/(22--114 blank)
22--113
TM 9--2320--360--34--2
22--114
TM 9--2320--360--34--2
CHAPTER 23
TRANSFER CASE MAINTENANCE
Contents Para Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23--1 23--1
Transfer Case Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23--2 23--2
Lubrication Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23--3 23--36
23--1. INTRODUCTION
This chapter contains instructions for replacement and repair of the transfer case and components at the
General Support maintenance level. Some parts must be removed before the transfer case components
can be accessed. They are referenced to other paragraphs of this manual or in TM 9--2320--360--20.
The HET transfer case is supplied as a dressed assembly including input and output yokes.
23--1
TM 9--2320--360--34--2
23--2. TRANSFER CASE REPAIR
This task covers:

INITIAL SETUP

Breather removed (TM 9--2320--360--20). Adhesive--Sealant, Silicone (Item 2, Appendix B )
Lockout shift chamber removed Adhesive--Sealant (Item 3, Appendix B)
(TM 9--2320--360--20). Adhesive--Sealant (Item 5, Appendix B)
Lubrication pump removed (para 8--7). Adhesive--Sealant (Item 6, Appendix B)
Cloth, Crocus (Item 16, Appendix B)
Tools and Special Tools Compound, Sealing (Item 25, Appendix B)
Tool Kit, Genl Mech (Item 202, Appendix E) Compound, Sealing, Pipe Thread (Item 28,
Adapter Kit, Transfer Case (Item 6.1, Appendix B)
Appendix E) Grease, General Purpose, Lithium Base
Adapter Tool, Transfer Case End Play (Item 34, Appendix B)
(Item 8, Appendix E) Lockwire (Item 36, Appendix B)
Compressor Unit, Air (Item 24, Appendix E) Oil, Lubricating (Item 48, Appendix B)
Dial Indicator, Magnetic (Item 32, Appendix E) Cleaning Compound, Solvent (Item 54, Appendix B)
Fixture, Transmission Holding (Item 45, Tags, Identification (Item 56, Appendix B)
Appendix E) Tape, Masking (Item 58, Appendix B)
Hammer, Soft--Faced (Item 63, Appendix E) Lockwashers (2) (Item 119, Appendix F)
Holder, Yoke (Figure C--15, Appendix C) Ring, Piston, Teflon (Item 274, Appendix F)
Lifting Tool, Rear Planetary (Item 97, Seal (Item 286, Appendix F)
Appendix E) Seal (Item 309, Appendix F)
Press, Hydraulic (Item 116, Appendix E) Seal (Item 310, Appendix F)
Puller Kit, Mechanical, Gear and Brg
(Item 124, Appendix E) Personnel Required
Shaft, Dummy, Transfer Case (Item 158, Two
Appendix E)
Socket, Sockethead Screw, 3/8 In.
(Item 172.1, Appendix E)
Stand, Engine (Item 181, Appendix E)
Wrench, Torque, 0--175 Lb--Ft (Item 236
Appendix E)
23--2
TM 9--2320--360--34--2
a. Disassembly
(1) Install transmission holding fixture (1) on
engine stand (2) with four screws (3).
(2) Install two adapters (4) on rear transfer case
housing (5) with four screws (6).
WARNING
Transfer case weighs 965 lb (438 kg).
Stay clear of transfer case when
supported by lifting device. Transfer
case may fall and cause serious
injury to personnel. 1 7
(3) Install two adapters (4) on transmission
holding fixture (1) with four screws (7).
(4) Deleted.
2 6
4
5
3
23--2.1/(23--2.2 blank)
TM 9--2320--360--34--2
23--2.2 Change 1
TM 9--2320--360--34--2
(5) Remove screw (8), washer (9), retainer (10),

and rear output yoke (11) from rear output
shaft (12).
(6) Remove screw (13), retainer (14), and front 18
output yoke (15) from front output shaft (16). 8
9
(7) Remove screw (13), retainer (14), and input
yoke (17) from input shaft (18). 11 10
17
14
13
12
16
15
14
13
24
25
20
21
(8) Position transfer case front half (19) up.
(9) Remove hose (20) from elbows (21 and 22).
(10) Remove elbow (22) from transfer case front 23
half (19).
(11) Remove elbow (21) from lower front bearing 16 22
bearing cap (23).
26
(12) Remove six screws (24) and lockwashers
(25) from lower front bearing cap (23). 19
(13) Remove lower front bearing cap (23) with
front output shaft (16) from transfer case
front half (19).
NOTE
· Note location of groove in
clutch collar before
removing.
· Lift on fork assembly to
remove clutch collar.
(14) Remove clutch collar (26) from transfer

case (5).
23--3
TM 9--2320--360--34--2
23--2. TRANSFER CASE REPAIR (CONT)

29 27
30
28
(15) Remove reducer (27) from end cap (28). 33 36
(16) Remove six screws (29), lockwashers (30), 34
and end cap (28) from transfer case front
37
half (19). Discard lockwashers. 19 32
(17) Remove speedometer drive shaft (31),
31
spring (32), thrust bearing (33), and thrust
38
washer (34) from shaft retaining plate (35). 35
(18) Remove shifter rod end (36), jam nut (37),

and actuator plate (38) from upper shift 39
rod (39).
40
49
47 41
(19) Position transfer case rear half (2) facing up. 46
(20) Remove two screws (40), lockwashers (41), 42
and cover (42) from transfer case rear half 48
(2). Discard lockwashers.
2
(21) Remove plug (43), outer spring (44), and
outer ball (45) from transfer case rear
half (2).
(22) Remove lube pump oil hose (46) and elbow
(47) from adapter strainer (48).
(23) Remove adapter strainer (48) from transfer
case rear half (2).
(24) Remove plug (49) from transfer case rear
half (2).
45
44
43
19
23--4
TM 9--2320--360--34--2
(25) Turn transfer case front half (19) up. 4

(26) Remove 20 screws (50) from transfer case
front half (19).
(27) Install two screws (50) in transfer case rear
19
half jackscrew holes (51) next to
dowels (52).
(28) Tighten two screws (50) alternately to force 50
transfer case front half (19) with dowels (52)
from rear half (2).
WARNING
Transfer case front half
weighs 200 lb (91 kg). Stay
clear of transfer case front
half when supported by lifting
device. Transfer case front
half may fall and cause
52
(29) Attach three straps (4) to transfer case front
half (19).
CAUTION
Lift transfer case front half
straight up to prevent possible
damage to shift rod.
(30) Lift transfer case front half (19) from rear
half (2) while assistant operates suitable 51
lifting device. Place on flat surface.
(31) Remove two screws (50) from transfer case
rear half (2). 2
50 51
23--5
TM 9--2320--360--34--2
(32) Place clean shop rag between center shaft

assembly (53) and input shaft 55
assembly (54).
56
(33) Remove two screws (55) and retainer plate 57
(56) from end of center shaft assembly (53).
(34) Remove shop rag.
(35) Install lifting eye (57) on center shaft 58
53
assembly (53).
59
WARNING
Center shaft weighs 140 lb (64 60
kg). Stay clear of center shaft
when supported by lifting 2
device. Center shaft may fall
and cause serious injury to
personnel.
(36) Remove center shaft assembly (53) from
transfer case rear half (2) while assistant
operates suitable lifting device.
NOTE
Check that eight spring disks
and spacer are removed with
lower shift rod.
(37) Remove lower shift fork assembly (58) with 54

spacer (59) and eight spring disks (60) from
transfer case rear half (2).
23--6
TM 9--2320--360--34--2
(38) Install lifting eye (57) in input shaft

assembly (54).
WARNING
Input shaft weighs 110 lb (50
kg). Stay clear of input shaft
device. Input shaft may fall
and cause serious injury to 65
personnel.
66
NOTE
· Inner detent ball will fall out 67
62
of bottom of transfer case
rear half when upper shift
rod is removed. 57
· Fork assembly and shaft
69 61
assembly must be removed
simultaneously to prevent
binding.
· Spacers are different in
68
length. Mark for proper
assembly.
(39) Remove input shaft assembly (54), upper

shift fork assembly (61), and two spacers
(62) and 63) from transfer case rear half (2)
while assistant operates suitable lifting
54
device. 63
(40) Remove inner spring (64) from transfer case
rear half (2).
64
(41) Remove six screws (65) and washers (66)
from transfer case rear half (2).
(42) Using soft--faced hammer, remove bearing
support (67) from transfer case rear half (2). 2
WARNING
Lower rear output shaft
weighs 110 lb (50 kg). Stay
clear of output shaft when
Lower rear output shaft may
fall and cause serious injury
to personnel.
(43) Remove lower rear output shaft assembly
(68) from transfer case rear half (2).
NOTE
Do step (44) if bearing or race
fail inspection.
(44) Remove outer race (69) from bearing

support (67).
23--7
TM 9--2320--360--34--2

74.2 74.1 70
75
74.3 71
77 72
(45) Turn transfer case rear half (2) so outside
surface faces up.
NOTE 78 74
Tag and mark shims before
removal. 73
80
(46) Remove six screws (70), lockwashers (71),
upper end cap (72), and shims (73) from
transfer case rear half (2). Discard 79
lockwashers.
(47) Remove plug (74) from upper end cap (72). 2
(47.1) Remove two screws (74.1), washers (74.2),
and cover plate (74.3) from adapter end
plate (77).
(48) Remove six screws (75), adapter end plate
(77), and shims (78) from transfer case rear
half (2).
NOTE 83
Do step (49) if bearings or races 81
fail inspection.
(49) Remove two outer races (79 and 80) from 84

82
85
86
(50) Remove seal (81) from lower end cap (82).

Discard seal.
(51) Remove six screws (83), lockwashers (84), 2
lower end cap (82), and shims (85) from
NOTE
Do step (52) if bearings or races
fail inspection.
(52) Remove outer race (86) from transfer case

rear half (2).
23--8
TM 9--2320--360--34--2
NOTE
Inner bearing races may fall out.
(53) Turn transfer case front half (19) so outside

surface faces up.
89 87
(54) Remove seal (87) from upper end cap (88).
Discard seal.
90
88
and upper end cap (88) from transfer case
front half (19). Discard lockwashers.
91
19
NOTE 92
Do step (56) if bearings or races 93
fail inspection.
(56) Remove two outer races (91 and 92) from 94

transfer case front half (19).
(57) Remove seal (93) from transfer case front
half (19). Discard seal.
(58) Remove pilot ring (94) from transfer case
front half (19).
NOTE
Do step (59) if dowel pins fail
inspection.
(59) Remove two dowel pins (95) from transfer 95

case front half (19).
96
WARNING 97
personnel.
18
NOTE
Yoke may be used to hold shaft
when removing screws.
(60) Remove two screws (96), pump drive plate

(97), and teflon piston ring (98) from input
shaft (18). Discard teflon piston ring.
23--9
TM 9--2320--360--34--2
99
100
(61) Remove bearing (99), spacer (100), and

large gear (101) from input shaft (18) using 101
puller.
18
102
103
102
104
105
(62) Remove two needle bearings (102), spacer
(103), and spacer (104) from input
shaft (18).
(63) Remove shift collar (105) from input 18

shaft (18).
23--10
TM 9--2320--360--34--2
107
108
(64) Position input shaft (18) in press and
support by small gear (106).
109
CAUTION
Properly support shaft during
removal. Shaft may drop
106
suddenly. Failure to comply
may result in damage to
equipment.
(65) Press top input shaft (18) out of spacer

(107), bearing (108), spacer (109), and
gear (106).
18
110
(66) Remove two needle bearings (110) and 111

spacer (111) from input shaft (18).
(67) Remove spacer (112) from input shaft (18). 110
112
18
WARNING 113
Center shaft weighs 140 lb (64
personnel.
(68) Remove bearing cone (113) from center
shaft (114).
23--11
TM 9--2320--360--34--2

114.1
114.2
115
(69) Turn center shaft (114) over so that smaller 114

gear is up.
(69.1) Remove two screws (114.1) and drive
coupling (114.2) from center shaft (114).
(70) Remove bearing cone (115) from center
shaft (114).
WARNING
Lower rear output shaft
weighs 110 lb (50 kg). Stay 116
clear of input shaft when
Lower rear output shaft may
fall and cause serious injury 117
to personnel.
NOTE
Perform disassembly if bearings
or bushing fail inspection.
(71) Remove bearing cone (116) from shaft

assembly (117).
118
119
117
(72) Turn rear output shaft (117) over.
(73) Remove bearing cone (118) from rear output
shaft assembly (117).
(74) Remove bushing (119) from rear output
shaft (117).
23--12
TM 9--2320--360--34--2
NOTE
Mark plug location for ease of
assembly.
(75) Remove plug (120) from lower front bearing

cap (23).
(76) Place bearing cap (23) in press. Press front
output shaft (16) from lower front bearing
cap (23).
(77) Remove bearing cone (121) from front

output shaft (16).
(78) Remove bearing cup (122) from lower front
bearing cap (23).
(79) Remove two spacers (123) from lower front
bearing cap (23).
(80) Press outer race (124), bearing (125), and

seal (126) from lower front bearing cap (23).
Discard seal.
23--13
TM 9--2320--360--34--2
23--2. TRANSFER CASE REPAIR (CONT) 127
128
(81) Cut lockwire (127) holding two screws (128).
(82) Remove two screws (128) and upper shift
rod (39) from fork (129). 129
(83) Remove spacer (59) and eight spring

disks (60). 39
(84) Cut lockwire (130) holding screw (131).
(85) Remove screw (131) from fork (132).
(86) Slide shift rod (133) from fork (132).
(87) Remove stud (134) from lower shift
rod (133). 134
59
60
133
132
b. Cleaning/Inspection 130
WARNING 131
Solvent cleaning compound MIL-PRF-680 Type II and III may be irritating to the eyes and skin. Use protective gloves and goggles. Use
in well-ventilated areas. Use respirator as needed. Accidental ingestion can cause irritation of digestive tract and respiratory tract, may
cause lung and central nervous system damage. Can be fatal if swallowed. Inhalation of high/massive concentrations can cause coma
or be fatal. First aid for ingestion: do not induce vomiting. Seek immediate medical attention. First aid for skin contact: remove
contaminated clothing. Wash skin thoroughly with soap and water. If symptoms persist, seek medical attention. First aid for eye contact:
flush with water for 15 minutes or until irritation subsides. If symptoms persist, seek medical attention. First aid for inhalation: move to
fresh air. If not breathing, provide artificial respiration. If symptoms persist, seek medical attention. Keep away from open flames and

(2) Clean all sealing surfaces.
23--14
TM 9--2320--360--34--2
WARNING
(3) Dry all parts, except bearings, with compressed air. Allow bearings to air dry.
(4) Inspect bearings for corrosion, scoring, pitting, or other damage.
(5) Inspect all machined surfaces for nicks, burrs, or scratches. Remove defects with
crocus cloth.
(6) Inspect both case halves for cracks or damage.
(7) Inspect all threads for peeled or crossed condition.
(8) Replace all oil seals and damaged parts.
c. Assembly
(1) Coat threads of stud (1) with grease.
1
(2) Install stud (1) in shift rod (2). Torque to
15 lb--ft (20 N.m).
8
(3) Slide shift rod (2) in fork (3).
WARNING
Adhesive--sealant can burn 7
soap and water.
(4) Coat threads of screw (4) with adhesive-- 3
sealant (Item 6, Appendix B).
(5) Align holes (5) in fork (3) and shift rod (2)
and install screw (4). Torque to 40 lb--ft
(54 N.m).
6
(6) Secure screw (4) with lockwire (6).
(7) Install eight spring disks (7), alternating
concaved surfaces, in pairs, and spacer (8) 5
on shift rod (2). 4
23--15
TM 9--2320--360--34--2
(8) Slide shift rod (9) on fork (10).
WARNING
10
soap and water.
(9) Coat threads of two screws (11) with
adhesive--sealant (Item 6, Appendix B). 11
12
(10) Install two screws (11) on fork (10). Torque 14

to 40 lb--ft (54 N.m).
(11) Secure two screws (11) together with
lockwire (12).
(12) Install two spacers (13) in bearing cap (14).

13
15
14
(13) Press bearing cup (15) and bearing cup (16) 13

in bearing cap (14). Seat against
spacers (13).
16
23--16
TM 9--2320--360--34--2
(14) Place inner bearing cone (17) on spline end

of output shaft (18). Press to seat against
shoulder of shaft.
17
18
16
14
(15) Install bearing cap (14) on splined end of

output shaft (18) until inner bearing cone
(17) is firmly seated in bearing cup (16).
18
17
19
(16) Place outer bearing cone (19) on spline end

of output shaft (18).
18
(17) Press to seat outer bearing cone (19) in
bearing cup (15). 15
23--17
TM 9--2320--360--34--2

21
WARNING
soap and water.
sealing compound. Install plug in bearing
cap (14).
(19) Install new seal (21) on bearing cap (14).
22
23
(20) Press bearing cone (22) on lower rear

output shaft (23).
(21) Coat bearing cone (22) with grease.
25
24
(22) Turn lower rear output shaft (23) over.
(23) Press bearing cone (24) on lower rear
output shaft (23). 23
(24) Coat bearing cone (24) with grease.
(25) Install bushing (25) in lower rear output
shaft (23).
23--18
TM 9--2320--360--34--2
WARNING
Center shaft weighs 140 lb (64
personnel. 26
(26) Place center shaft (26) in press with large
gear up using lifting device.
(27) Press bearing cone (27) on center
shaft (26).
(28) Turn center shaft (26) over in press so that

smaller gear is up.
28
(29) Install bearing cone (28).
WARNING 26
Adhesive sealant can burn
soap and water.
(29.1) Coat threads of two screw holes in center
shaft (26) with adhesive--sealant
(Item 6, Appendix B).
(29.2) Install drive coupling (28.1) on center shaft
(26) with two screws (28.2). Torque to 31
40 lb--ft (54 N.m).
(30) Remove center shaft (26) from press with 32
lifting device.
31
30
WARNING
29
personnel.
(31) Place top input shaft (29) in press so spline

end is up.
(32) Install spacer (30), needle bearing (31),
spacer (32), and needle bearing (31).
23--19
TM 9--2320--360--34--2
33
(33) Coat two needle bearings (31) with grease.

29
(34) Install gear (33) with small teeth down on
top input shaft (29). Seat against spacer
(30). 31
30
35
34
29
(35) Install spacer (34) on top input shaft (29).
(36) Press bearing (35) to seat against

spacer (34).
37
38
37
36
29
(37) Turn top input shaft (29) over and support

gear (33). 33
(38) Install spacer (36), needle bearing (37),

spacer (38), and needle bearing (37).
23--20
TM 9--2320--360--34--2
(39) Install shift collar (39) with larger taper up on

input shaft (29).
39
29
42
(40) Coat two needle bearings (37) with grease.
(41) Install large gear (40) over top input shaft 41
(29) with collar gears facing down.
(42) Install spacer (41) over top input shaft (29).
40
NOTE
Yoke may be used to hold shaft
when installing screws. 29
37
(43) Press bearing (42) to seat against
spacer (41).
43
WARNING
45
Adhesive sealant can burn
soap and water.
adhesive--sealant (Item 5, Appendix B).
(45) Install new piston ring (44) and pump drive
plate (45) on input shaft (29) with screws
(43). Torque to 60 lb--ft (81 N.m).
23--21
TM 9--2320--360--34--2

50
54
53
47
NOTE 52
Only the shims removed during
disassembly are installed at this
time. 46
55
(46) Install center shims (46) and adapter end 48 51
plate (47) in transfer case rear half (48) with
six screws (50). Torque to 60 lb--ft (81 N.m).
NOTE
Align oil port on bearing housing
with port on transfer case rear
half.
(47) Install upper shims (51) and bearing housing

(52) in transfer case rear half (48) with six
to 60 lb--ft (81 N.m).
59
WARNING
soap and water.
56
sealing compound.
(49) Install plug (55) in bearing housing (52).
48
NOTE
Only the shims removed during
disassembly are installed at this
time.
(50) Install shims (56) and lower end cap (57) in

transfer case rear half (48) with six new
to 60 lb--ft (81 N.m).
(51) Turn transfer case rear half (48) over.
23--22
TM 9--2320--360--34--2
(52) Coat lower bearing outer race (60) with

grease. 64
(53) Install lower bearing outer race (60) in 65
63
WARNING
Be careful not to trap hands
between gear assembly and 62
transfer case. Injury to
personnel may result.
61
(54) Install rear output shaft assembly (61) in
transfer case rear half (48) through lower
bearing outer race (60).
(55) Coat upper bearing race (62) with grease.
60
NOTE
Do step (56) if bearing race was 48
removed.
(56) Install upper bearing outer race (62) in

bearing retaining plate (63).
WARNING
soap and water.
(57) Coat threads of six screws (64) with 67

(58) Install bearing retaining plate (63) on 66 48
transfer case rear half (48) with six washers
(65) and screws (64). Torque to 88 lb--ft 23
(119 N.m).
(59) Turn transfer case rear half (48) over so
outside surface faces up.
(60) Install screw (66) in lower rear output
shaft (23).
(61) Lightly tap down on lower rear output shaft
(23) to seat bearings.
(62) Install dial indicator (67) on rear output
shaft (23).
(63) Pry up on screw (66).
23--23
TM 9--2320--360--34--2

67
NOTE
End play must be 0.003--0.006
66 48
in. (0.076--0.15 mm). If end play
is less than 0.003 in. (0.076
23
mm), shims must be added. If
end play is greater than 0.006
in. (0.15 mm), shims must be
removed.
(64) Check and record end play measured on

dial indicator (67).
(65) Remove screw (66) and dial indicator (67)
from lower rear output shaft (23).

lower end cap (57), and shims (56) from
transfer case rear half (48). Discard
lockwashers. 59 68
WARNING
58
soap and water. 56
(67) Coat shims (56) and screws (59) with

NOTE 48
The number of shims installed is
amount required to obtain
correct end play.
(68) Install shims (56) and lower end cap (57) on

transfer case rear half (48) with six new
to 60 lb--ft (81 N.m).
NOTE
Seal is installed with numbered
side out.
(69) Install new seal (68) in lower end cap (57).
23--24
TM 9--2320--360--34--2
(70) Install top bearing race (69) and center

bearing race (70) in transfer case rear
half (48).
(71) Install spring (71) and ball (72) in transfer
case rear half (48). Hold spring and ball in
place with dummy shaft (73).
(72) Coat shaft of upper shift fork assembly (74)
with grease.
77
(73) Install lifting eye (75) in top input shaft (29).
75
WARNING
Input shaft weighs 110 lb (50 29
74
and cause serious injury to 70
personnel.
78
NOTE
69
· End of fork shift rod with 48
threaded hole must face up.
· Shift fork will push dummy
shaft out during assembly.
· The cutoff part of fork faces 72
center shaft. 71
· Fork assembly and shaft

assembly must be installed
simultaneously to prevent
binding.
(74) Install top input shaft assembly (76), shift

fork (74), and two spacers (77 and 78) in
transfer case rear half (48) while assistant
(75) Remove lifting eye (75) from top input 73
shaft (29).
23--25
TM 9--2320--360--34--2
(76) Install lifting eye (75) in center shaft (26).

75
81
WARNING
Center shaft weighs 140 lb (64 80
personnel. 26
(77) Install center shaft assembly (79) in transfer

case rear half (48) while assistant operates 82
lifting device.
(78) Remove lifting eye (75) from center
shaft (26).
79
83
WARNING
soap and water.
48
(79) Coat holes in retainer plate (80) and two
screws (81) with adhesive--sealant (Item 6,
Appendix B).
(80) Install retainer plate (80) on center shaft (26)
with two screws (81). Torque to 40 lb--ft
(54 N.m).
NOTE
Lip on collar should face top of
case.
(81) Install collar (82) on lower fork

assembly (83).
(82) Coat hole (84) in bearing retaining plate (63)
and shaft of lower shift fork assembly (83)
with grease.
(83) Install lower shift fork assembly (83) in
bearing retaining plate (63).
23--26
TM 9--2320--360--34--2
(84) Coat shafts of upper shift fork assembly (74)

and lower shift fork assembly (83) with
grease.
(85) Coat bushing (25), hole in bearing retaining
plate (63), and bearing cone (24) with
grease.
WARNING
soap and water.
(86) Coat inner edge of flange on transfer case
rear half (48), just inside holes, with
NOTE 63
25
Do step (87) if dowel pins were 24 85
removed.
(87) Install two dowel pins (85) on transfer case 72

front half (86).
83
CAUTION
Lower transfer case front half
straight down to prevent
possible damage to shift rod.
(88) Lower transfer case front half (86) onto

transfer case rear half (48) while aligning
dowel pins (85) while assistant operates
suitable lifting device.
(89) Coat threads of screws (87) with adhesive--
sealant (Item 6, Appendix B). 48
(90) Install 20 screws (87) in housing. Torque to
88 lb--ft (119 N.m).
48
23--27
TM 9--2320--360--34--2

89
90
WARNING
soap and water.
86
(91) Coat area in and around lower opening (88)
with adhesive--sealant (Item 3, Appendix B).
(92) Coat threads of screws (89) with
(93) Install bearing cap (14) on transfer case
front half (86) with new lockwashers (90)
and screws (89). Torque to 60 lb--ft (81N.m).
(94) Install bearing races (91 and 92) in transfer
case front half (86).
98
97
(95) Coat mating surfaces of upper end cap (93) 99

and end cap (94) with adhesive--sealant
(Item 3, Appendix B). 94
95 93
sealant (Item 6, Appendix B). 86 96
(97) Install upper end cap (93) on transfer case
front half (86) with six new lockwashers (96)
and screws (95). Torque to 60 lb--ft (81 N.m).
NOTE
side up.
(98) Install new seal (97) in upper end cap (93).
(100) Install end cap (94) on transfer case front
half (86) with six new lockwashers (99) and
screws (98). Torque to 60 lb--ft (81 N.m).
(101) Install end play adapter (100) in center hole
(101) of end cap (94).
23--28
TM 9--2320--360--34--2
(102) Turn transfer case (102) over so rear half

(48) faces up.
100
(103) Lightly tap down on center shaft (26)
through hole (103) in adapter end plate (47) 101
to seat bearings.
94
(104) Install dial indicator (67) through hole (103)
in adapter end plate (47).
CAUTION
Do not overtighten end play
adapter screw. Damage to
center shaft end plate may
result.
(105) Turn end play adapter screw (100) clockwise

until tight. 102
NOTE
End play must be 0.003--0.006
in. (0.076--0.15 mm). If end play
48
is less than 0.003 in. (0.076
in. (0.15 mm), shims must be 103 67
removed. 47
26
(107) Remove end play adapter (100) from end
cap (94).
(108) Remove dial indicator (67) from adapter end
plate (47).
47
100
23--29
TM 9--2320--360--34--2

103.1 103.3
(109) Remove six screws (50), adapter end plate
(47), and shims (46) from rear half (48). 50 103.2
WARNING 47
soap and water.
NOTE
correct end play.
(111) Install shims (46) and adapter end plate (47)

on rear half (48) with six screws (50).
(111.1) Install cover plate (103.1) on adapter end
plate (47) with two washers (103.2) and
screws (103.3). 102
(112) Turn transfer case (102) over so front half
67
(86) faces up.
(113) Install screw (66) in front input shaft (29).
66
(114) Lightly tap down on front input shaft (29) to
seat bearings.
66
(115) Install dial indicator (67) on front input 86
shaft (29).
(116) Pry up on screw (66) on front input shaft (29).
NOTE
End play must be 0.003--0.006 29
in. (0.076--0.15 mm). If end play
is less than 0.003 in (0.076
in. (0.15 mm), shims must be
removed.

102
(118) Remove screw (66) and dial indicator (67)
from front input shaft (29).
23--30
TM 9--2320--360--34--2
NOTE 54
If end play is within specifica-
tions, go to step (123). If not, go 53
to step (119).
52
(48) faces up.
51
bearing housing (52), and shims (51) from
rear half (48). Discard lockwasher.
WARNING 48
soap and water. 102

NOTE
correct end play.
(122) Install shims (51) and bearing housing (52)

on rear half (48) with six new lockwashers
(53) and screws (54). Torque to 60 lb--ft
(81 N.m).
23--31
TM 9--2320--360--34--2
111
WARNING 110
soap and water.
sealing compound.
(124) Install detent ball (105), spring (106), and
plug (104) in transfer case front half (86).
(125) Install speedo drive shaft (107), spring
(108), thrust washer (109), and thrust
bearing (110) through end cap (94).
(126) Install reducer (111) in end cap (94).
NOTE
Speedo drive shaft may fall out
if not retained.
(127) Install tape on reducer (111) to retain speedo 113 118

drive shaft (107). 112
117
119 14
114
86 116
(128) Install elbow (112) and hose (113) on
bearing cap (14).
(129) Install elbow (114) and hose (113) on 115
transfer case front half (86).
(130) Install seal (115), actuator plate (116), jam 74
nut (117), and shift rod end (118) on upper
shift rod (74).
(131) Install pilot ring (119) in transfer case front
half (86).
23--32
TM 9--2320--360--34--2

(48) faces up.
126
120
WARNING 122 125
123
124
121
soap and water.
(133) Coat threads of plug (120), strainer (121),
and elbow (122) with pipe thread sealing
compound.
(134) Install plug (120) in transfer case rear
half (48).
(135) Install adapter strainer (121), elbow (122),
and lube pump oil supply hose (123) on
(136) Install shift cover (124) on transfer case rear
half (48) with new lockwashers (125) and
screws (126). 102
WARNING 29
On direct contact, uncured
silicone sealant irritates eyes.
In case of contact, flush eyes 23
with water and seek medical
attention. In case of skin
contact, wipe off and flush
with water.
(137) Coat ends and splines of shaft (18), shaft
(23), and shaft (29) with silicone adhesive--
sealant.
18
23--33
TM 9--2320--360--34--2
WARNING
soap and water.
(138) Coat threads of three screws (127, 128,

and 129) with adhesive--sealant
(139) Install spacer (130), input yoke (131),
retainer (132), and screw (127) on input
shaft (29). Torque to 375 lb--ft (508 N.m).
(140) Install front output yoke (133), retainer (132),
and screw (128) on front output shaft (18).
(141) Install rear output yoke (133), retainer
(134), washer (135), and screw (129) on
rear output shaft (23). Torque to 308 lb--ft
(418 N.m).
129
29
135
133 134
130
131
132
127
23
18
133
132
128
23--34
TM 9--2320--360--34--2
(142) Deleted.
WARNING
Transfer case weighs 965 lb
(438 kg). Stay clear of transfer
case when supported by lifting
device. Transfer case may fall
personnel.
(143) Remove four screws (136) and two adapters

(137) from transmission holding fixture
(138).
(144) Remove four screws (139) and two adapters
(137) from rear transfer case housing (48).
138 136
(145) Remove four screws (140) and transmission
holding fixture (138) from engine stand
(141).
141 139
137
48
140
(1) Install breather (TM 9--2320--360--20).
(2) Install lockout shift chamber (TM 9--2320--360--20)
(3) Install lubrication pump (para 8--7).
23--35
TM 9--2320--360--34--2
23--3. LUBRICATION PUMP REPAIR
This task covers:

INITIAL SETUP

Lubrication pump on clean work surface Grease, Automotive and Artillery (Item 32,
Appendix B)
Tools and Special Tools Paper, Abrasive, Garnet (Item 49, Appendix B)
Packings, Preformed (2) (Item 173, Appendix F)
Seal (Item 290, Appendix F)
a. Disassembly
NOTE
Alignment sleeves may come
out with head.
(1) Remove two screws (1), head (2), and 1

preformed packing (3) from casing (4).
Discard preformed packing. 2
(2) Remove shaft (5) with gear (6) from
casing (4).
(3) Remove shaft (7) with gear (8) from
casing (4). 6
4 5
3
7
4
8
11
10
(4) Remove casing (4) and preformed packing
(9) from end plate (10). Discard preformed
packing.
12
(5) Remove two alignment sleeves (11) from
end plate (10).
(6) Remove seal (12) from end plate (10).
Discard seal.
23--36
TM 9--2320--360--34--2
WARNING
and goggles. Use in well-ventilated areas. Use respirator as needed. Accidental ingestion can cause irritation of digestive t
ract and respiratory tract, may cause lung and central nervous system damage. Can be fatal if swallowed. Inhalation of high/
persist, seek medical attention. First aid for eye contact: flush with water for 15 minutes or until irritation subsides. If s
ymptoms persist, seek medical attention. First aid for inhalation: move to fresh air. If not breathing, provide artificial respiration.
If symptoms persist, seek medical attention. Keep away from open flames and other sources of ignition. Failure to follow this
•loths or rags saturated with solvent cleaning compound must be disposed of IAW authorized facilities' 5
•Eye shields must be worn when cleaning with a wire brush. Flying rust and metal particles may
cause injury.
4
3
2
(2) Inspect all parts for wear or damage.
1
(3) Replace all worn or damaged parts.
c. Assembly
NOTE
Install seal with lip away from
bracket.
(1) Coat new seal (1) with grease and install in 10
end plate (2).
(2) Install two alignment sleeves (3) in end plate (2). 9
(3) Install new preformed packing (4) on casing (5).
NOTE
Install casing with preformed
packing facing bracket.
(4) Install casing (5) in end plate (2).
6
(5) Install shaft (6) in casing (5) and end plate
(2) until end of shaft extends 1--5/8 in.
(41.3 mm).
(6) Install shaft (7) in casing (5) and end 8
plate (2).
(7) Coat new preformed packing (8) with
7
grease and install on head (9).
(8) Align screw holes in head (9) with
sleeves (3).
5
NOTE
Install head with preformed 2
packing facing casing.
(9) Install head (9) on casing (5) and end plate
(2) with two screws (10).
23--37/(23--3823
blank)
--37
TM 9--2320--360--34--2
23--38
TM 9--2320--360--34--2
CHAPTER 24
FRONT AXLE MAINTENANCE
Contents Para Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24--1 24--1
Axle No. 1 Differential Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24--2 24--2
24--1. INTRODUCTION
This chapter contains maintenance instructions for repair of axle no. 1 at the General Support
maintenance level. Some subassemblies and parts must be removed before axle components
can be accessed. They are referenced to other paragraphs of this manual.
24--1
TM 9--2320--360--34--2
24--2. AXLE NO. 1 DIFFERENTIAL REPAIR
This task covers:

c. Cleaning/Inspection f. Follow--on Maintenance
INITIAL SETUP

Pivot, spindle, and axle shaft Adhesive--Sealant, Silicone (Item 2, Appendix B)
removed (para 9--4). Adhesive--Sealant (Item 6, Appendix B)
Tools and Special Tools Compound, Sealing, Pipe Thread
Tool Kit, Genl Mech (Item 202, Appendix E) (Item 28, Appendix B)
Holder, Yoke (Figure C--15, Appendix C) Dye, Prussian Blue (Item 30, Appendix B)
Gage, Preload, Differential Carrier Oil, Lubricating (Item 44, Appendix B)
(Figure C--16, Appendix C) Cleaning Compound, Solvent (Item 54, Appendix B)
Installer, Bearing Cone (Figure C--20, Tags, Identification (Item 56, Appendix B)
Appendix C) Locknuts (3) (Item 82, Appendix F)
Adapter, Differential Maintenance (Item 0.1, Nut (Item 150, Appendix F)
Appendix E) Seal, Oil (Item 305, Appendix F)
Dial Indicator, Magnetic (Item 32,
Indicator, Dial (Item 74, Appendix E) Two
Multiplier, Torque (Item 99, Appendix E)
Socket, 55 mm (Item 163.1, Appendix E)
Stand, Maintenance, Automotive Axle
Wrench Set, Socket, 1 In. Drive (Item 230,
Appendix E)
Wrench Set, Socket, 3/8 In. Drive (Item 232,
Appendix E)
Appendix E)
Wrench, Torque, 0--150 Lb--In (Item 234,
Appendix E)
Appendix E)
Appendix E)
24--2
TM 9--2320--360--34--2
a. Removal 3
NOTE 6
Matchmark differential and axle
housing. 7
(1) Position axle (1) with differential assembly 8

(2) pointing up. 4
(2) Attach lifting device to yoke (3). 5 2
(3) Remove 11 screws (4) and washers (5) from 1

differential assembly (2).
(4) Remove three locknuts (6), washers (7), and
taper dowels (8) from studs (9). Discard
locknuts.
WARNING
Differential assembly weighs
approximately 260 lb (118 kg).
Stay clear of differential
assembly when it is sup-
9
differential falls, serious
injury or death may result. 10
(5) Lift differential assembly (2) from axle 11
housing (1) while assistant operates lifting 12
device. 13
13
(6) Remove two breather hoses (10) from

elbows (11).
(7) Remove breather (12) and adapter (13) from 14
10
tee (14).
11
(8) Remove tee (14) and adapter (15) from axle 15
housing (1). 3
(9) Remove two elbows (11) from tee (14).
1
2
b. Disassembly
(1) Install adapter (1) on stand (2) with six
screws (3).
(2) Install differential assembly (5) on adapter
(1) with six screws (6). 5
6
(3) Remove lifting device from differential 1
assembly (5).
24--3
TM 9--2320--360--34--2
24--2. AXLE NO. 1 DIFFERENTIAL REPAIR (CONT)

(4) Position differential assembly (5) so pinion
shaft (8) points down.
12
(5) Check backlash of differential (9) to pinion 9
shaft (8).
(6) Hold yoke (10) so that pinion gear (11) does
not move.
13
NOTE
Do not allow pinion gear to turn
while doing steps (7) thru (9).
(7) Turn differential (9) counterclockwise until it

stops to take up backlash.
NOTE
Shaft from dial indicator must be
at right (90o) angle to face of
tooth when in contact.
(8) Install dial indicator (12) on face of

differential gear tooth (13). 5
(9) Turn differential (9) clockwise until it stops.

8 11
NOTE
Backlash should be 0.010-- 10
0.016 in. (25--41 mm). To
increase backlash, reduce
thickness of shims installed in 15.1
carrier housing. To decrease
15
backlash, increase thickness of 14
shims.
(10) Record differential (9) to pinion shaft (8)

backlash measured on dial indicator (12).
18
10 17
16
(11) Unstake nut (14) on yoke (10).
8
(12) Position yoke holder (15) on yoke (10).
(13) Remove nut (14) and yoke (10) from pinion
shaft (8) using yoke holder (15) and socket
(15.1) with aid of assistant.
(14) Remove screw (16) and nut lock plate (17)
from bearing cap (18).
24--4
TM 9--2320--360--34--2
(15) Remove four screws (19) from two bearing

caps (18). 19
18
(16) Remove two bearing caps (18) and
18 20
adjusting nut (20) from differential housing
(21).
(17) Lift differential (9) from housing (21) with the 9
aid of assistant. Place on work surface.
21
NOTE
· Remove taper bearings only
if they fail inspection.
· To remove taper bearing
25
from gear side of 26
differential, first remove 9
cage and rollers from inner
race. Then pry inner race
24
high enough to install puller. 23
· Tag and mark shims before 22
removal.
(18) Remove adjusting shim (22), taper race
(23), and taper bearing (24) from gear side
of differential (9).
(19) Remove taper race (25) and taper bearing 14
(26) from other side of differential (9).
21
CAUTION
During removal of pinion gear,
do not allow gear teeth to
engage with the inside of the
housing and cover assembly. 8
result. 11
(20) Install nut (14) loosely on end of pinion

shaft (8).
(21) Remove pinion gear (11) from housing (21)
while assistant supports pinion gear (11).
(22) Remove and discard nut (14).
24--5
TM 9--2320--360--34--2
27
28
(23) Remove pinion seal (27), taper bearing (28),
and taper race (29) from housing (21).
Discard pinion seal. 29
NOTE 21
Tag and mark shims before
removal.
(24) Remove taper race (30) and shim (31) from

housing (21).
31
30
33
32
(25) Remove taper bearing (32) and shim (33)

from pinion shaft (8).
21
34
(26) Remove filler plug (34) from housing (21).
24--6
TM 9--2320--360--34--2
(1) Clean old gasket material from housing
and/or caps.
WARNING
(2) Clean sealant residue from threaded holes

with solvent cleaning compound.
CAUTION
Wash machined parts separately to avoid damage from parts bumping together.
(3) Wash metal parts in solvent cleaning compound.
WARNING
air. Allow bearings to air dry.
(5) Remove small nicks or burrs with crocus
cloth.
(6) Coat parts with light coat of lubricating oil.
(7) Inspect housing and caps for damage.
(8) Inspect all parts and bearings with machined
surfaces for deep scratches or wear
grooves. 2
1
d. Assembly
(1) Install filler plug (1) in differential
housing (2).
24--7
TM 9--2320--360--34--2

5.1
NOTE
If installing new gear set, record 3
size of pinion gear (engraved on
pinion end). Compare dimen-
sion with new gear set. If new
4
size is larger, pinion gear shims
5
will be thinner.
(2) Coat bearings (3 and 4) with lubricating oil.

(3) Press taper bearing (3) on pinion shaft (5)
using pinion bearing cone installer (5.1).
(3.1) Install shim (6) over end of pinion shaft (5).
NOTE
If small shim thickness is
increased or decreased, large
shim must be changed
accordingly.
7
(4) Install shim (7) and taper race (8) in housing
(2) until fully seated.
8
(5) Install pinion shaft (5) through housing (2).
(6) Install taper race (9) and taper bearing (4)
on pinion shaft (5) while assistant supports
pinion shaft (5). 5
24--8
TM 9--2320--360--34--2
WARNING
or death, keep away from 12.1
soap and water. 12
(7) Coat new pinion seal (10) outer edge with

adhesive--sealant.
NOTE 11
Pinion seal is installed properly
when top of seal is 1/16 in. (1.59
mm) below surface of housing.
10
(8) Install new pinion seal (10) in housing (2).
5
WARNING
In case of contact, flush eyes
with water. 2
(9) Coat splines of pinion shaft (5) with silicone

adhesive--sealant.
(10) Coat threads of pinion shaft (5) with

adhesive--sealant.
NOTE
Yoke should be positioned so
large openings of yoke align
with notches of pinion shaft.
This will ease staking of nut.
(11) Install yoke (11) and new nut (12) on pinion

shaft (5) using socket (12.1). Torque to
486--572 lb--ft (659--775 N.m).
(12) Stake edge of nut (12) in notches of pinion

shaft (5) directly 180 degrees apart.
(13) Check pinion preload by turning nut (12)

with torque wrench. Torque should be
38--48 lb--in. (4.31--5.44 N.m).
24--9
TM 9--2320--360--34--2
(14) Install taper bearings (13 and 14) on

differential gear (15).
17
NOTE 13
If thickness of pinion gear shims 15
increased, differential shim must
be decreased by same amount. 14
decreased, differential shim
16
must be increased by same
amount. Refer to TM
9--2320--360--34P for proper
identification of parts.
(15) Measure thickness of shim (16) and change

thickness if necessary.
(16) Install differential gear (15), bearing races
(17 and 18), and shim (16) in differential
housing (2).
19
WARNING 20 20
sealant gets on skin or
(17) Coat threads of capscrews (19) with

adhesive--sealant.
(18) Install two bearing caps (20) on housing (2)
with four capscrews (19). Torque to 25 2
lb--in. (2.82 N.m).
(19) Install adjusting nut (21) in bearing cap (20).
24--10
TM 9--2320--360--34--2
(20) Install differential carrier preload gage (22)

on bearing cap (20) with screw (24).
(20.1) Position magnetic base of dial indicator (23)
on bearing cap (20).
(20.2) Position probe of dial indicator (23) on
differential carrier preload gage (22). 20
25 19
(20.3) Zero dial indicator (23). 24
(21) Tighten adjusting nut (21) until bearing caps

(20) expand 0.013--0.017 in. (.33--.43 mm).
(21.1) Remove screw (24), differential carrier
preload gage (22) and dial indicator (23)
from bearing caps (20). 22
23
21
(22) Tighten capscrews (19) to 125 lb--ft 24
(169 N.m).
(23) Coat capscrew (24) with adhesive--sealant.
(24) Install capscrew (24) in lockplate (25) and
bearing cap (20). Torque to 132--216 lb--in.
(14.9--24.4 N.m).
20
shaft (5).
(26) Hold yoke (11) so that pinion gear (26) does
not move.
NOTE
Do not allow pinion gear to turn 15

stops to take up backlash. 22
15
NOTE
Shaft from dial indicator must be 27
tooth when in contact. 28

differential gear tooth (27).
NOTE
Backlash should be 0.010--
0.013 in. (0.25--0.33 mm). To 11
increase backlash, reduce 26
thickness of shim. To decrease 5
backlash, increase thickness of
shim.

24--11
TM 9--2320--360--34--2
(31) Coat gear teeth of ring gear (28) with

prussian blue dye. Check for correct pattern
by rotation. Remove and adjust shims as 6
necessary.
TOOTH
DEPTH
ROOT
HEEL
TOP LAND
TOE
7
RING GEAR TOOTH NOMENCLATURE
5
NOTE
Any time pinion depth is
changed, backlash may change.
Check and adjust backlash as 28
needed. A correct pattern is
clear of toe and centers evenly
along width of face between top
land and root. Length and
shape of pattern may vary and
is acceptable as long as pattern
does not run off tooth at any
point. 16
(32) Move ring gear (28) away from pinion shaft
(5) by using a thinner shim (16) and thicker
shims (6) and (7) if pattern is too close to top
of tooth.

shims (6) and (7) if pattern is too close or off
tooth root.
(34) Move ring gear (28) toward pinion shaft (5)

by using a thicker shim (16) and thinner
tooth heel.

shims (6) and (7) if pattern is too close to
bottom of tooth.
24--12
TM 9--2320--360--34--2
e. Installation
(1) Attach lifting device to yoke (1).
(2) Remove six screws (2) and differential
assembly (4) from adapter (5).
WARNING
On direct contact, uncured 1
In case of contact, flush eyes 4 2
5
with water.
(3) Coat around mounting flange of differential
assembly (4) with silicone adhesive--sealant.
WARNING
Stay clear of differential
assembly when it is sup-
differential falls, serious
(4) Install differential assembly (4) on axle

device.
10
WARNING 1
11 8
open flame and use in well--
4
soap and water.
(5) Coat three studs (7) with adhesive--sealant.

Install three taper dowels (8), washers (9)
and nuts (10) on studs (7). Torque to
140--152 lb--ft (190--206 N.m). 7
(6) Coat 11 screws (11) with adhesive--sealant.
Install washers (12) and screws (11) in
differential assembly (4). Torque to
140--152 lb--ft (190--206 N.m).
24--13
TM 9--2320--360--34--2
WARNING
soap and water.
(7) Coat threads of two elbows (13), adapter
(14), adapter (15), and breather (16) with
(8) Install two elbows (13) on tee (17).
(9) Install tee (17) and adapter (14) in axle
6
housing (6).
(10) Install adapter (15) and breather (16) on
tee (17).
(11) Install two breather hoses (18) on elbows 18
(13).
16
15
13
18
17
13
14
Install axle shafts, pivots, and spindles (para 9--4).
24--14
TM 9--2320--360--34--2
CHAPTER 25
REAR AXLES MAINTENANCE
Contents Para Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25--1 25--1
25--1. INTRODUCTION
This chapter contains maintenance instructions for repair of axle no. 2, axle no. 3, and axle no. 4 at the
General Support maintenance level. Some subassemblies and parts must be removed before axle
components can be removed. They are referenced to other paragraphs of this manual.
25--1
TM 9--2320--360--34--2
This task covers:

INITIAL SETUP

Oil drained from differential assembly Wrench Set, Socket, 3/8 In. Drive (Item 232,
(LO 9--2320--360--12). Appendix E)
Axle manifold removed (TM 9--2320--360--20). Wrench, Torque, 600 Lb--Ft (Item 233,
Brake chambers removed Appendix E)
(TM 9--2320--360--20). Wrench, Torque, 150 Lb--In. (Item 234,
Axle shafts removed (para 10--8). Appendix E)
Tool Kit, Genl Mech (Item 202, Appendix E) Wrench, Torque, 0--175 Lb--Ft (Item 236,
Blocks, Wooden (Figure C--3, Appendix C) Appendix E)
Extractor, Jet (Figure C--11, Appendix C)
Holder, Yoke (Figure C--15, Appendix C) Materials/Parts
Gage, Preload, DIfferential Carrier Adhesive--Sealant, Silicone (Item 2,
Figure C--16, Appendix C) Appendix B)
Installer, Bearing Cone (Figure C--20, Adhesive--Sealant (Item 3, Appendix B)
Appendix C) Adhesive--Sealant (Item 4, Appendix B)
Adapter, Differential Maintenance Adhesive--Sealant (Item 6, Appendix B)
(Item 0.1, Appendix E) Cloth, Crocus (Item 16, Appendix B)
Caliper Set, Micrometer (Item 15, Appendix E) Compound, Sealing, Pipe Thread
Crowbar (Item 30, Appendix E) (Item 28, Appendix B)
Dial Indicator, Magnetic (Item 32, Dye, Prussian Blue (Item 30, Appendix B)
Appendix E) Grease, Ball Bearing (Item 33, Appendix B)
Goggles, Industrial (Item 57, Appendix E) Oil, Lubricating (Item 48, Appendix B)
Multiplier, Torque (Item 99, Appendix E) Rags (Item 51, Appendix B)
Press, Hydraulic (Item 116, Appendix E) Cleaning Compound, Solvent (Item 54, Appendix B)
Puller Kit, Mechanical, Gear and Brg Tags, Identification (Item 56, Appendix B)
(Item 124, Appendix E) Locknuts (14) (Item 82, Appendix F)
Remover/Setter, Stud (Item 137, Appendix E) Locknuts (5) (Item 96, Appendix F)
Sling, Endless Strap (Item 161, Appendix E) Nuts (2) (Item 149, Appendix F)
Socket, 63 mm (Item 163.2, Appendix E) Nut (Item 146, Appendix F)
Socket, Sockethead Screw, 10 mm Packings, Preformed (Item 166, Appendix F)
(Item 175, Appendix E) Packing, Preformed (Item 174, Appendix F)
Socket, Spanner (Item 176, Appendix E) Seals, Oil (2) (Item 305, Appendix F)
Socket, Spanner (Item 177, Appendix E)
Socket, Spanner (Item 178, Appendix E) Personnel Required
Stand, Engine (Item 181, Appendix E) Two
Appendix E)
Appendix E)
25--2
TM 9--2320--360--34--2
a. Removal
1 3
(1) Remove five locknuts (1), screws (2), 4
cushion clips (3), and six hoses (4) from axle
housing (5). Discard locknuts.
2
3 1
4 2
4
2 2
3
2 3
3
1
WARNING
Axle weighs 2160 lb (981 kg).
Use caution when lifting or
moving axle. Failure to do so
may result in serious injury or
death to personnel.
(2) Attach suitable lifting device to axle housing

(5) and install in axle stand with aid of
assistant.
(3) Unstake nut (6) on output yoke (7).
5
(5) Remove nut (6) and output yoke (7) from
output housing (9) using socket (9.1) with
aid of assistant. Discard nut.
8
9.1 9
25--3
TM 9--2320--360--34--2
(6) Remove nut (10) from output housing (9).

(7) Remove seal (11) from output housing (9).
(8) Remove spanner nut (12) from output
housing (9) using socket (13).
(9) Remove seven screws (14), clip (15), and
rear output housing (9) from differential
assembly (16). 9
11
10
(10) Remove four locknuts (17) and washers (18) 16
15
from axle housing (5). 14
WARNING
Axle weighs 2160 lb (980 kg).
Use caution when lifting or
moving axle. Failure to do so
may result in serious injury or
death to personnel.
13
(11) Position axle housing (5) in stand so input 9 12
yoke (19) is pointing up.
WARNING
Differential assembly weighs 19
Use caution while lifting or
moving differential assembly.
Failure to do so may result in 20
serious injury to personnel. 16
21
(12) Attach three lifting straps to differential
assembly (16).
NOTE
Studs may come out of housing
rather than nuts from studs. 23
(13) Remove 10 locknuts (20) and washers (21)
from studs (22). Discard locknuts. 22
(14) Separate differential assembly (16) from 5

axle housing (5) while assistant operates 18
lifting device. 17
NOTE
Studs may come out of housing
rather than nuts from studs.
(15) Remove four studs (23) from differential

assembly (16).
25--4
TM 9--2320--360--34--2
(16) Remove breather hose (24) from adapter

(25).
(17) Remove adapter (25) from axle housing (5). 27
(18) Remove breather hose (24) from 26

adapter (26).
(19) Remove breather (27) from adapter (26).
24
25
25--4.1/(25--4.2 blank)
TM 9--2320--360--34--2
25--4.2 Change 1
TM 9--2320--360--34--2
b. Disassembly
1
(1) Install adapter (1) on stand (2) with six 3
screws (3).
WARNING
950 lb (431 kg). Use caution 2
while lifting or moving
differential assembly. Failure
to do so may result in serious

(1) with six screws (6).
5 6
(3) Unstake nut (8) on yoke (9). 11.1
(4) Position differential assembly (5) with input

yoke (9) pointing up.
8
(6) Remove nut (8), yoke holder (10), and input 9 12
yoke (9) from input shaft (11) using socket
13
(11.1) with aid of assistant. Discard nut. 10
from cover (14). 11 14
15
(8) Remove cover (14) from front housing
cover (15).
NOTE
Piston pin may stay in cover or
housing cover. 14
(9) Remove piston pin (16) from cover (14) or 18
housing cover (15).
(10) Remove preformed packing (17) from piston
pin (16). Discard preformed packing.
16
(11) Remove fitting (18) from cover (14).
17
25--5
TM 9--2320--360--34--2
19.1
(12) Remove six screws (19), two screws (19.1), 19 20

and manifold bracket (20) from front housing
cover (15).
15
NOTE
Cover is removed by lifting up
on cover while assistant taps on
input shaft. 5
(13) Remove front housing cover (15) from

differential assembly (5) using puller.
21
23
22
(14) Remove oil seal (21) from front housing
cover (15). Discard oil seal.
24
(15) Remove seal cage nut (22) from front
housing cover (15) using socket (23).
(16) Remove bearing (24) from front housing 15
cover (15).
29
28
27
(17) Remove four screws (25) from pump
assembly (26).
(18) Remove pump assembly (26), two
preformed packings (27), and preformed
packing (28) from front housing (29).
Discard preformed packings.
26
25
25--6
TM 9--2320--360--34--2
(19) Remove fork (30), spring (31), and pinion

(32) from front housing (29). 32
(20) Remove 20 screws (33) from front

housing (29).
30
31
29
33
(21) Attach lifting device and lifting strap to front

housing (29).
WARNING
Front housing weighs 85 lb
(39 kg). Keep clear of front
housing during separation
from carrier assembly. 29
Failure to comply may result
in injury to personnel.
(22) Separate front housing (29) from carrier

housing (34).
34
(23) Remove lifting device and lifting strap from
front housing (29).
35
39 36
29
(24) Remove two screws (35), deflector (36), and
pipe (37) from front housing (29). 38
NOTE
42
Tag shim before removal.
(25) Remove bearing race (38) and shim (39)

from front housing (29).
37
25--7
TM 9--2320--360--34--2
29
(26) Remove plug (40) and preformed packing
(41) from front housing (29). Discard
preformed packing. 41
40
NOTE
Do step (27) only if dowels fail 29
inspection.
(27) Remove two dowels (42) from front

housing (29). 42
43
34
(28) Remove pinion (43) from carrier housing

(34) with aid of assistant.
NOTE 43
45
bearings fail inspection.
(29) Remove bearing (44) from pinion (43).

44
(30) Turn pinion (43) over. Remove bearing (45)
from pinion (43).
25--8
TM 9--2320--360--34--2
(31) Remove six screws (46) and three plates

(47) from ring and pinion assembly (48). 46 49
(32) Remove ring gear carrier (49) from gear
carrier assembly (50). 47
11
(33) Remove input shaft (11) and gear carrier
assembly (50) from carrier housing (34). 50
48
34
WARNING
injury. 51
(34) Remove retaining ring (51) from input

shaft (11).
50
(35) Place gear carrier assembly (50) on wooden
blocks.
(36) Remove gear carrier assembly (50) from
input shaft (11) using soft--faced hammer.
53
NOTE 11
55
Do step (37) only if sleeve fails
inspection. 54
52
(37) Remove sleeve (52) from input shaft (11).
56
(38) Remove retaining ring (53) from sun

gear (54).
(39) Remove washer (55) and sun gear (54) from
pinion shaft (56).
25--9
TM 9--2320--360--34--2
(40) Unstake inner edge of nut (57) away from

bearing cover (58). 59
(41) Remove nut (57) from bearing cover (58)

using spanner nut socket (59) and torque
multiplier with aid of assistant. Discard nut.
57
(42) Attach lifting device to ring and pinion
(43) Remove ring and pinion assembly (48) from 56
bearing cover (58) while assistant operates
lifting device. 46 48
(44) Remove lifting device and screws (46) from
ring and pinion assembly (48) with aid of
assistant. 58
(45) Remove deflector (60) from ring and pinion

assembly (48).
WARNING
released causing severe eye 63
injury.
48
NOTE
Tag and mark shim before
removal.
(46) Remove retaining ring (61) and shim (62)

from ring and pinion assembly (48).
(47) Press bearing (63) from ring and pinion
assembly (48).
25--10
TM 9--2320--360--34--2
(48) Rotate carrier housing (34) so pinion shaft

(56) is pointing down.
NOTE
0.013 in.(0.25--0.33 mm). 67
66
(49) Check backlash of differential (64) to pinion
shaft (56).
(50) Hold pinion shaft (56) so pinion gear (65) 64
does not move.
NOTE

NOTE
(52) Install dial indicator (66) on face of 56 65

34
70
71 64
(55) Remove screw (68) and nut lock plate (69) 70

from bearing cap (70). 69
68
(56) Remove four screws (71) from bearing caps (70).
(57) Remove two bearing caps (70) from carrier
housing (34).
(58) Remove adjusting nut (72) from differential (64).
34
(59) Install crowbar (73) through differential (64).
(60) Install strap on crowbar (73).
73
WARNING 72
Differential is heavy and
requires the aid of assistant
to move or lift it. Failure to
use caution may result in
(61) Remove differential (64) from carrier

housing (34) with aid of assistant.
(62) Remove crowbar (73) and strap.
25--11
TM 9--2320--360--34--2
NOTE 74
Do step (63) only if dowels fail
inspection. 34
(63) Remove four dowels (74) from carrier
housing (34).
64
(64) Remove shim (75) and taper races (76) from
differential (64). 76 77 76
78 75
NOTE
from gear side of
up high enough to install
puller.
(65) Remove bearing (77) from differential (64)
using puller. 56
79
(66) Remove bearing (78) from differential (64)
using puller. 81
34
(56) is parallel to floor.
(68) Unstake inner edge of nut (79) away from
pinion shaft (56).
(69) Position jet extractor (80) between teeth of 80
pinion gear (65) and housing (34) with aid of
assistant.
(70) Remove nut (79) from pinion shaft (56)
using spanner nut socket (81) and torque 65
multiplier with aid of assistant. Discard nut.
(71) Remove jet extractor (80) from housing (34).
25--12
TM 9--2320--360--34--2

(56) is pointing up. 34
CAUTION
Ensure assistant supports
pinion shaft during removal.
(73) Drive pinion shaft (56) through carrier

housing (34) while assistant supports pinion 82
shaft (56).
(74) Remove spacer (82) and taper bearing (83) 83
56
84
87
88
58
(75) Remove taper bearing (84) from bearing
cover (58). 89
(76) Remove taper race (85), shim (86), and
taper race (87) from bearing cover (58). 34
(77) Remove eight screws (88) from bearing
cover (58).
(78) Remove bearing cover (58) from carrier
housing (34).
(79) Remove taper race (89) from carrier
housing (34).
86
85
25--13
TM 9--2320--360--34--2
(80) Position output housing (90) in press with 91

long end of shaft facing up.
CAUTION
Ensure shaft does not drop to 90
floor. Failure to comply may
result in damage to equipment.
(81) Press output shaft (91) with bearing (92)
from output housing (90).
92
(82) Position output shaft (91) in press.

(83) Press output shaft (91) from bearing (92). 92
91
(1) Clean old gasket material from housing and/or caps.
WARNING
(2) Clean sealant residue from threaded holes with solvent cleaning compound.
CAUTION
(3) Wash parts in solvent cleaning compound.
25--14
TM 9--2320--360--34--2
WARNING
personal protective
gloves, etc.).
(4) Dry all parts, except bearings, with

compressed air. Allow bearings to air dry.
(5) Remove all small nicks or burrs with crocus
cloth.
(8) Inspect all parts and bearings with machined
surfaces for deep scratches or wear
grooves.
d. Assembly
(1) Position output shaft (1) and bearing (2) in
press.
(2) Press bearing (2) on output shaft (1).
Remove from press.
(3) Install output housing (3) and output shaft 3

(1) in press with aid of assistant.
(4) Press output housing (3) on output shaft (1).
Remove from press.
25--15
TM 9--2320--360--34--2

4
5
WARNING
(5) Coat threads of eight screws (4) with

(6) Install bearing cover (5) on carrier housing
(6) with eight screws (4). Torque to 80 lb--ft
(108 N.m).
9
(7) Position carrier housing (6) so rear faces up.
(8) Install taper race (7) in carrier housing (6). 6 8
NOTE
· If same pinion and differen-
tial are being reused, same
shim may be used.
· If new pinion and differential
are being used, shim
thickness is determined by
comparing dimension 5
engraved on new pinion
with dimension on old
pinion. If dimension is 10
larger, shim must be 7
reduced by difference. If
dimension is smaller, shim
must be increased by
13.1 12
difference.
(9) Install shim kit (8), taper race (9), and taper 11
race (10) in bearing cover (5).
13
(10) Install taper bearing (11) on pinion shaft (13)

using pinion bearing cone installer (13.1).
(10.1) Install spacer (12) on pinion shaft (13).
25--16
TM 9--2320--360--34--2
14
(11) Rotate carrier housing (6) so bearing cover
(5) bore is parallel to ground.
5
(12) Coat taper bearing (11) with lubricating oil. 6
(13) Install pinion shaft (13) in carrier housing (6).
while assistant supports pinion shaft (13).
13
11
(15) Position carrier housing (6) so pinion shaft

(13) is parallel to floor.
(16) Position jet extractor (15) between housing 6
(6) and teeth on pinion gear (16) with aid of
assistant.
WARNING
17
ventilated area. If sealing
13
(17) Coat new nut (17) with adhesive--sealant

(18) Install new nut (17) on pinion shaft (13) flat 6
side first.
(19) Tighten nut (17) to 528--564 lb--ft 15
(716--765 N.m).
(20) Stake edge of nut (17) in notches in pinion
shaft (13). 16
25--17
TM 9--2320--360--34--2
WARNING
Differential is heavy and
18
(22) Install differential (18) in press.
(23) Press bearing (19) on differential (18). 20
22
(24) Turn differential (18) over in press.
21 23
(25) Press bearing (20) on differential (18). 19
(26) Remove differential (18) from press.
(27) Install taper races (21 and 22) on bearings
(19 and 20).
(28) Position shim (23) on gear end of
differential (18).
18
(29) Install crowbar (24) through differential (18). 19

(31) Coat taper bearings (19 and 20) with
lubricating oil.
20
(32) Position carrier housing (6) with pinion shaft
(13) down.
25
NOTE 24
Do step (33) if dowels were
6
removed.
(33) Install four dowels (25) in carrier housing (6). 13

(34) Install differential (18) in carrier housing (6)
(35) Remove strap and crowbar (24) from
differential (18).
25--18
TM 9--2320--360--34--2
WARNING
26
27
(36) Coat four screws (26) with adhesive--sealant

(37) Install two bearing caps (27) on carrier
housing (6) with four screws (26). Torque to
25 lb--in. (2.83 N.m). 6
(38) Install adjusting nut (28) on differential (18).
28
differential carrier preload gage (29).
(39.3) Zero dial indicator (30).
(39.4) Tighten adjusting nut (28) until bearing caps
(27) expand 0.013--0.018 in. (.33--.46 mm).
preload gage (29) and dial indicator (30) 27
from bearing caps (27). 32 26
31
(40) Tighten screws (26) to 123--138 lb--ft
(167--187 N.m).
WARNING
28
soap and water.
(41) Coat screw (31) with adhesive--sealant (Item

6, Appendix B). 27
27
(42) Install nut lock plate (32) on bearing cap (27)
with screw (31). Torque to 132--216 lb--in.
(14.9--24.4 N.m).
25--19
TM 9--2320--360--34--2
18
shaft (13).
(44) Hold pinion shaft (13) so pinion gear (16)
does not move.
NOTE

13 16
18
NOTE
33
differential gear tooth (33). 34
NOTE
0.013 in. (0.25--0.33 mm). To
thickness of shim. To decrease
backlash, increase thickness of
shim.

(13) faces down. 13
6
25--20
TM 9--2320--360--34--2
NOTE
Do steps (50) thru (54) to adjust
tooth contact pattern.
(50) Coat gear teeth of differential gear (34) with

of rotation. If needed, remove and adjust
shims as required. A correct pattern is clear
of toe and centers evenly along width of face
between top land and root. Length and
shape of pattern may vary and is acceptable
as long as pattern does not run off tooth at
any point.
TOOTH
DEPTH
ROOT 8
HEEL
TOP LAND
TOE
13
34
NOTE
Check and adjust backlash as
needed.
23
(51) Move differential gear (34) away from pinion
shaft (13) by using a thinner shim (23) and
thicker shim (8) if pattern is too close to top
of tooth.
(52) Move differential gear (34) away from pinion

shaft (13) by using thinner shim (23) and
thicker shim (8) if pattern is too close or off
tooth root.
(53) Move differential gear (34) toward pinion

shaft (13) by using thicker shim (23) and
thinner shim (8) if pattern is too close or
off tooth heel.
(54) Move differential gear (34) toward pinion

shaft (13) by using thicker shim (23) and
thinner shim (8) if pattern is too close to
bottom of tooth.
25--21
TM 9--2320--360--34--2
13
6
(13) is pointing up.
WARNING
leased causing severe eye 36
injury. 36
(56) Install retaining ring (35) in ring and pinion

assembly (36).
(57) Measure and record distance C between
bottom of retaining ring (35) and shim land
on ring and pinion assembly (36).
(58) Measure and record width D of bearing (37). 37
25--22
TM 9--2320--360--34--2
(59) Calculate shim (38) thickness by subtracting

distance C from width D. Shim thickness =
35
D -- C +0.004 in. (0.10 mm).
(60) Remove retaining ring (35) from ring and
pinion assembly (36). 37
(61) Press bearing (37) in ring and pinion
assembly (36).
38
(62) Install shim (38) and retaining ring (35) in
ring and pinion assembly (36).
(63) Coat bearing (37) with lubricating oil.
36
36
(64) Install ring and pinion assembly (36) in

carrier housing (6) with aid of assistant.
25--23
TM 9--2320--360--34--2
44
WARNING
43
with soap and water. 39
13
(65) Coat new nut (39) with adhesive--sealant
(Item 6, Appendix B). 5
36
(66) Install new nut (39) using spanner nut socket
(40). Torque to 325--362 lb--ft (441--491 N.m).
(67) Stake edge of nut (39) in notches of bearing
cover (5).
(68) Install deflector (41) in ring and pinion
assembly (36).
(69) Install sun gear (42) on pinion shaft (13) flat
side first.
(70) Install washer (43) on sun gear (42).
WARNING
injury.
(71) Install retaining ring (44) on pinion shaft (13).

47
(72) Coat end of pinion shaft (13) with grease.
46
NOTE
Do step (73) if spacer was
45
removed.
(73) Install spacer (45) on input shaft (46).

(74) Install gear carrier (47) on input shaft (46).
(75) Install retaining ring (48) on input shaft (46).
25--24
TM 9--2320--360--34--2
(76) Install gear carrier (47) in ring and pinion

assembly (36). 50 49
(77) Install ring gear carrier (49) on gear 51

carrier (47).
WARNING 47
(78) Coat threads of six screws (50) with

(79) Install three plates (51) on ring and pinion

assembly (36) with six screws (50). Torque
to 120 lb--in. (13.6 N.m).
52 53
52
(80) Press two bearings (52) on pinion (53).
(81) Coat bearings (52) with lubricating oil. 53
(82) Install pinion (53) in carrier housing (6) with

aid of assistant.
25--25
TM 9--2320--360--34--2
(83) Install new preformed packing (54) and plug 55

(55) in front housing (56).
54
WARNING
with water.
(84) Fill plug (55) slot with silicone adhesive--
sealant.
NOTE
59
removed. 60
57
(85) Install two dowels (57) in front housing (56).
(86) Coat end of pipe (58) with silicone 56
adhesive--sealant.
WARNING
sealant gets on skin or 58

(88) Install pipe (58), deflector (60), and two
screws (59) in front housing (56). Torque to
78 lb--in. (8.8 N.m).
25--26
TM 9--2320--360--34--2
(89) Measure and record distance D between top

and bottom of bearing surface in front 56
housing (56).
(90) Measure and record distance E, height of

bearing race (61). 61
(91) Calculate shim (62) thickness by subtracting 62

distance E from D. Shim thickness = D -- E.
(92) Install shim (62) and bearing race (61) in
front housing (56). 56
WARNING 61
(93) Coat mating surface of carrier housing (6)

(94) Attaching lifting strap and lifting device to
front housing (56).
56
(95) Coat threads of 20 screws (63) with
adhesive--sealant.
(96) Lower front housing (56) on carrier 6
assembly while assistant operates lifting
device.
(97) Remove lifting device and strap from front
housing (56).
(98) Install 20 screws (63) in front housing (56).
25--27
TM 9--2320--360--34--2
(99) Install two new preformed packings (64) and 56

new preformed packing (65) on pump
assembly (66). 65
64
(100) Coat preformed packings (67) with
lubricating oil.
WARNING
68
(101) Coat mounting surface of pump (66) with

(103) Install pump assembly (66) on front housing
(56) with four screws (68). Torque to 29
lb--ft (39 N.m).
71
70
69
56
(104) Install spring (69), fork (70), and pinion (71)

in front housing (56).
25--28
TM 9--2320--360--34--2
WARNING
73.1
sealant gets on skin or 76 73
with soap and water. 75
(105) Coat mating surface of front housing cover

(72) with adhesive--sealant (Item 4, 72
Appendix B).
(106) Coat threads of six screws (73) and two
screws (73.1) with adhesive--sealant (Item 6,
Appendix B).
56
(107) Install front housing cover (72) and manifold
bracket (74) on front housing (56) with six
screws (73) and two screws (73.1). Torque
to 46 lb--ft (62 N.m).
(108) Install bearing (75) in front housing
cover (72).
(109) Coat bearing (75) with lubricating oil.
(110) Coat seal cage nut (76) with adhesive--
(111) Install seal cage nut (76) in front housing
cover (72). Torque to 217--253 lb--ft
(294--343 N.m).
NOTE
Oil seal is installed properly
when top surface of seal is 1/16
in. (1.59 mm) below housing.
(112) Install new oil seal (77) in front housing

cover (72). 80
81
79
(113) Install new preformed packing (78) on piston

pin (79). 78
(114) Install piston pin (79) in cover (80).
(115) Install fitting (81) in cover (80).
25--29
TM 9--2320--360--34--2
WARNING
86.1
ventilated area. If adhesive-- 85 83
(116) Coat mating surface of cover (82) with 46 82

adhesive--sealant (Item 4, Appendix B). 72

(118) Install cover (82) on front housing cover (72)
with four washers (84) and screws (83).
WARNING
with water.
(119) Coat splines of shaft (46) with silicone
adhesive--sealant.
(120) Coat threads of shaft (46) with
adhesive--sealant.
NOTE
Large openings of yoke must
align with notches in input shaft
to ease staking of nut.
(121) Install input yoke (85) on input shaft (46)

with new nut (86) using socket (86.1).
Torque to 680--796 lb--ft (922--1079 N.m).
(122) Stake edge of new nut (86) in notches of
input shaft (46).
25--30
TM 9--2320--360--34--2
e. Installation
(1) Attach suitable lifting device to differential
assembly (1).
4
(2) Remove six screws (2) and differential
2
WARNING
with water. 7
1
(3) Coat mating surface of axle housing (5) with
silicone adhesive--sealant. 6
WARNING
Differential weighs 950 lb (431
kg) and requires the aid of
assistant to move or lift it.
Failure to use caution may
result in injury to personnel. 8
(4) Install differential assembly (1) in axle 5
device.
(5) Install 10 washers (6) and new locknuts (7)
on studs (8). Torque to 190--206 lb--ft
(140--152 N.m).
(6) Position axle housing (5) so input yoke (9) is
parallel to floor.
25--31
TM 9--2320--360--34--2
WARNING
(7) Coat four studs (10) with adhesive--sealant

(8) Install four studs (10) in differential assembly
(1). Torque to 76 lb--ft (103 N.m).
(9) Install four washers (11) and nuts (12) on
studs (10). Torque to 117--137 lb--ft
(159--186 N.m).
11 10
(10) Remove lifting device and lifting straps.
12
(11) Coat mounting surface of rear section of

output housing (13) with adhesive--sealant 1
14
15
(12) Install output housing (13) and clip (14) on
differential assembly (1) with seven screws
(15). Torque to 61--80 lb--ft (83--108 N.m).
(13) Install nut (16) on output housing (13).
(14) Coat threads of spanner nut (17) with
18
adhesive--sealant (Item 6, Appendix B). 13 17
(15) Install spanner nut (17) on output housing
16
(13) using socket (18). Torque to
210--230 lb--ft (285--312 N.m).
25--32
TM 9--2320--360--34--2
NOTE
Oil seal is installed properly 13
19
(16) Install new oil seal (19) on output

housing (13).
WARNING
contact, wipe off and flush 21
22.1 22
with water. 20
(17) Coat splines of output shaft (20) with
silicone adhesive--sealant.
(18) Coat threads of output shaft (20) with
NOTE
(19) Install output yoke (21) and new nut (22) on

output shaft (20) using socket (22.1).
(20) Tighten nut (22) to 486--572 lb--ft
(659--775 N.m).
(21) Stake edges of nut (22) in notches of
shaft (20).
25--33
TM 9--2320--360--34--2
26 24
23
25
25
25
(22) Install six hoses (23) on axle housing (5)
with five clips (24), screws (25), and new 24
locknuts (26).
26
24
WARNING 23 24 26 5
soap and water.
24
(23) Coat threads of adapter (27) and breather
26
(24) Install breather (28) in adapter (29).
(25) Install breather hose (30) on adapter (29).
28
(26) Install adapter (27) on axle housing (5). 30
(27) Install breather hose (30) on adapter (27). 29
27
(1) Install axle shafts (para 10--8).
(2) Install brake chambers (TM 9--2320--360--20).
(3) Install axle manifolds (TM 9--2320--360--20).
25--34
TM 9--2320--360--34--2
This task covers:

INITIAL SETUP

Oil drained from differential Stand, Maintenance, Differential/Transfer
(LO 9--2320--360--12). Case (Item 183, Appendix E)
Axle manifold removed (TM 9--2320--360--20). Wrench Set, Socket, 1 In. Drive (Item 230,
Brake chambers removed Appendix E)
(TM 9--2320--360--20). Wrench Set, Socket, 3/8 In. Drive (Item 232,
Axle shafts removed (para 10--8). Appendix E)
Tool Kit, Genl Mech (Item 202, Appendix E) Wrench, Torque, 0--150 Lb--In. (Item 234,
Eyes, Lifting (2) (Figure C--8, Appendix C) Appendix E)
Extractor, Jet (Figure C--11, Appendix C) Wrench, Torque, 0--300 Lb--In. (Item 235,
Holder, Yoke (Figure C--15, Appendix C) Appendix E)
Gage, Preload, Differential Carrier Wrench, Torque, 0--175 Lb--Ft (Item 236,
(Figure C--16, Appendix C) Appendix E)
Installer, Bearing Cone (Figure C--20,
Appendix C) Materials/Parts
Installer, Bearing Cone (Figure C--21, Adhesive--Sealant, Silicone (Item 2, Appendix B)
Appendix C) Adhesive--Sealant (Item 3, Appendix B)
Adapter, Differential Maintenance Adhesive--Sealant (Item 4, Appendix B)
(Item 0.1, Appendix E) Adhesive--Sealant (Item 6, Appendix B)
Adapter, 3/4 Female --1 In. Male (Item 6, Compound, Sealing, Pipe Thread
Appendix E) (Item 28, Appendix B)
Caliper Set, Micrometer (Item 15, Appendix E ) Dye, Prussian Blue (Item 30, Appendix B)
Compressor, Air Unit (Item 24, Appendix E) Oil, Lubricating (Item 44, Appendix B)
Crowbar (Item 30, Appendix E) Cleaning Compound, Solvent (Item 54, Appendix B)
Dial Indicator, Magnetic (Item 32, Appendix E ) Locknuts (2) (Item 82, Appendix F)
Gage, Depth, Micrometer (Item 48, Nuts, Adjusting (2) (Item 149, Appendix F)
Appendix E) Nut, Adjusting (Item 150, Appendix F)
Goggles, Industrial (Item 57, Appendix E) Packing, Preformed (Item 166, Appendix F)
Multiplier, Torque (Item 99, Appendix E) Packing, Preformed (Item 167, Appendix F
Press, Hydraulic (Item 116, Appendix E) Seals, Oil (2) (Item 305, Appendix F)
Puller Kit, Mechanical, Gear and Brg (Item 124,
Remover, Setter, Stud (Item 137, Appendix E ) Two
25--35
TM 9--2320--360--34--2
a. Removal
(1) Unstake nut (1) on yoke (2).
(3) Remove nut (1) and yoke (2) from output
shaft assembly (4) using socket (4.1) with
aid of assistant.
(4) Remove oil seal (5) from output shaft
assembly (4). Discard oil seal.
(5) Remove two screws (6) from output shaft
assembly (4).
(6) Remove output shaft assembly (4) and
preformed packing (7) from axle housing (8).
Discard preformed packing.
(7) Remove two locknuts (9) and washers (10)
from studs (11). Discard locknuts.
11 10
9 4 5
3
2
1
4.1
8 7
(8) Attach lifting device to axle housing (8).
25--36
TM 9--2320--360--34--2
WARNING
Axle weighs approximately
1927 lb (875 kg). Use caution
when lifting or moving axle.
Failure to do so may result in
serious injury or death to 15
personnel.
(9) Position axle housing (8) in axle stand with 13
input shaft (12) pointing up.
(10) Remove two screws (13) from differential 14
carrier (14) and install lifting eyes (15).
(11) Attach lifting device to lifting eyes (15).
(12) Remove 12 nuts (16), washers (17), and 10
taper rings (18) from studs (19). 16
WARNING 17 12
Differential weighs approxi-
mately 750 lb (341 kg) and 18 14
CAUTION
Lift carrier straight out of axle
housing. Failure to comply may 19
result in binding and damage to
studs.
(13) Remove differential carrier (14) from axle

device.
8
NOTE
Do step (14) only if studs fail
inspection.
(14) Remove 12 studs (19) from axle

housing (8).
(15) Remove breather (20) and adapter (21) from
21
axle housing (8).
20
25--37
TM 9--2320--360--34--2

b. Disassembly
1
WARNING 3
mately 750 lb (341 kg) and
to move or lift it. Failure to 5 8
2
1
(1) Install adapter (1) on stand (2) with six
screws (3).
6
(3) Remove two lifting eyes (8) from differential
assembly (5).
13.1
(4) Unstake nut (9) on yoke (10). 9
(5) Position rear housing (11) with input shaft

(12) pointing up. 10
13
(7) Remove nut (9), yoke holder, and input yoke
(10) from input shaft (12) using socket (13.1)
14
with aid of assistant. Discard nut.
(8) Remove input shaft seal (14) from seal
17 16
cover (15). Discard seal.
NOTE 15
Tag and mark shim.
22 18
(9) Remove five screws (16), screw (17), seal
23
cover (15), and shim (18) from rear housing 21
19
(11). Discard seal.
(10) Remove 13 screws (19) from front
housing (20). 20
NOTE
It may be necessary to loosen
12
housing by striking with rubber
mallet.
(11) Remove front housing (20) from rear

housing (11). 11
(12) Remove taper bearing race (21) from front
housing (20).
(23) from front housing (20). Discard
preformed packing.
25--38
TM 9--2320--360--34--2
(14) Remove split torque differential (24) from

rear housing (11).
(15) Remove two taper bearings (25 and 26)
25
from split torque differential (24).
24
26
11
(16) Remove two screws (27), washers (28), and

differential lock actuating cylinder (29) from
rear housing (11).
29
28
27
31
34
11 30
(17) Remove pin (30) and fork (31) from rear
housing (11).
33
(18) Remove retaining clip (32), clutch gear (33),
and two shift dogs (34) from fork (31).
32
25--39
TM 9--2320--360--34--2
(19) Position rear housing (11) so pinion shaft

(35) points down. 39

shaft (35).
does not move. 38
NOTE
while doing steps (22) thru (24). 36
NOTE

NOTE
Backlash should be 0.010-- 0.016
in. (25--41 mm). To increase
backlash, reduce thickness of 11
35
shims installed in carrier housing.
To decrease backlash, increase
thickness of shims.

25--40
TM 9--2320--360--34--2
(26) Remove two studs (39) from rear

housing (11). 39
43
(27) Remove screw (40) and lockplate (41) from
bearing cap (42). 42
(28) Remove four capscrews (43), bearing caps 42
(42), and adjusting nut (44) from
housing (11). 47
(29) Install crowbar (45) through differential (36).
WARNING 45
mately 750 lb (341 kg) and 47 46
requires the aid of assistant 36
to move or lift it. Failure to 11
injury to personnel. 48
(31) Remove shim (46), differential (36), and
races (47) with aid of assistant. 41
(32) Remove crowbar (45), strap, shim (46), and 40
two races (47) from differential (36).
NOTE 42
Do step (33) only if dowels fail
inspection.
(33) Remove four dowels (48) from rear 44

housing (11).
NOTE
36
from gear side of 49 49
differential, first remove
puller.
(34) Remove taper bearings (49) from differential
(36) using puller.
25--41
TM 9--2320--360--34--2
11
51
(35) Position rear housing (11) so pinion shaft 37
(35) points up.
(36) Unstake pinion nut (50) on pinion shaft (35).
(37) Position jet extractor (51) between teeth of
pinion gear (37) and housing (11) with aid of
assistant.
(38) Remove pinion nut (50) from pinion
shaft (35).
CAUTION
50
do not allow gear teeth to hit
inside of housing. Damage to
11
NOTE
Step down gear and spacers
may come out with pinion gear
or stay in housing.
(40) Remove pinion gear (35) from rear

housing (11). 35
37
54
53
55
52
(41) Remove step down gear (52) and two
spacers (53) from pinion shaft (35) or inside 57
rear housing (11). 59 60
(42) Remove taper bearing (54), two taper races 11
(55), and shim (56) from rear housing (11).
(43) Remove taper race (57) from rear
housing (11). 58
(44) Remove taper bearing (58) from pinion
56
shaft (35).
35
(45) Remove two screws (59) and cover plate 55
(60) from rear housing (11).
53
25--42
TM 9--2320--360--34--2
63
62
61
(46) Separate and remove cover (61) and shim
(62) from output housing (63).
64
(47) Place shaft (64) in press with output housing
(63) at bottom. Press shaft (64) from
housing (63).
63
64
(48) Turn shaft (64) over. Press bearing (65) off

shaft (64).
65
61
(49) Remove two grease fittings (66) from

cover (61).
66
25--43
TM 9--2320--360--34--2

(1) Remove sealant from housing mating surfaces.
WARNING
WARNING
(4) Inspect bearings for abnormal wear or chipping.
(5) Remove residual adhesive--sealant from screws and threaded holes.
(6) Remove burrs from seal bores.
(7) Inspect all parts for other damage. Replace damaged parts.
(8) Inspect differential housing studs for bending or damaged threads.
d. Assembly
WARNING
silicone sealant irritates eyes. In
case of contact, flush eyes with
water and seek medical atten-
tion. In case of skin contact,
wipe off and flush with water.
(1) Coat mating surface of cover plate (1) with
silicone adhesive--sealant. 3
1
WARNING
and clothing. To avoid injury or
death, keep away from open fire
and use in well--ventilated area.
If adhesive--sealant gets on skin
or clothing, wash immediately
(3) Install cover plate (1) on rear housing (3)
with two screws (2). Torque to 47 lb--ft (65 N.m).
25--44
TM 9--2320--360--34--2
NOTE
If installing new gear set,
compare dimension marked on
new pinion head of pinion gear
with dimension on original 5.1
pinion gear. If dimension is
bigger, pinion gear shim will be
thinner. If dimension is smaller, 4
pinion gear shim will be thicker. 5
(4) Install taper race (4) in rear housing (3).

(4.1) Install taper race (5) in rear housing (3)
using power divider bearing cone installer
(5.1).
8
7
10
(5) Position housing (3) so differential cradle (6)
faces up. 9
(6) Install shim (7) and taper race (8) in
housing (3).
using pinion bearing cone installer (10.1). 6
(8) Coat taper bearing (9) with lubricating oil.

6
(9) Install drop gear (11) and spacer (12) in rear
housing (3). 3
(10) Install pinion shaft (10) in rear housing (3)
10.1
thru drop gear (11) and spacer (12).
12
11
25--45
TM 9--2320--360--34--2

3
(11) Position rear housing (3) so pinion shaft (10)

is parallel to floor.
(12) Install spacer (13) and taper bearing (14) on
pinion shaft (10) while assistant supports
pinion shaft (10). 15
(13) Position jet extractor (15) between gear
tooth on pinion gear (16) and housing (3)
16
(14) Install new pinion nut (17) on pinion shaft (10).
Torque to 543--572 lb--ft (736--776 N.m).
3
(15) Stake edges of nut (17) in notches of shaft (10).
10
13
NOTE
Assembled pinion gear should 14
rotate with 38--47 lb--in. (4.4--
5.4 N.m) of torque. Repeat
assembly steps (4) thru (14) if
17
over these limits.
(17) Check rolling resistance of assembled gear

by turning pinion nut (17).
21
18
22
(18) Install two shift dogs (18), clutch gear (19), 19

and retaining clip (20) on fork (21).
(19) Install assembled fork (21) and pin (22) in
rear housing (3).
20
(20) Lock pin (22) in place by staking three
points.
3
WARNING
(21) Coat pin (22) area with layer of silicone
adhesive--sealant.
25--46
TM 9--2320--360--34--2
23 23
24
(22) Install two taper bearings (23) on
differential (24).
(23) Coat taper bearings (23) with lubricating oil.
(24) Position rear housing (3) so pinion shaft (10)

points down.
NOTE
removed.
(25) Install four dowels (25) on rear

housing (3). 26
WARNING
27
24
ventilated area. If adhesive-- 29 28
30 29
soap and water.
(26) Coat threads of four screws (26) with

NOTE
If pinion gear shims were 3
25
increased in thickness,
differential bearings must be
decreased by same amount. If 10
pinion gear shims were
decreased in thickness,
differential bearings must be
increased by same amount.
(27) Install differential (24), bearing caps (27),

shim (28), and races (29) on rear housing
(3) with four screws (26). Torque to 25 lb--in.
(2.8 N.m).
(28) Position adjusting nut (30) in rear
housing (3).
25--47
TM 9--2320--360--34--2
25--3. AXLE NO. 3 DIFFERENTIAL REPAIR (CONT) 27

32
(29.3) Zero dial indicator (32). 31
(30) Tighten adjusting nut (30) until bearing caps 30

(27) expand 0.014--0.018 in. (.36--.46 mm). 35
preload gage (31) and dial indicator (32)
from bearing caps (27).
(31) Tighten screws (26) on bearing caps (27) to
120--137 lb--ft (163--186 N.m).
27
27

shaft (10).
does not move.
NOTE 32
Do not allow pinion gear to turn 24
(34) Turn differential (24) counterclockwise until it 32
33
NOTE
(35) Install dial indicator (32) on face of 24
NOTE
0.016 in. (25--41 mm). To
thickness of shims installed in
carrier housing. To decrease
backlash, increase thickness of 10 16
shims.
25--48
TM 9--2320--360--34--2

of rotation. If needed, remove and adjust
shims as required. A correct pattern is clear
of toe and centers evenly along width of face
between top land and root. Length and
shape of pattern may vary and is acceptable
as long as pattern does not run off tooth at
any point.
TOOTH
DEPTH
ROOT
HEEL
TOP LAND
TOE

27
34
7
17
NOTE
Check and adjust backlash as
needed.
(39) Move ring gear (34) away from pinion gear
shim (7) if pattern is too close to top of tooth.
(40) Move ring gear (34) away from pinion gear

shim (7) if pattern is too close or off tooth
root.
(41) Move ring gear (34) toward pinion gear (17)

shim (7) if pattern is too close or off tooth
heel.
(42) Move ring gear (34) toward pinion gear (17)

shim (7) if pattern is too close to bottom of
tooth.
25--49
TM 9--2320--360--34--2
WARNING 36
26
(43) Coat threads of screw (35) with adhesive--

(44) Install lock plate (36) on bearing cap (26)
with screw (35). Torque to 132--216 lb--in.
(15--24 N.m).
(45) Coat two studs (37) with adhesive--sealant
(46) Install two studs (37) in rear housing (3). 3
(47) Rotate rear housing (3) so pinion shaft (10)

points up. 38
(48) Install two bearing cones (38) on split torque
differential (39). 39
(49) Install split torque differential (39) in rear
housing (3).
WARNING
silicone sealant irritates eyes. In 10
case of contact, flush eyes with 3
(50) Coat mating surface of differential lock
actuating cylinder (40) with silicone
42
41
(52) Install differential lock actuating cylinder (40)
on rear housing (3) with two washers (42)
and screws (41). Torque to 47 lb--ft
(64 N.m).
25--50
TM 9--2320--360--34--2
WARNING
easily, can give off harmful 10.1
45
soap and water.
(53) Coat rear housing (3) sealing surface with

(54) Install front housing (43) on rear housing (3).
(55) Coat 13 screws (44) with adhesive--sealant.
(56) Install screws (44) in front housing (43).
(57) Install taper race (45) in front housing (43)
using power divider bearing cone installer
(10.1).
(58) Install new preformed packing (46) and drain
plug (47) in front housing (43).
48
49
45
43
(59) Measure and record distance A on raised

portion of bottom seal cover (48).
(60) Measure and record distance B between
face of front housing (43) and taper
race (45).
(61) Calculate shim (49) thickness by subtracting
distance A from B. Shim thickness is B -- A
+0.002 in. (0.05 mm).
B A
25--51
TM 9--2320--360--34--2
WARNING
silicone sealant irritates eyes. In 55.1
water and seek medical atten- 55
54
(62) Coat front housing (43) sealing surface with 56
WARNING
vapors, and is harmful to skin 51 50
soap and water.
(63) Coat threads of five screws (50) and screw (51) 43

(64) Install shim (49) and seal cover (48) on front
housing (43) with five screws (50) and screw
(51). Torque screws (50) to 44 lb--ft (60 N.m)
and screw (51) to 56 lb--ft (104 N.m).
NOTE
in. (1.59 mm) below cover.
(65) Install new yoke seal (52) in seal cover (48).

(66) Coat splines of input shaft (53) with silicone
adhesive--sealant.
(67) Install yoke (54) and new pinion nut (55) on 57
input shaft (53) using socket (55.1). Torque
58
to 680--796 lb--ft (922--1079 N.m) using yoke
holder (56) with aid of assistant. 57
(68) Stake edges of new nut (55) in notches of
shaft (53).
(69) Install two grease fittings (57) on cover (58).
25--52
TM 9--2320--360--34--2
(70) Press bearing (59) in output housing (60).

(71) Press shaft (61) on bearing (59).
59 60
61
(72) Measure distance C between machine

surface of output housing (60) and top of
bearing (59).
(73) Measure distance D between machine
surface and bottom of first land in cover
(58). 60
(74) Calculate shim thickness (62) by subtracting 59
distance C from distance D. Shim
thickness = D-- C.
62
58
D
58
WARNING
tion. In case of skin contact, 60
(75) Coat mating surface of cover (58) with
(76) Install shim (62) and cover (58) and on
housing (60).
25--53
TM 9--2320--360--34--2
1
e. Installation
2 3
(1) Remove two screws (1) from differential
assembly (2).
(2) Install two lifting eyes (3) in differential 6
assembly (2).
(3) Attach lifting device to lifting eyes (3).
(4) Remove six screws (4) and differential 4
WARNING
soap and water.
NOTE
studs were removed.
(5) Coat threads of 12 studs (7) with

(6) Install 12 studs (7) in axle housing (8).
25--54
TM 9--2320--360--34--2
WARNING
(7) Coat contact surface of differential assembly
(2) with silicone adhesive--sealant.
WARNING
Differential weighs approxi- 11
10
to move or lift it. Failure to 9
CAUTION
Lower carrier straight into axle 7
housing. Failure to comply may
result in binding and damage to
studs.
8
device.
(9) Install 10 taper rings (9) on studs (7).
(10) Install 12 washers (10) and locknuts (11) on
studs (7). Torque to 140--152 lb--ft
(191--206 N.m).
(11) Remove two lifting eyes (3) and lifting device
from differential assembly (2).
(12) Install two screws (1) in differential
assembly (2).
WARNING
11.1
pound can burn easily, can 11.2
soap and water.
(12.1) Coat adapter (11.1) and breather (11.2) with
pipe thread compound.
(12.2) Install adapter (11.1) and breather (11.2) on
axle housing (8).
25--55
TM 9--2320--360--34--2

(15) Install two washers (13) and new locknuts
(14) on studs (15).
(16) Install output shaft assembly (16) and new
preformed packing (17) on differential
assembly (2).
WARNING

(18) Install two screws (18) on output shaft
assembly (16). Torque to 90 lb--ft (122 N.m).
2
NOTE 15 13
when top surface of seal is 1/16 14 16 19
in. (1.59 mm) below cover. 20
(19) Install new oil seal (19) on output shaft
assembly (16).
WARNING
water and seek medical atten- 18 21
21.1
tion. In case of skin contact, 22
(20) Coat splines of output shaft assembly (16)
with silicone adhesive--sealant.
(21) Install yoke (20) on output shaft assembly
(16) with nut (21) using socket (21.1).
Torque to 486--572 lb--ft (659--775 N.m)
using yoke holder (22) with aid of assistant.
(22) Stake nut (21) in notches of output shaft
assembly (16).
(1) Install axle shafts (para 10--8).
(2) Install axle manifold (TM 9--2320--360--20).
(3) Install brake chambers (TM 9--2320--360--20).
25--56
TM 9--2320--360--34--2
This task covers:

INITIAL SETUP

Pivot, spindle, and axle shafts removed Adhesive--Sealant (Item 4, Appendix B)
(para 10--7). Adhesive--Sealant (Item 6, Appendix B)
Axle no. 4 manifold removed Adhesive--Sealant, Silicone (Item 2, Appendix B)
(TM 9--2320--360--20). Cloth, Crocus (Item 16, Appendix B)
Compound, Sealing, Pipe Thread (Item 28,
Tool Kit, Genl Mech (Item 202, Appendix E) Dye, Prussian Blue (Item 30, Appendix B)
Holder, Yoke (Figure C--15, Appendix C) Oil, Lubricating (Item 44, Appendix B)
Gage, Preload, DIfferential Carrier Cleaning Compound, Solvent (Item 54, Appendix B)
(Figure C--16, Appendix C) Tags, Identification (Item 56, Appendix B)
Installer, Bearing Cone (Figure C--20, Ties, Cable, Plastic (Item 60, Appendix B)
Appendix C) Locknuts (3) (Item 82, Appendix F)
Adapter, Differential Maintenance (Item 0.1, Nut (Item 150, Appendix F)
Appendix E) Seal, Pinion (Item 305, Appendix F)
Dial Indicator, Magnetic (Item 32, Appendix E)
Multiplier, Torque (Item 99, Appendix E) Personnel Required
Press, Hydraulic (Item 116, Appendix E) Two
Appendix E)
Appendix E)
Appendix E)
Appendix E)
Appendix E)
Appendix E)
Appendix E)
25--57
TM 9--2320--360--34--2

a. Removal 10
11
NOTE
Location of plastic cable ties 1
should be marked before
removal.
14
(1) Remove plastic cable ties (1) from hoses no.
2109 (2), no. 2140 (3), no. 2018 (4), and 15
breather hose (5). 12
(2) Remove hose no. 2109 (2) from fitting (6). 9
(3) Remove hose no.2140 (3) from fitting (7).

5
18
13
6
7
2
4
16
17
3

cushion clip (11) from standoff bracket (12)
and four hoses (13, 14, 15, and 5). Discard
locknut.
(6) Remove hose no. 2109 (13) from fitting (6).
NOTE
· Fitting must be removed to
remove breather hose from
bracket. 16
· Cut hose directly behind
fitting.
(9) Cut breather hose (16) and remove
fitting (17). 19
(10) Remove breather hose (16) from
bracket (18).
(11) Remove breather hose (16) from elbow (19).
25--58
TM 9--2320--360--34--2
NOTE 1 25
Location of plastic cable ties
should be marked before 26
removal. 27
21
(12) Remove plastic cable tie (1) from hoses no.
2873 (20), no. 2141 (21), no. 2016 (22), and
breather hose (23). 22

cushion clip (26) from standoff bracket (27)
and four hoses (20, 21, 22, and 23).
24
Discard locknut.
23
32
28
30
29
31
NOTE 34
· Fitting must be removed to
remove breather hose from
bracket.
· Cut hose directly behind
fitting.
(17) Cut breather hose (23) and remove
fitting (31).
33.1
(18) Remove breather hose (23) from 19
bracket (32).
(19) Remove breather hose (23) from elbow (33). 33.2
(19.1) Remove breather (33.1) and adapter (33.2) 33

from tee (33.3).
(19.2) Remove tee (33.3) and adapter (33.4) from 33.3 23
axle housing (34).
(19.3) Remove elbow (19) and elbow (33) from tee 33.4
(33.3).
25--59
TM 9--2320--360--34--2
(20) Attach lifting device to axle housing (34).
WARNING
Axle weighs approximately
2040 lb (926 kg). Use caution 34
when lifting or moving axle.
Failure to do so may result in 35
serious injury or death to
personnel.
NOTE
Matchmark differential and axle
housing.
(21) Position axle housing (34) in axle stand with

differential assembly (35) pointing up.
(23) Remove 11 screws (37), washers (38), and 36

two brackets (39) from differential 37 40
assembly (35).
41
(24) Remove three locknuts (40), washers (41), 38
and taper dowels (42) from studs (43). 42
Discard locknuts.
39
WARNING
Differential weighs approxi- 35
use caution may result in 34
(25) Lift differential assembly (35) from axle

device.
25--60
TM 9--2320--360--34--2
b. Disassembly
(1) Install adapter (1) on stand (2) with six 1
screws (3). 3

(3) Remove lifting device from yoke (8). 2
(4) Position differential assembly (5) so pinion 5

shaft (9) points down. 6
1
shaft (9).
(6) Hold yoke (8) so pinion gear (11) does not
move.
NOTE

stops to take up backlash. 12
10
NOTE
NOTE
Backlash should be
0.008--0.011 in. (0.003--0.004
mm). To increase backlash,
reduce thickness of shims
installed in carrier housing. To
decrease backlash, increase
thickness of shims.
5
backlash measured on dial indicator (12). 9 11
25--61
TM 9--2320--360--34--2
15.1
15
(11) Unstake nut (14) on yoke (8). 14

(13) Remove nut (14), yoke (8), and yoke holder
(15) from pinion shaft (9) using socket (15.1)
(14) Remove screw (16) and nut lock plate (17)
18
8 17
16
19
(15) Remove four screws (19) from two bearing 18
caps (18). 18 20
(16) Remove two bearing caps (18) and
adjusting nut (20) from housing (21).
10
(17) Lift differential (10) from housing (21) with
the aid of assistant.
21
25--62
TM 9--2320--360--34--2
NOTE
· Remove taper bearings only 25
26
if they fail inspection. 10
from gear side of 24
22
puller.
· Tag and mark shims before
removal.
(18) Remove adjusting shim (22), taper
14
race (23), and taper bearing (24) from
gear side of differential (10).
27
(19) Remove taper race (25) and taper bearing
(26) from other side of differential (10).
28
29
21
34
CAUTION
do not allow gear teeth to hit the
inside of the housing and cover
assembly. Damage to
(20) Install nut (14) loosely on end of pinion

shaft (9). 31
(21) Remove pinion gear (11) from housing (21)
while assistant supports pinion gear (11).
(22) Remove and discard nut (14). 30 33
(23) Remove pinion seal (27), taper bearing (28),
and taper race (29) from housing (21). 32
Discard pinion seal.
NOTE
Tag and mark shims before 9
removal.
(24) Remove taper race (30) and shim (31) from 11

housing (21).
(25) Remove taper bearing (32) and shim (33)
(26) Remove filler plug (34) from housing (21).
25--63
TM 9--2320--360--34--2

(1) Clean old gasket material from housing and/or caps.
WARNING
irritation of digestive tract and respiratory tract, may cause lung and central nervous system damage. Can
be fatal if swallowed. Inhalation of high/massive concentrations can cause coma or be fatal. First aid for
ingestion: do not induce vomiting. Seek immediate medical attention. First aid for skin contact: remove
contaminated clothing. Wash skin thoroughly with soap and water. If symptoms persist, seek medical
attention. First aid for eye contact: flush with water for 15 minutes or until irritation subsides. If symptoms
persist, seek medical attention. First aid for inhalation: move to fresh air. If not breathing, provide artificial
respiration. If symptoms persist, seek medical attention. Keep away from open flames and other sources
of ignition. Failure to follow this warning may result in injury or death to personnel.
damage equipment.
•Fire extinguishers should be placed nearby when using solvent cleaning compound. Failure to follow
this warning may result in injury or death.
CAUTION
WARNING
(4) Dry parts, except bearings, with compressed air. Allow bearings to air dry.
(5) Remove small nicks or burrs with crocus cloth.
(6) Coat parts with light coat of lubricating oil.
(8) Inspect all parts and bearings with machined surfaces for deep scratches or wear grooves.
2
d. Assembly
(1) Install filler plug (1) in differential
housing (2).
25--64
TM 9--2320--360--34--2
NOTE
If installing new gear set, record
size of pinion gear (engraved on 5.1
pinion end). Compare dimen-
sion with new gear set. If new
size is larger, pinion gear shims 6
will be thinner.
3
(2) Coat bearings (3 and 4) with lubricating oil.
(3) Press taper bearing (3) on pinion shaft (5)
using pinion bearing cone installer (5.1)
4
(3.1) Install shim (6) over end of pinion shaft (5). 5
9
(4) Install shim (7) and taper race (8) in housing
(2) until fully seated.
NOTE 2
If small shim thickness is
increased or decreased, large
shim must be changed
accordingly.
(5) Install pinion shaft (5) through housing (2).

(6) Install taper race (9) and taper bearing (4)
on pinion shaft (5) while assistant supports
pinion shaft (5). 7
25--65
TM 9--2320--360--34--2
10
WARNING
(7) Coat outer edge of new pinion seal (10) with
NOTE
Pinion seal is installed properly
12.1
(8) Install new pinion seal (10) in housing (2).
(9) Coat splines of pinion shaft (5) with silicone
12
NOTE
(10) Install yoke (11) and new nut (12) on pinion

shaft (5) using socket (12.1). Torque to 11
486--572 lb--ft (659--775 N.m) using yoke
holder (13) with aid of assistant.
5
(11) Stake edge of nut (12) in notches of pinion
shaft (5). 2
NOTE
Pinion gear should rotate with
38--48 lb--in. (4.4--5.4 N.m) of
torque. Repeat steps (1) thru
(11) if over these limits.
(12) Check pinion preload by turning nut (12)

with torque wrench.
25--66
TM 9--2320--360--34--2
(13) Install taper bearings (14 and 15) on

differential (16).
18
NOTE 14
increased, differential shim must
be decreased by same amount. 15
decreased, differential shim
must be increased by same 17
amount. Refer to TM
9--2320--360--34P for proper
identification of parts.
(14) Measure thickness of shim (17) and change

thickness if necessary.
(15) Install differential (16), bearing races (18
and 19), and shim (17) in differential housing
(2).
20
WARNING 21
soap and water.
(16) Coat threads of capscrews (20) with

(17) Install two bearing caps (21) on housing (2)
with four capscrews (20). Torque to 25 lb--in.
(2.82 N.m). 2
(18) Install adjusting nut (22) in bearing cap (21).
on bearing cap (21) with screw (25). 24
(19.1) Position magnetic base of dial indicator (24) 23

(19.2) Position probe of dial indicator (24) on 25
(19.3) Zero dial indicator (24).
(20) Tighten adjusting nut (22) until bearing caps
(21) expand 0.013--0.017 in. (.33--.43 mm).
22
preload gage (23) and dial indicator (24) 21
21
from bearing caps (21).
(21) Tighten capscrews (20) to 125 lb--ft
(169 N.m).
25--67
TM 9--2320--360--34--2
WARNING
26
25
soap and water. 16
(22) Coat capscrew (25) with adhesive--sealant

(23) Install capscrew (25) in lockplate (26) and 29
bearing cap (21). Torque to 11--18 lb--ft
(15--24 N.m).
shaft (5).
(25) Hold yoke (11) so pinion gear (27) does not
move.
NOTE

NOTE 5 27
at right (90o) angle to face of 11

NOTE
Backlash should be 30
0.008--0.011 in. (0.003--0.004
mm). To increase backlash,
reduce thickness of shim. To
decrease backlash, increase
thickness of shim.

by rotation. Remove and adjust shims as
necessary.
25--68
TM 9--2320--360--34--2
NOTE
Any time pinion depth is TOOTH
changed, backlash may change. DEPTH
ROOT
Check and adjust backlash as HEEL 6
needed. A correct pattern is TOP LAND
clear of toe and centers evenly TOE
along width of face between top

land and root. Length and RING GEAR TOOTH NOMENCLATURE
shape of pattern may vary and
is acceptable as long as pattern
does not run off tooth at any
point.
30 7
17

shims (6) and (7) if pattern is too close to top
of tooth.

tooth root.

tooth heel.

shims (6) and (7) if pattern is too close to
bottom of tooth.
25--69
TM 9--2320--360--34--2

e. Installation
(2) Remove six screws (2) and differential 1
4 2
5
WARNING
(3) Coat around mounting flange of differential
assembly (4) with silicone adhesive--sealant.
WARNING

device.
(5) Coat three studs (7) with silicone adhesive--
11 10
sealant.
(6) Install three taper dowels (8), washers (9), 9
12
and nuts (10) on studs (7). Torque to
140--152 lb--ft (190--206 N.m). 8
13
WARNING
Adhesive--sealant may burn 4
or give off harmful vapors. It
7
keep away from open flame 6
and use in well--ventilated
area. If adhesive--sealant gets
on skin or clothing, wash
immediately with soap and
water.
(7) Coat 11 screws (11) with adhesive--sealant

(8) Install washers (12), screws (11), and two
standoff brackets (13) in differential
(190--206 N.m).
25--70
TM 9--2320--360--34--2
(9) Route breather hose (14) through

bracket (15).
WARNING
soap and water. 15.3
30
(9.1) Coat threads of elbow (16), elbow (30),
adapter (15.1), adapter (15.2), and breather
(15.3). 15.2
(9.2) Install elbow (16) and elbow (30) on tee 16

(15.4).
(9.3) Install tee (15.4) and adapter (15.1) in axle 15.4 14
housing (6).
(9.4) Install adapter (15.2) and breather (15.3) on 15.1

tee (15.4).
(10) Install breather hose (14) on elbow (16).
27
25
24
13
20
(11) Install fitting (17) on breather hose (14).
(12) Install hose no. 2016 (18) on fitting (19).
18
(14) Install hose no. 2873 (22) on fitting (23). 26 6

(15) Install four hoses (14, 18, 20, and 22) on
standoff bracket (13) with cushion clip (24), 22
screw (25), and new locknut (26).
NOTE 15
Plastic cable ties should be
positioned in locations marked 23
during removal. 19
21
(16) Secure hoses no. 2873 (22), no. 2141 (20),
no. 2016 (18), and breather hose (14) with 14
plastic cable ties (27) as required. 17
25--71
TM 9--2320--360--34--2

(17) Route breather hose (28) through
bracket (29). 28
29
(18) Install breather hose (28) on elbow (30).

28
30
(19) Install fitting (31) on breather hose (28).

38
37
(21) Install hose no. 2140 (34) on fitting (35). 27
(23) Install four hoses (28, 32, 34, and 36) on 34
standoff bracket (13) with cushion clip (37),
screw (38), and new locknut (39). 32
13
NOTE
Plastic cable ties should be 39
positioned in locations marked
during removal.
33
(24) Secure hoses no. 2018 (32), no. 2140 (34),
no. 2109 (36), and breather hose (28) with 29
plastic cable ties (27) as required. 36

40
28
41
31
(1) Install pivot, spindle, and axle shafts (para 10--7).
(2) Install no. 4 axle manifold (TM 9--2320--360--20)
25--72
TM 9--2320--360--34--2
CHAPTER 26
BRAKE SYSTEM MAINTENANCE
Contents Para Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26--1 26--1
Air Compressor Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26--2 26--2
26--1. INTRODUCTION
This chapter contains maintenance instructions for repair of the brake system at the General Support
maintenance level. Some subassemblies and parts must be removed before components can be
removed. They are referenced to other paragraphs of this manual.
26--1
TM 9--2320--360--34--2
26--2. AIR COMPRESSOR REPAIR
This task covers:

INITIAL SETUP

Air compressor on clean work surface. Oil, Lubricating (Item 46, Appendix B)
Plastigage (Item 50, Appendix B)
Tool Kit, Genl Mech (Item 202, Appendix E) Parts Kit, Compressor (Item 209, Appendix F)
Caliper Set, Micrometer (Item 15, Appendix E) Parts Kit (Item 202, Appendix F)
Compressor Unit, Air (Item 24, Appendix E) Parts Kit (Item 203, Appendix F)
Compressor, Piston Ring (Item 19, Parts Kit (Item 204, Appendix F)
Appendix E) Parts Kit (Item 205, Appendix F)
Gage Set, Telescoping (Item 56, Appendix E) Parts Kit (Item 206, Appendix F)
Puller Kit, Mechanical, Gear and Brg
Remover and Installer, Piston Ring (Item 135,
Appendix E)
Wrench, Crow’s Foot, 1/2 In. (Item 221,
Appendix E)
Wrench, Crow’s Foot, 9/16 In. (Item 218,
Appendix E)
Appendix E)
Appendix E)
3
1
4 5
a. Disassembly
5 2
(1) Loosen nut (1) on discharge manifold
assembly (2). 6
(2) Remove two screws (3), screws (4), four 8
lockwashers (5), discharge manifold 6
assembly (2), and two gaskets (6) from
cylinder heads (7 and 8). Discard
lockwashers and gaskets.
7
26--2
TM 9--2320--360--34--2
(3) Remove discharge manifold (9) from

tube (10).
(4) Remove preformed packing (11) from
discharge manifold (9). Discard preformed
12
packing.
(5) Remove nut (1) from discharge 10
manifold (12).
(6) Remove tube (10) from discharge 1
manifold (12).
11
7
16
(7) Remove four screws (13), lockwashers (14),

intake manifold assembly (15), and two 15
gaskets (16) from two cylinder heads (7 and
8). Discard lockwashers and gaskets.
14
13
16
19
(8) Remove intake manifold (17) from hose 18

(18). 17
(9) Remove intake manifold (19) from hose
(18).
26--3
TM 9--2320--360--34--2
26--2. AIR COMPRESSOR REPAIR (CONT) 22 24
20 23
25
(10) Remove four screws (20) and connecting 26

plate (21) from two cylinder heads (7 and 8).
21 27
(11) Remove screw (22), washer (23), two
screws (24), washers (25), unloader cover 30
(26), and gasket (27) from cylinder head (7). 8
Discard gasket.
28
(12) Remove two unloader pins (28), and springs
29
(13) Remove two preformed packings (30) from
unloader pins (28). Discard preformed
packings.
34
31
(14) Remove remaining three screws (31) from

cylinder head (7).
(15) Remove cylinder head (7) and gasket (32) 32
from cylinder block (33). Discard gasket.
cylinder head (7). Discard preformed
packing.
cylinder head (8). 33
26--4
TM 9--2320--360--34--2
(18) Remove six screws (35). lockwashers (36),

35
plate (37), and gasket (38) from crankcase
assembly (39). Discard lockwashers and 40
37 36
gasket.
41
(19) Remove four screws (40), lockwashers (41),
plate (42), and gasket (43) from crankcase 42
38
assembly (39). Discard lockwashers and
gasket.
NOTE 43 44
Rotate crankshaft to gain
access to connecting rod
screws. 46
(20) Remove two screws (44) from connecting 47

rod (45) and connecting rod cap (46). 39
48
NOTE
Matchmark caps and connecting
rods before removing caps. 49
(21) Remove connecting rod cap (46) and 45
bearing half (47) from crankshaft (48).
(22) Repeat steps (20) and (21) for remaining 33
three piston and rod assemblies (49). 50
51
54
52
NOTE
Matchmark cylinder block and
crankcase assembly.
39
(51) from cylinder block (33). Discard
lockwashers.
(24) Remove cylinder block (33) and gasket (52)
from crankcase assembly (39). Discard 53
gasket. 53
(25) Remove two bearing halves (53) from 45
connecting rods (45). 45
cylinder block (54).
26--5
TM 9--2320--360--34--2
26--2. AIR COMPRESSOR REPAIR (CONT)
49
49
(27) Push four piston and rod assemblies (49)

out through bottom of two cylinder
blocks (33 and 54).
33
54
57
58 56
(28) Remove four screws (55) and bearing end

cover (56) from crankcase assembly (39).
(29) Remove preformed packing (57) from 39
bearing end cover (56) Discard preformed 59
packing. 55
(30) Remove oil flow regulator (58) and spring
(59) from bearing end cover (56).
63
60
62
(31) Remove cotter pin (60) from nut (61).
Discard cotter pin.
(32) Remove nut (61) and drive coupling (62)
from crankshaft (48).
(33) Remove key (63) from crankshaft (48).
48
61
26--6
TM 9--2320--360--34--2
WARNING

WARNING
3 1
(3) Clean carbon deposits from cylinder head
interior surfaces, piston crowns, and piston
ring grooves.
(4) Clean interior air and water passageways
and blow out with compressed air.
(5) Remove gasket material from gasket mating
surfaces.
(6) Inspect cylinder heads, cylinder blocks, and
crankcase assembly for cracks and
damaged threads. Gasket surfaces must be
free of nicks and gouges.
(7) Inspect intake and exhaust valves for wear
grooves, cracks, or pits.
(8) Inspect pistons for scoring, cracks, or other 2
damage.
(9) Measure piston (1) outside diameter.
Measure cylinder bore (2) inside diameter
using telescoping gage. Piston (1) to bore
(2) clearance should not exceed 0.008 in.
(0.20 mm). Replace pistons and cylinder
block if clearance is exceeded.
(10) Inspect cylinder bores for scratches, scoring,
and pitting.
(11) Inspect bores (2) for out--of--round or taper.
Bores (2) must not be out--of--round more
than 0.0005 in. (0.013 mm). Bores (2) must
not taper more than 0.001 in. (0.025 mm)
from top to bottom of bore. Replace cylinder
block if limits are exceeded.
(12) Inspect piston rings for cracks or wear.
Clearance between rings (3) and piston (1)
grooves must not exceed 0.0045 in. (0.114 mm).
26--7
TM 9--2320--360--34--2
26--2. AIR COMPRESSOR REPAIR (CONT) 2 4
2
5
(13) Position compression ring (4) in cylinder
bore (2) and measure end gap clearance.
Replace rings if clearance exceeds 0.017 in.
(0.43 mm).
(14) Position oil ring (5) in cylinder bore (2) and
measure end gap clearance. Replace rings 6
if clearance exceeds 0.055 in. (1.40 mm).
(15) Inspect connecting rod bearings (6) for
scoring, pitting, or visible wear. Clearance
between bearings (6) and crankshaft
journals (7) must be 0.005--0.0021 in.
(0.053--0.127 mm) after assembly. Replace
bearings if clearance is exceeded.
(16) Measure distance between side of
connecting rod bearing cap (8) and
crankshaft (9). Clearance must not exceed 9
7
0.010 in. (0.254 mm) after assembly.
Replace connecting rod if clearance is
exceeded.
(17) Check ball bearings for worn or damaged
balls; rotate bearings by hand to detect 8
roughness. Replace crankcase assembly if
wear, roughness, or damage is evident.
c. Assembly
1
(1) Position crankcase assembly (1) in vise.
2
(2) Install key (2) in crankshaft (3).
NOTE 6
When proper torque is reached, 4
continue to tighten until slot in
nut aligns with hole in
crankshaft for cotter pin.
(3) Install drive coupling (4) and nut (5) on

crankshaft (3). Torque to 80 lb--ft (108 N.m).
(4) Install new cotter pin (6) through nut (5) and
crankshaft (3). 3
26--8
TM 9--2320--360--34--2
(5) Install spring (7) and oil flow regulator (8) in

bearing end cover (9).
(6) Install new preformed packing (10) in
bearing end cover (9).
10
NOTE
When properly installed, tab on 8 9
oil flow regulator should be up.
(7) Install bearing end cover (9) on crankcase

assembly (1) with four screws (11).
(8) Coat cylinder walls (12) and piston and rod 1
assemblies (13) with lubricating oil. 7
11
(9) Install four piston and rod assemblies (13) in 17 17
two cylinder blocks (14 and 15) using piston
ring compressor (16).
18
13 18
NOTE
Locating tabs on bearing halves
must insert in locating notches
in connecting rods. 14
16
12
(10) Install two bearing halves (17) on connecting
15
rods (18).
(11) Coat two bearing halves (17) with lubricating oil.
NOTE
Cylinder block should be in-
stalled on crankcase as marked
during removal.
(12) Install new gasket (19) and cylinder block 14

(14) on crankcase assembly (1). 21
NOTE
20
· Two center screws should
15
be tightened to 96 lb--in. 19
(11 N.m).
· Four outer screws then
should be tightened to 96
lb--in. (11 N.m).
· Two center screws then
should be tightened to 19
27--33 lb--ft (37--45 N.m).
· Four outer screws then
should be tightened to
27--33 lb--ft (37--45 N.m).
(13) Install six new lockwashers (20) and screws

(21) on cylinder block (14). Torque to 27--33 1
lb--ft (37--45 N.m).
(14) Repeat steps (10) thru (13) for cylinder block (15).
26--9
TM 9--2320--360--34--2
26--2. AIR COMPRESSOR REPAIR (CONT) 33

29
(15) Coat connecting rod journal (22) on 31 32
crankshaft (3) with lubricating oil. 28
(16) Position connecting rod (18) on 27
crankshaft (3).
NOTE
· Locating tab on bearing half 26 25
must insert in locating notch
in connecting rod cap. Align 24 30
arrows on connecting rod
23
and cap.
· Rotate crankshaft to gain 22
1
access to connecting rod
screws.
(17) Install bearing half (23) and connecting rod
cap (24) on crankshaft (3).
13
(18) Install two screws (25) in connecting rod cap
3 18
(24) and connecting rod (18). Torque to
105--135 lb--in. (11.9--15.3 N.m).
(19) Repeat steps (15) thru (18) for three
remaining piston and rod assemblies (13). 45 43
(20) Install new gasket (26) and plate (27) on
crankcase assembly (1) with four new 44 42
41
37
to110--150 lb--in. (12.4--17 N.m). 40
36
(21) Install new gasket (30) and plate (31) on 38
crankcase assembly (1) with six new
lockwashers (32) and screws (33). Torque 39
to110--150 lb--in. (12.4--17 N.m).
35 46
47
(22) Position new gasket (34) and cylinder head
(35) on cylinder block (14) with three screws
(36). Do not tighten screws. 34
(23) Install two new preformed packings (37) on
unloader pins (38).
(24) Install two springs (39) and unloader pins 14
34
(38) in cylinder head (35).
(25) Install new gasket (40) and unloader cover
(41) on cylinder head (35) with two washers
(42) and screws (43). Torque to 10 lb--in.
(1.13 N.m).
(26) Position washer (44) and screw (45) on
cylinder head (35). Do not tighten screw.
(27) Install new preformed packing (46) on
cylinder head (47).
cylinder head (47).
26--10
TM 9--2320--360--34--2
(29) Position connecting plate (48) on two 49

cylinder heads (35 and 47) with four screws
(49). Do not tighten screws.
43 45
CAUTION 48
Head screws must be tightened 36
in the following order. Damage
to equipment may result.
35 45
(30) Tighten three screws (36), screw (45), and
two screws (49) on cylinder head (35) to 43
18--22 lb--ft (24.4--30 N.m). Retighten to
27--33 lb--ft (37--45 N.m) in same order. 47
(31) Tighten two screws (43) to 100--150 lb--in.

(11.3--17.0 N.m).
(32) Repeat steps (29) and (30) for cylinder
head (47).
(33) Install intake manifold (50) on hose (51).

(34) Install intake manifold (52) on hose (51).
51
50
52
35
47
53
(35) Install two new gaskets (53) and intake

manifold assembly (54) on two cylinder
heads (35 and 47) with four new 54
to 110--150 lb--in. (12.4--17.0 N.m).
55
56
53
26--11
TM 9--2320--360--34--2
26--2. AIR COMPRESSOR REPAIR (CONT)
(36) Install tube (57) in discharge manifold (58). 58

(37) Install nut (59) on discharge manifold (58). 57
Do not tighten.
(38) Install new preformed packing (60) in 59
discharge manifold (61).
60
(39) Install discharge manifold (61) on tube (57).
61
65
59
66 64
64 63
62
(40) Install two new gaskets (62) and discharge
manifold assembly (63) on two cylinder 35
62
heads (35 and 47) with four new
lockwashers (64), two screws (65), and
screws (66). Torque to 110--150 lb--in
(12.4--17.0 N.m).
47
(41) Tighten nut (59) on discharge manifold
assembly (63).
26--12
TM 9--2320--360--34--2
CHAPTER 27
STEERING SYSTEM MAINTENANCE
Contents Para Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27--1 27--1
Steering Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27--2 27--2
Auxiliary Steering Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27--2.1 27--22.1
Front Steering Gear Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27--3 27--23
Rear Steering Gear Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27--4 27--32
Tee Gear Box Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27--5 27--41
Gear Reducer Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27--6 27--52
27--1. INTRODUCTION
This chapter contains instructions for repair of steering system components at the General Support maintenance
level.
27--1
TM 9--2320--360--34--2
27--2. STEERING PUMP REPAIR
This task covers:

Disassembly Assembly
Cleaning/Inspection
INITIAL SETUP

Steering pump on clean work surface. Adhesive--Sealant (Item 5, Appendix B)
Tape, Plastic (Item 59, Appendix B)
Tools and Special Tools Gaskets (2) (Item 24, Appendix F)
Tool Kit, Genl Mech (Item 202, Appendix E) Gaskets (2) (Item 26, Appendix F)
Caliper Set, Micrometer (Item 15, Appendix E) Packings, Preformed (8) (Item 169, Appendix F)
Caps, Vise Jaw (Item 17, Appendix E) Packings, Preformed (4) (Item 172, Appendix F)
Compressor Unit, Air (Item 24, Appendix E) Packings, Preformed (2) (Item 170, Appendix F)
Goggles, Industrial (Item 57, Appendix E) Packings, Preformed (2) (Item 171, Appendix F)
Nut, 5/8 In. (Item 101, Appendix E) Packings, Preformed (2) (Item 184, Appendix F)
Pliers, Retaining Ring (Item 108, Appendix E) Packings, Preformed (2) (Item 187, Appendix F)
Press, Hydraulic (Item 116, Appendix E) Packing, Preformed (Item 185, Appendix F)
Puller Kit, Mechanical, Gear and Brg Rings, Retaining (2) (Item 234, Appendix F)
(Item 124, Appendix E) Seals, Oil (2) (Item 311, Appendix F)
Screw, 5/8 x 4--1/2 In. (Item 149, Appendix E)
Socket, Power Steering (Item 166, Appendix E)
Washers, Flat, 5/8 In. (4) (Item 209, Appendix E)
Appendix E)
Appendix E)
Appendix E)
NOTE
Steering pump consists of two 4
similar housings.
a. Rear Housing Disassembly

(1) Remove shipping plug (1) from valve
block (2).
(2) Remove hose (3) from elbow (4). 5
3
(3) Remove hose (3) from fitting (5).
4
(4) Remove elbow (4) and preformed packing
(6) from compensator body (7). Discard 6
preformed packing.
(5) Remove four screws (8), compensator
body (7), gasket (9), and preformed
packing (10) from valve block (2).
10 9
Discard preformed packing and gasket. 7 8
1 2
27--2
TM 9--2320--360--34--2
(6) Remove six screws (11), valve block (2),

gasket (12), and bracket (13) from pump 13
14
12
2
11
(7) Remove wafer plate (15), pin (16), and

piston (17) from valve block (2).
WARNING
act as projectiles when re- 25
2
injury. 16
(8) Remove retaining ring (18), rod (19), and

preformed packing (20) from valve block (2).
15
24
NOTE
Do step (9) if valve fails
inspection.
18
(9) Remove seat (21), valve (22), and spring 20
(23) from valve block (2).
19
(10) Position valve block (2) in soft--jawed vise.
NOTE 23 17
When removing bearing cup, 22
21
frequently reposition slide
hammer hook.
(11) Remove bearing cup (24) from valve

block (2).
(26) from valve block (2). Discard
preformed packing.
27--3
TM 9--2320--360--34--2
27--2. STEERING PUMP REPAIR (CONT)
30
(13) Remove fitting (27) and preformed packing 65
32 27
(28) from adapter (29). Discard preformed 33 28
31
packing.
(14) Remove two plugs (30) and preformed
packings (31) from adapter (29). Discard
preformed packings.
(15) Remove adapter (29) and preformed 29 30
packing (32) from valve block (2). Discard 34
preformed packing.
WARNING
injury.
(16) Remove retaining ring (33) from

adapter (29).
(17) Remove orifice plug (34) from adapter (29).
39
38
(18) Remove bearing (35) and spacer (36) from 37

shaft (37).
(19) Remove cylinder block (38) and three pins
(39) from shaft (37).
36
(20) Remove shoe plate (40), nine pistons (41),
35
and spherical washer (42) from cylinder
block (38). 38
43
(21) Remove pin retainer (43) from cylinder 42
block (38). 41
40
27--4
TM 9--2320--360--34--2
WARNING
Cylinder block spring must be
held by screw, washers, and 46
nut before removing retaining
ring. Spring and retaining 44
ring are under high tension
and can act as projectiles 47
when released. Failure to
comply may result in injury to 48
personnel.
CAUTION 49
Do not clamp on flat surface of
cylinder block. Failure to
comply may result in damage to 50
machined surface.
(22) Position cylinder block (38) in soft--jawed

vise.
(23) Position four washers (44), screw (45), and 38
nut (46) through cylinder block (38).
(24) Tighten nut (46) and remove retaining
ring (47).
(25) Loosen nut (46) to relieve spring tension. 44
(26) Remove nut (46), four washers (44) and
screw (45) from cylinder block (38).
(27) Remove spring washer (48), spring (49),
and spring washer (50), from cylinder block 45
(38).
(28) Remove four screws (51), pintle cover (52),

and shim kit (53) from pump housing (14).
(29) Remove preformed packing (54), pintle
bearing spacer (55), bearing cup (56), and 58
bearing cone (57) from pump housing (14).
14
(31) Remove preformed packing (61), pintle 59
61
bearing cone (64) from pump housing (14). 62
Discard preformed packing. 63
64
57
56
55
54
51 53
52
27--5
TM 9--2320--360--34--2
(32) Remove shaft (65), yoke (66), and bearing 14

(67) from pump housing (14).
69
(33) Remove seat (68) and spring (69) from 68
pump housing (14).
65
NOTE 71
Do step (34) if seat fails 70
inspection.
(34) Remove seat (70) and roll pin (71) from

yoke (66). 67
NOTE
Do steps (35) and (36) if bearing
fails inspection. 66
(35) Position shaft (65) in press with wide edge

of bearing (67) down.
(36) Press bearing (67) from shaft (65).
75
(37) Remove two screws (72), washers (73), 74
pump housing (14), coupler (74), and
preformed packing (75) from pump housing
76
(76). Discard preformed packing.
73
72
14
WARNING
injury.
(38) Remove retaining ring (77) from housing 79

(14). Discard retaining ring.
Discard seal.
(40) Remove bearing race (79) from
housing (14).
27--6
TM 9--2320--360--34--2
b. Front Housing Disassembly

8
(1) Remove shipping plug (1) from valve
block (2). 6 7
(2) Remove hose (3) from elbow (4).
4
(3) Remove hose (3) from fitting (5). 9
(4) Remove elbow (4) and preformed packing 10

(6) from compensator body (7). Discard 3
preformed packing and gasket. 12
(5) Remove four screws (8), compensator body 11

(7), gasket (9), preformed packing (10), 5
12
spool (11) and two preformed packings (12)
3
from valve block (2). Discard preformed
packings and gasket.
1 2
15
14
(6) Remove six screws (13), valve block (2), 2

and gasket (14) from pump housing (15).
Discard gasket.
13
27--7
TM 9--2320--360--34--2

(7) Remove wafer plate (16), pin (17), and 25
26
piston (18) from valve block (2).
2
(8) Remove rod (19) and preformed packing
(20) from valve block (2). Discard 17
preformed packing.
24 16
NOTE
inspection.
18
(9) Remove seat (21), valve (22), and spring
(10) Position valve block (2) in soft--jawed vise. 20
(11) Remove bearing cup (24) from valve 19
block (2).
21
(13) Remove fitting (27) and preformed packing 30

(28) from adapter (29). Discard preformed 27
packing. 2 28
31
33 34
(14) Remove two plugs (30) and preformed
packings (31) from adapter (29). Discard
preformed packings.
(15) Remove adapter (29) and preformed
packing (32) from valve block (2). Discard 29
preformed packing. 32 30
WARNING
injury.
(16) Remove retaining ring (33) from

adapter (29).
(17) Remove orifice plug (34) from adapter (29).
27--8
TM 9--2320--360--34--2
(18) Remove bearing (35) and spacer (36) from

shaft (37).
(19) Remove cylinder block (38) and three pins 39
(39) from shaft (37). 38
and spherical washer (42) from cylinder
block (38).
(21) Remove pin retainer (43) from cylinder 37
block (38).
36
35
38
43
42
41
40
WARNING
Cylinder block spring must be 46
held by screw, washers, and
44
ring. Spring and retaining 47
ring are under high tension 48
and can act as projectiles
comply may result in injury to
personnel. 49
50
CAUTION
cylinder block. Failure to
machined surface.
(22) Position cylinder block (38) in soft--jawed 38

vise.
(23) Install four washers (44), screw (45), and nut
(46) through cylinder block (38).
44
ring (47).
(25) Loosen nut (46) to relieve spring tension.
(26) Remove nut (46), screw (45), and four
washers (44) from cylinder block (38). 45
and spring washer (50) from cylinder block
(38).
27--9
TM 9--2320--360--34--2

(28) Remove four screws (51), pintle cover (52), and shim kit (53) from pump housing (15).
(29) Remove preformed packing (54), pintle bearing spacer (55), bearing cup (56) and bearing
cone (57) from pump housing (15). Discard preformed packing.
(30) Remove four screws (58), pintle cover (59), and shim kit (60) from pump housing (15).
(31) Remove preformed packing (61), pintle bearing spacer (62), bearing cup (63) and bearing
cone (64) from pump housing (15). Discard preformed packing.
15
58
59
60
61
62
63
64
57
56
55
54
53
51 52
(32) Remove shaft (65), yoke (66), and bearing

(67) from pump housing (15).
15
(33) Remove seat (68) and spring (69) from
pump housing (15). 69
68
NOTE
65
Do step (34) if seat fails
71
inspection. 70
(34) Remove seat (70) and rollpin (71) from

yoke (66).
67
NOTE
Do steps (35) and (36) if bearing
fails inspection.
(35) Position shaft (65) in press with wide edge 66

of bearing (67) down.
(36) Press bearing (67) from shaft (65).
27--10
TM 9--2320--360--34--2
WARNING
injury. 73
(37) Remove retaining ring (72) from housing
(15). Discard retaining ring. 74
Discard seal.
(39) Remove bearing race (74) from
housing (15).
WARNING
flush with water for 15 minutes or until irritation subsides. If symptoms persist, seek medical attention. First aid
for inhalation: move to fresh air. If not breathing, provide artificial respiration. If symptoms persist, seek medica
l attention. Keep away from open flames and other sources of ignition. Failure to follow this warning may result
in injury or death to personnel.
WARNING
Compressed air for cleaning purposes will not exceed 30 psi (207kPa). Use
only with effective chip guarding and personal protective equipment
(goggles/shield, gloves, etc.)
CAUTION
Bearings must be air dried or damage to bearing will result.
(2) Dry parts, except bearings, with compressed air.
(3) Inspect parts for damage. Replace non--serviceable damaged parts.
Remove all burrs with crocus cloth.
(4) Inspect face of wafer plate for wear, scratches, and fractures.
(5) Inspect springs for wear and check that ends are parallel.
Replace warped or worn springs.
(6) Inspect yoke face for wear, roughness, and scoring.
(7) Inspect shaft for wear, chipped splines, and burrs.
NOTE
Wobble shoe plate to ensure that each piston is free within its bore
in the cylinder block.
(8) Check cylinder block bore for excessive wear. Piston should be close fit but
slide in and out easily. If binding exists, clean and lubricate block and piston
with clean hydraulic fluid. If binding persists, replace cylinder block.
27--11
TM 9--2320--360--34--2

(9) Check for excessive end play between
piston and shoe.
NOTE
Piston faces’ thickness
dimensions must within 0.001
in. (0.025 mm) of each other.
(10) Measure thickness of nine piston faces.
NOTE
Pins, bearings, and races are
replaced in sets. If one is
defective, replace both.
(11) Inspect pins for equal length and bent

condition. Replace if damaged.
(12) Remove burrs from pin retainer
(13) Inspect bearings for scoring, pitting, and
roughness when turned in race. Replace if
damaged.
(14) Inspect bearing spacers for burrs.
(15) Press in check valve (1). Valve should
return and hold firm against seat. Replace if 1
damaged.
(16) Inspect spherical washer for burrs, wear,
and scratches due to pin breakage.
d. Front Housing Assembly
CAUTION
Use plastic tape on shaft to
prevent damage to seal when
installing.
NOTE
Bearing race is installed with
narrow side to inside of housing.
(1) Install bearing race (1) in pump housing (2).

2
(2) Install seal (3) in pump housing (2).
4
WARNING 3
rings. Retaining rings are un- 1
jury.
(3) Install retaining ring (4) in pump housing (2).
27--12
TM 9--2320--360--34--2
(4) Position bearing (5) in press with narrow

side down. 10
(5) Press shaft (6) into bearing (5). 11
NOTE 6
Do step (6) if seat and roll pin 7
were removed. 8
(6) Install roll pin (7) and seat (8) on yoke (9).
(7) Install spring (10) and seat (11) in pump 5
housing (2). 2
(8) Install yoke (9) and shaft (6) in pump

housing (2).
NOTE
· When properly assembled, yoke
should be stiff, but loose enough
to be moved by hand.
· If yoke is too tight in housing,
add or remove shims until
correct preload is obtained. 15 18
14
13
(9) Install bearing cone (12), bearing cup (13), 2 12
bearing spacer (14), and preformed packing
(15) in pump housing (2).
NOTE
· Shims must be adjusted only if 17
new bearings are installed. 16
· If shim thickness is greater than
0.02 in., another shim must be
added to opposite side of yoke
to reduce total shim thickness to
less than 0.02 in. Shim
thickness at either pintle must
4 1
not exceed 0.02 in.
(10) Install shim kit (16) and pintle cover (17) on

pump housing (2) with four screws (18).
2 3
Cross--tighten to 175--185 lb--in.
(237--251N.m).
27--13
TM 9--2320--360--34--2
2
(11) Install bearing cone (19), bearing cup (20),
bearing spacer (21), and new preformed
packing (22) in pump housing (2).
19
20
(12) Install shim kit (23) and pintle cover (24) on 21
pump housing (2) with four screws (25). 22
(237--251 N.m).
4 1
23
24
25
2 3
32
30
33
28
(13) Install spring washer (26), spring (27), and
spring washer (28) in cylinder block (29).
(14) Position four washers (30), screw (31), and 27
26
NOTE
Tighten nut only enough to
install retaining ring.
(15) Tighten nut (32) to compress spring (27). 29
WARNING
rings. Retaining rings are un- 30
jury.
31
(16) Install retaining ring (33) in cylinder
block (29).
washers (30).
27--14
TM 9--2320--360--34--2
NOTE
Pin retainer must be installed 29
0.25 in. (6.4 mm) below surface.
35
(18) Install pin retainer (34) in cylinder block (29). 34
36
NOTE 37
Pins must be installed in
cylinder block until they bottom
against spring washer. 38
(19) Install three pins (35) in cylinder block (29).
(20) Position spherical washer (36) on top of
three pins (35).
(21) Install shoe plate (37) with nine pistons (38)
over spherical washer (36) and into cylinder
block (29).
(22) Install cylinder block (29) on shaft (6). 29
(23) Install bearing spacer (39) and bearing (40)
on shaft (6).
39
40
(24) Install orifice plug (41) in adapter (42) with

45
new retaining ring (43).
(25) Install two new preformed packings (44) and 44
plugs (45) on adapter (42). 49 42
47 46
(26) Install new preformed packing (46) and
fitting (47) on adapter (42).
adapter (42) on valve block (49).
41
43 44
48 45
27--15
TM 9--2320--360--34--2

(28) Install new preformed packing (50) and plug
(51) in valve block (49).
50
51
NOTE 49
· Do step (29) if seat, valve, and 59
spring were removed.
· When properly installed, seat
55
60
should be flush with face of
valve block.
(29) Install spring (52), valve (53), and seat (54)

in valve block (49).
(30) Install bearing cup (55) in valve block (49).
(31) Install new preformed packing (56) on 56
rod (57). 57
WARNING
52 58
Adhesive--sealant can burn 53 54
ventilated areas. If adhesive--
soap and water.
(32) Coat threads of rod (57) with adhesive--

sealant. 2
(33) Install rod (57) and new preformed packing
(56) in valve block (49). 61
(34) Install piston (58), pin (59), and wafer plate 49
(60) on valve block (49).
(35) Install new gasket (61) and valve block (49)

on pump housing (2) with six screws (62).
Torque to 23--26 lb--ft (31--35 N.m).
62
27--16
TM 9--2320--360--34--2
(36) Install two new preformed packings (63) and

spool (64) in valve block (49). 68
(37) Install new preformed packing (65), new 69 67
gasket (66), and compensator (67) on valve
block (49) with four screws (68). Torque to 71
60--70 lb--in. (6.8--7.9 N.m) 66
70
elbow (70) on compensator (67). Tighten 65
72
jam nut (71). 63
(39) Install hose (72) on fitting (46) on valve 64
block (49).
63 46
(40) Install hose (72) on elbow (70). 72
(41) Install coupling (73) on shaft (6).
(42) Install shipping plug (74) in valve block (49).
6
73
74 49
e. Rear Housing Assembly
NOTE
Bearing race is installed with
narrow side to inside housing.
(1) Install bearing race (1) in pump housing (2). 2
NOTE 4
side out. 3
(2) Install seal (3) in pump housing (2). 1
WARNING
injury.
(3) Install retaining ring (4) in pump housing (2).
27--17
TM 9--2320--360--34--2
(4) Install new preformed packing (5) and pump

housing (2) on valve block (6) with two
washers (7) and screws (8).
7
8
2
(5) Position bearing (9) in press with narrow
side down.
(6) Press shaft (10) into bearing (9).
NOTE 2
Do step (7) if seat and roll pin
were removed. 14
15
(7) Install roll pin (11) and seat (12) on
yoke (13).
(8) Install spring (14) and seat (15) in pump 10 12
housing (2). 11
(9) Install yoke (13) and shaft (10) in pump

housing (2). 9
13
27--18
TM 9--2320--360--34--2
NOTE
· When properly assembled, yoke should be stiff, but loose enough
to be moved by hand.
· If yoke is too tight in housing, add or remove shims until correct
preload is obtained.
(10) Install bearing cone (16), bearing cup (17), bearing spacer (18), and
preformed packing (19) in pump housing (2).
NOTE
· Shims must be adjusted only if new bearings are installed.
· If shim thickness is greater than 0.02 in., another shim must be
added to opposite side of yoke to reduce total shim thickness to
less than 0.02 in. Shim thickness at either pintle must not exceed 0.02 in.
(11) Install shim kit (20) and pintle cover (21) on pump housing (2) with four
screws (22). Cross--tighten to 175--185 lb--in. (237--251 N.m).
(12) Install bearing cone (23), bearing cup (24), bearing spacer (25), and new
preformed packing (26) in pump housing (2).
(13) Install shim kit (27) and pintle cover (28) on pump housing (2) with four
screws (29). Cross--tighten to 175--185 lb--in. (237--251 N.m).
19
18
17
16
22
21
20
23
24
25
26 2
4 1
27
28
29 2 3
27--19
TM 9--2320--360--34--2
(14) Install spring washer (30), spring (31), and 36

spring washer (32) in cylinder block (33).
34
(15) Position four washers (34), screw (35), and
nut (36) through cylinder block (33). 37
NOTE 32
Tighten nut only enough to
install retaining ring.
31
(16) Tighten nut (36) to compress spring (31).
30
WARNING
injury.

block (33).
34
washers (34) from cylinder block (33).
35
NOTE
Pin retainer must be installed
0.25 in. (6.4 mm) below surface.
(19) Install pin retainer (38) in cylinder block (33).

33
NOTE
Pins must be installed in 39
cylinder block until they bottom 38
against spring washer. 40
41
(20) Install three pins (39) in cylinder block (33).
three pins (39). 42

block (33).
27--20
TM 9--2320--360--34--2
(23) Install cylinder block (33) on shaft (10).

(24) Install bearing spacer (43) and bearing
(44) on shaft (10).
10
33
43
44
49
(25) Install orifice plug (45) in adapter (46) with 48
new retaining ring (47).
53 46
(26) Install two new preformed packings (48) and 51 50
plugs (49) on adapter (46).
fitting (51) on adapter (46).
adapter (46) on valve block (53).
45
47 48
52 49

(55) in valve block (53).
NOTE
· Do step (30) if seat, valve, and 55
54
spring were removed. 53
· When properly installed, seat 64
valve block.
59 65
(30) Install spring (56), valve (57), and
seat (58) in valve block (53).
(31) Install bearing cup (59) in valve block (53).
(32) Install new preformed packing (60) and rod
(33) Install new retaining ring (62) on rod (61). 60
(34) Install piston (63), pin (64), and wafer plate 61
(65) on valve block (53).
56 63
57 58
27--21
TM 9--2320--360--34--2
(35) Install bracket (66), new gasket (67), and

valve block (53) on pump housing (2) with
six screws (68). Torque to 23--26 lb--ft
(31--35 N.m).
66
2
67
53
68
(36) Install new gasket (69), new preformed

packing (70), and compensator (71) on
valve block (53) with four screws (72).
Torque to 60--70 lb--in. (6.8--7.9 N.m). 74
52
76
74
75
73

elbow (74) on compensator (71). Tighten 70 69
jam nut (75). 53 71 72
77
(38) Install hose (76) on fitting (52) on valve
block (53).
(39) Install hose (76) on elbow (74).
(40) Install shipping plug (77) in valve block (53).
27--22
TM 9--2320--360--34--2
27--2.1. AUXILIARY STEERING PUMP REPAIR
This task covers:

INITIAL SETUP

Auxiliary steering pump on clean work surface. Cloth, Crocus (Item 16, Appendix B)
Tools and Special Tools Piston Rod Kit (Item 227.1, Appendix F)
Tool Kit, Genl Mech (Item 202, Appendix E) Rotating Group Kit (Item 274.1, Appendix F )
Caliper Set, Micrometer (Item 15, Appendix E) Seal Kit (Item 296.1, Appendix F)
Caps, Vise Jaw (Item 17, Appendix E) Shaft Bearing Kit (Item 321.1, Appendix F)
Compressor Unit, Air (Item 24, Appendix E) Yoke Bearing Kit (Item 347, Appendix F)
Nut, 1/2 in. (Item 100.1, Appendix E)
Puller Kit, Mechanical (Item 124, Appendix E)
Screw, 1/2 x 3 1/2 in. (Item 148.1, Appendix E)
Washers, 1/2 in. (2) (Item 208.1, Appendix E
Appendix E)
Appendix E)
a. Disassembly 1
2
(1) Remove four screws (1), compensator body
(2), gasket (3), preformed packing (4), and 4
preformed packing (5) from valve block (6).
Discard gasket and preformed packings. 3
5 6
27--22.1
TM 9--2320--360--34--2
27--2.1. AUXILIARY STEERING PUMP REPAIR (CONT)

7
(2) Remove five screws (7), valve block (6), and

6
gasket (8) from pump housing (9). Discard
gasket.
(3) Remove wafer plate (10) and piston (11)

from valve block (6). 8
WARNING
injury.
(4) Remove retaining ring (12) and rod (13) 10 11

from valve block (6).
13
NOTE
inspection. 6
(5) Remove seat (14), valve (15), and spring 12

(6) Remove two pins (17) from valve block (6). 22
14
(7) Remove plug (18) and preformed packing 17
preformed packing.
(8) Remove plug (20) and preformed packing 16
(21) from valve block (6). Discard
(9) Position valve block (6) in soft jawed vice.
NOTE
When removing bearing, 21
frequently reposition slide
hammer hook. 19 20
(10) Remove bearing (22) from valve block (6).
18
27--22.2
TM 9--2320--360--34--2
23
(11) Remove cylinder block (23) and three pins

27
(24) from shaft (25).
24
and spherical washer (28) from cylinder 26
block (23). 28
(13) Remove pin retainer (29) from cylinder
block (23). 29
25
23
WARNING
Cylinder block spring must be
held by screw, washer, and
ring. Spring and retaining
ring are under high tension
and can act as projectiles
comply may result in injury to
personnel.
CAUTION 32
cylinder block. Failure to 30
machine surface. 33
(14) Position cylinder block (23) in soft--jawed 34

vice.
35
(15) Position two washers (30), screw (31), and
36
NOTE
Spring must be compressed to
allow retaining ring to be
removed.
23
ring (33). 30
(17) Loosen nut (32) to relieve spring tension.
(18) Remove nut (32), two washers (30), and
screw (31) from cylinder block (23). 31
and spring washer (36) from cylinder
block (23).
27--22.3
TM 9--2320--360--34--2
37
(20) Remove two pins (37) from pump 9

housing (9).
(21) Remove four screws (38), pintle cover (39), 39

40
Discard shim kit. 38
(22) Remove preformed packing (41), pintle
and shim kit (47) from pump housing (9). 41
Discard shim kit. 42
43
(24) Remove preformed packing (48), pintle 44
bearing spacer (49), bearing cup (50), and
51
50
49
48
47
45 46
54
(25) Remove yoke (52) from housing (9).
53
(26) Remove seat (53) and spring (54) from 55
pump housing (9). 56
NOTE
Do step (27) if seat fails
inspection. 9
(27) Remove seat (55) and roll pin (56) from

yoke (52). 52
27--22.4
TM 9--2320--360--34--2
WARNING
act as projectiles when released
(28) Remove retaining ring (57) and shaft (25) 25
from pump housing (9). 57
(29) Remove seal (58) from pump housing (9).
Discard seal.
(30) Remove retaining ring (59) from shaft (25). 9 58
(31) Position shaft (25) on press with long end of
shaft (25) facing down. 59
(32) Press shaft (25) from bearing (60).
61
(33) Remove retaining ring (61) from shaft (25).
25
WARNING 60
WARNING
CAUTION
Bearing must be air dried or damage to bearing cone will result.
(2) Dry parts, except bearing cones, with compressed air.
(3) Inspect parts for damage. Replace non--serviceable damaged parts. Remove all
burrs with crocus cloth.
(4) Inspect face of wafer plate for wear, scratches, and fractures.
(5) Inspect springs for wear and check that ends are parallel. Replace warped or worn
springs.
27--22.5
TM 9--2320--360--34--2
(6) Inspect yoke face for wear, roughness, and scoring.

(7) Inspect shaft for wear, roughness, and scoring.
NOTE
Wobble shoe plate to ensure that each piston is free within its bore in the cylinder
block.
(8) Check cylinder block bore for excessive wear. Piston should be close fit but slide in
and out easily. If binding exists, clean and lubricate block and piston with clean
hydraulic fluid. If binding persists, replace cylinder block.
(9) Check for end play between piston and shoe.
NOTE
Piston face thickness dimensions must be within 0.001 in. (0.025 mm) of each
other.
(10) Measure thickness of nine piston faces.
NOTE
Pins, bearings, and races are replaced in sets. If one is defective, replace both.
(11) Inspect pins for equal length and bent condition. Replace if damaged.
(12) Remove burrs from pin retainer.
(13) Inspect bearings for scoring, pitting, and roughness when turned in race. Replace if
damaged.
(14) Inspect bearing spacers for burrs.

1
(15) Press in check valve (1). Valve should

return and hold firm against seat. Replace if
damaged.
(16) Inspect spherical washer for burrs, wear,
and scratches due to pin breakage.
2
c. Assembly
(1) Install new seal (1) in pump housing (2).
27--22.6
TM 9--2320--360--34--2
WARNING
injury.
(2) Install new retaining ring (3) on shaft (4).

5
(3) Position bearing (5) on press.
(4) Press shaft (4) on bearing (5) until bearing
(5) contacts retaining ring (3).
(5) Install new retaining ring (6) on shaft (4).
4
7
(6) Install shaft (4) and new retaining ring (7) on
pump housing (2).
11
NOTE 12
Do step (7) if roll pin and seat 9
were removed. 8
(7) Install roll pin (8) and seat (9) on yoke (10).
(8) Install spring (11) and seat (12) in pump
housing (2). 2
(9) Install yoke (10) in pump housing (2).
10
27--22.7
TM 9--2320--360--34--2
NOTE
· When properly assembled, yoke
should be stiff, but loose enough
to be moved by hand. 25
· If yoke is too tight in pump 24 26
housing, add or remove shims
until correct preload is obtained.
2
(10) Install bearing cone (13), bearing cup (14),
NOTE 23
22
· Shims must be adjusted only if
20
21
new bearings are installed.
· If shim thickness is greater than
0.02 in. (0.508 mm), another 13
shim must be added to opposite 14
side of yoke to reduce total shim 15
thickness to less than 0.02 in. 16
Shim thickness at either pintle 17
must not exceed 0.02 in. (0.508 19 18
mm).
(11) Install shim kit (17) and pintle cover (18) on

(237--251 N∙m)
(12) Install bearing cone (20), bearing cup (21), 4 1
(13) Install shim kit (24) and pintle cover (25) on 2 3
(237--251 N∙m).
27
2
(14) Install two pins (27) in pump housing (2).
27--22.8
TM 9--2320--360--34--2
(15) Install spring washer (28), spring (29), and

spring washer (30) in cylinder block (31). 34
(16) Position two washers (32), screw (33), and 32

nut (34) in cylinder block (31).
35
NOTE 30
Nut should be tightened only
enough to install retaining ring.
29
(17) Tighten nut (34) to compress spring (29).
28
WARNING
injury. 32

block (31).
(19) Remove nut (34), screw (33), and two 33
washers (32) from cylinder block (31).
NOTE
Pin retainer must be installed
0.25 in. (6045 mm) below
surface. 31
(20) Install pin retainer (36) in cylinder block (31).
40
NOTE
Pins must be installed in
cylinder block until they contact 39
spring washer. 38
(21) Install three pins (37) in cylinder block (31). 36
4
three pins (37). 37

31
block (31).
(24) Install cylinder block (31) on shaft (4).
27--22.9
TM 9--2320--360--34--2

46
47 50
49
(27) Install bearing (46) in valve block (43).
41
(28) Install two pins (47) in valve block (43).
44
NOTE 42
· Do step (29) if seat, valve, and
45
spring were removed.
· When properly installed, seat 53
valve block.
54
(29) Install spring (48), valve (49), and seat (50) 51
in valve block (43).
(30) Install rod (51) and retaining ring (52) on

valve block (43). 43
(31) Install piston (53) and wafer plate (54) on 56
valve block (43). 52
43
61 60
55
(32) Install new gasket (55) and valve block (43) 57
on pump housing (2) with five screws (56).
Torque to 23--26 lb--ft (31--35 N∙m). 59
2
58
43
(33) Install new preformed packing (57), new

preformed packing (58), gasket (59), and
compensator body (60) on valve block (43)
with four screws (61).
27--22.10
TM 9--2320--360--34--2
27--3. FRONT STEERING GEAR REPAIR
This task covers:

INITIAL SETUP

Steering gear on clean work surface. Cloth, Crocus (Item 16, Appendix B)
Tool Kit, Genl Mech (Item 202, Appendix E) Oil, Hydraulic (Item 39, Appendix B)
Drill Set, Twist (Item 33, Appendix E) Cleaning Compound, Solvent (Item 54, Appendix B)
Drill, Electric, Portable, 14 In. (Item 34, Gasket/Seal Kit (Item 71, Appendix F)
Hammer, Soft--Faced (Item 63, Appendix E) Pin, Roll (Item 226, Appendix F)
Pan, Oil Drain (Item 102, Appendix E) Seal, Quad Ring (Item 319, Appendix F)
Puller Kit, Mechanical, Slide Hammer
Wrench Set, Socket 3/4 In. Drive (Item 231,
Appendix E)
Appendix E)
Appendix E)
NOTE
Front and rear steering gears
are assembled differently. Parts
are not interchangeable. 1
12
5
a. Disassembly
9
2
(1) Position housing (1) in vise. 3
(2) Remove two plugs (2) from housing (1).
(3) Remove relief valve (3) and preformed
packing (4) from bearing cap (5). Discard
packing (7) from cylinder head (8).
(5) Position drain pan under housing (1). 11 10
(6) Turn actuating shaft (9) fully clockwise then
fully counterclockwise to drain oil through 7
6 8
relief valve holes. 2
(7) Remove eight screws (10) and lockwashers

(11) from pinion gear cover (12). Discard
lockwashers.
27--23
TM 9--2320--360--34--2
27--3. FRONT STEERING GEAR REPAIR (CONT)
13
(8) Remove paint/foreign matter from output
shaft (13) with crocus cloth. 1
(9) Using a soft--faced hammer, tap end of
output shaft (13) to loosen cover (12). 14
12
(10) Remove cover (12) and preformed packing
(14) from housing (1). Discard preformed
packing.
15
NOTE
Do step (11) if bearing fails
inspection.
12
(11) Remove bearing (15) from cover (12).
(12) Remove output shaft (13) and pinion gear

(16) from housing (1).
NOTE 1
· Do not separate pinion gear
from output shaft unless one of 13
them must be replaced.
· Do steps (13) thru (15) if 16 18
replacing pinion gear or shaft.
(13) Remove roll pin (17) from pinion gear (16).

Discard roll pin.
(14) Using 3/8 in. (9.5 mm) bit, drill retaining pin
(18) from pinion gear (16) and output
shaft (13).
(15) Remove pinion gear (16) from output 17
shaft (13).
27--24
TM 9--2320--360--34--2
(16) Remove plug (19) from cylinder head (8).

(17) Remove 12 screws (20) and lockwashers
(21) from cylinder head (8). Discard
lockwashers.
1
(18) Remove cylinder head (8) and preformed 22
packing (22) from housing (1). Discard
preformed packing.
19
8
20 21 1
(19) Remove plug (23) and grease fitting (24)
(20) Remove 12 screws (25) and lockwashers 24
(26) from bearing cap (5). Discard 5
lockwashers. 23
NOTE 26
Bearing cap is removed from
housing by turning input shaft
counterclockwise out of piston.
(21) Remove bearing cap (5) and preformed

25
NOTE 29
Do steps (22) thru (29) if
replacing seals or actuating
shaft.
9
(22) Position bearing cap (5) in soft--jawed vise
with actuating shaft (9) up.
(23) Using 5/64 in. (2 mm) bit, drill retaining pin 5
(28) from bearing cap (5).
(24) Remove bearing retainer (29) from bearing
cap (5).
28
NOTE
Do not separate bearing from
actuating shaft. They are
replaced as an assembly.
(25) Remove actuating shaft (9) from bearing

cap (5).
27--25
TM 9--2320--360--34--2
(26) Position bearing cap (5) in vise with outside

of bearing cap up.
(27) Remove seal (30) and seal (31) from 30
bearing cap (5). 5
31
NOTE
High--pressure seal must be
removed by pressing from
outside of bearing cap.
Some steering gears do not
have backup washer.
(28) Remove high--pressure seal (32) and
backup washer (32.1) from bearing cap (5).
Discard seal and washer. 32.1
(29) Remove bearing cap (5) from vise.

32
NOTE
Do not disassemble piston. It
must be replaced as an assembly.
33 35
1
(30) Remove piston (33) from housing (1).
(31) Remove quad ring seal (34) from housing
(1). Discard quad ring seal.
NOTE
Do step (32) if bearing fails 34
inspection.
(32) Remove bearing (35) from housing (1).
WARNING

(2) Inspect parts for damage, cracks, breaks, or deterioration.
(3) Inspect parts with machined surfaces for deep scratches.
(5) Coat internal parts with light coating of hydraulic fluid.
(6) Replace unserviceable parts.
27--26
TM 9--2320--360--34--2
c. Assembly
(1) Lubricate new quad ring seal (1) with
hydraulic oil and install in housing (2).
NOTE
· Do step (2) if bearing was
removed.
· Bearing must be pressed in until
flush with inside surface of
housing.
(2) Install bearing (3) in housing (2).
NOTE
Do steps (3) thru (12) if seals or
actuating shaft were removed.
(3) Position bearing cap (4) in vise with inside
surface up.
CAUTION
Seals must be evenly pressed in
bearing cap. Failure to comply
may result in damage to seals.
NOTE
· High--pressure seals must be
installed by pressing from inside
of bearing cap to outside.
· Backup washer must be

installed on all steering gears.
(4) Install new backup washer (4.1) and new
high--pressure seal (5) in bearing cap (4)
until it rests against shoulder.
(5) Lubricate high--pressure seal (5) with
hydraulic oil.
(6) Press actuating shaft (6) into bearing
cap (4).
NOTE
Bearing retainer should be
tightened securely to prevent
actuating shaft end play.
(7) Install bearing retainer (7) on bearing
cap (4).
(8) Install new retaining pin (8) in bearing
cap (4).
27--27
TM 9--2320--360--34--2

10
4 9
surface facing up. 5
NOTE
Seals are installed lip--side out.
(10) Install new seal (9) in bearing cap (4) until it

rests against high--pressure seal (5).
(11) Install new seal (10) in bearing cap (4) until
flush with face of bearing cap (4).
11
(13) Lubricate piston (11) with hydraulic oil and
install in housing (2).
NOTE 13
Do steps (14) thru (16) if pinion 12
14
gear or shaft was removed.
(14) Position pinion gear (12) on output

shaft (13).
15
(15) Install retaining pin (14) through hole in
pinion gear (12) into slot on output
shaft (13).
(16) Install roll pin (15) in pinion gear (12).
27--28
TM 9--2320--360--34--2
WARNING 2
Timing marks on piston and
pinion must be properly 12
aligned. Failure to comply
will cause steering gear to fail 13
and loss of vehicle control
which may cause serious
(17) Center timing mark (16) on pinion gear (12)

between timing marks (17) on piston (11)
and install output shaft (13) in housing (2).
11
17 16
NOTE 18
removed during disassembly.
19
flush with face of cover.
(18) Install bearing (18) in cover (19).
20
(19) Lubricate new preformed packing (20) with
hydraulic oil and install on cover (19).
(20) Install cover (19) on housing (2) with eight
new lockwashers (21) and screws (22).
Torque to 170--180 lb--ft (231--244 N.m)
19
21
22
27--29
TM 9--2320--360--34--2

hydraulic oil and install on cylinder
head (24).
(22) Align relief valve hole (25) on cylinder head
(24) with relief valve hole (26) in piston (11).
NOTE
Screws for cylinder head are
shorter than screws for bearing 2
cap.
24 11
(23) Install cylinder head (24) on housing (2) with
12 new lockwashers (27) and screws (28). 29
Torque to 35--45 lb--ft (48--61 N.m).
WARNING
is harmful to skin and cloth- 23 26
28 27
use in well--ventilated areas.
If pipe thread sealing com-
soap and water.

sealing compound.
(25) Install plug (29) in cylinder head (24).
hydraulic oil and install on bearing cap (4).
2
NOTE
Bearing cap is installed on 32
housing by turning actuating 36
shaft clockwise into piston. 11 31 35
(27) Install bearing cap (4) on housing (2).
33
(28) Align relief valve hole (31) in bearing cap (4)
with relief valve hole (32) in piston (11).
(29) Install bearing cap (4) on housing (2) with 12
Tighten to 35--45 lb--ft (47--61 N.m) torque.
(30) Coat threads of plug (35) with pipe thread 30
34
sealing compound. 4
(31) Install plug (35) in bearing cap (4).
(32) Install grease fitting (36) in bearing cap (4).
27--30
TM 9--2320--360--34--2
NOTE
Relief valves have different
lengths. Shorter relief valve
goes in cylinder head.
2
hydraulic oil and install on relief valve (38). 4
41
NOTE 40
Relief valve must be installed
until head is flush with outside
face of cylinder head.
(34) Install relief valve (38) in cylinder head (24).

(35) Lubricate new preformed packing (39) with 39
hydraulic oil and install on relief valve (40).
NOTE
face of bearing cap. 37 24
38 41
(36) Install relief valve (40) in bearing cap (4).
(37) Install two plugs (41) in housing (2).
(38) Remove housing (2) from vise.
27--31
TM 9--2320--360--34--2
27--4. REAR STEERING GEAR REPAIR
This task covers:

INITIAL SETUP

Steering gear on clean work surface. Cloth, Crocus (Item 16, Appendix B)
Tool Kit, Genl Mech (Item 202, Appendix E) Oil, Hydraulic (Item 39, Appendix B)
Drill Set, Twist (Item 33, Appendix E) Cleaning Compound, Solvent (Item 54, Appendix B )
Drill, Electric, Portable, 1/4 In. (Item 34, Gasket/Seal Kit (Item 71, Appendix F)
Hammer, Soft--Faced (Item 63, Appendix E) Pin, Roll (Item 226, Appendix F)
Pan, Oil Drain (Item 102, Appendix E) Seal, Quad Ring (Item 319, Appendix F)
Wrench Set, Socket 3/4 In. Drive (Item 231,
Appendix E)
Appendix E)
Appendix E)
NOTE
Front and rear steering gears
are assembled differently.
Parts are not interchangeable.
1
12 2
a. Disassembly
(1) Position housing (1) in vise. 5
2
(2) Remove three plugs (2) from housing (1). 3
packing (4) from bearing cap (5). Discard 7
preformed packing.
(4) Remove relief valve (6) and preformed 4
packing (7) from cylinder head (8).
(5) Position drain pan under housing (1).
(6) Turn actuating shaft (9) fully clockwise then 11 10
fully counterclockwise to drain oil through 6 9
relief valve holes.
8
(7) Remove eight screws (10) and lockwashers 2
(11) from pinion gear cover (12). Discard
lockwashers.
27--32
TM 9--2320--360--34--2
(8) Remove paint/foreign matter from output

shaft (13) with crocus cloth. 13
(9) Using a soft--faced hammer, tap end of 1
output shaft (13) to loosen cover (12).
(10) Remove cover (12) and preformed packing 14
(14) from housing (1). Discard preformed 12
packing.
NOTE 15
inspection.
(11) Remove bearing (15) from cover (12).

12
(12) Remove output shaft (13) and pinion gear

(16) from housing (1).
NOTE
· Do not separate pinion gear 1
from output shaft unless one of
them must be replaced. 13
· Do steps (13) thru (15) if
18
16
replacing pinion gear or shaft.
(13) Remove roll pin (17) from pinion gear (16).

Discard roll pin.
(14) Using 3/8 in. (9.5 mm) bit, drill retaining pin
(18) from pinion gear (16) and output
shaft (13).
(15) Remove pinion gear (16) from output
shaft (13). 17
27--33
TM 9--2320--360--34--2
27--4. REAR STEERING GEAR REPAIR (CONT)
(16) Remove plug (19) from cylinder head (8).

(21) from cylinder head (8). Discard
lockwashers. 22 8
(18) Remove cylinder head (8) and preformed
packing (22) from housing (1). Discard 19
preformed packing.
21
(19) Remove plug (23) and grease fitting (24) 20
(26) from bearing cap (5). Discard 5
23 24
lockwashers.
NOTE 26
Bearing cap is removed from
housing by turning input shaft
clockwise out of piston.
(21) Remove bearing cap (5) and preformed

25
NOTE
Do steps (22) thru (29) if 29
replacing seals or actuating
shaft.
(22) Position bearing cap (5) in soft--jawed vise 9

with actuating shaft (9) up.
(23) Using 5/64 in. (2 mm) bit, drill retaining pin 5
(28) from bearing cap (5).
(24) Remove bearing retainer (29) from bearing
cap (5).
28
NOTE
Do not separate bearing from
actuating shaft. They are
replaced as an assembly.
(25) Remove actuating shaft (9) from bearing

cap (5).
27--34
TM 9--2320--360--34--2

of bearing cap up.
(27) Remove seal (30) and seal (31) from
bearing cap (5). 30
NOTE 5
High--pressure seal must be 31
removed by pressing from
outside of bearing cap.
Some steering gears do not
have backup washer.
(28) Remove high--pressure seal (32) and
backup washer (32.1) from bearing cap (5).
Discard seal and washer.
32.1
NOTE 32
Do not disassemble piston. It
must be replaced as an assembly. 33
1 35
(30) Remove piston (33) from housing (1).
(31) Remove quad ring seal (34) from housing
(1). Discard quad ring seal.
NOTE 34
inspection.
(32) Remove bearing (35) from housing (1).
WARNING

(5) Coat internal parts with light coating of hydraulic fluid.
27--35
TM 9--2320--360--34--2
c. Assembly
(1) Lubricate new quad ring seal (1) with
hydraulic oil and install in housing (2).
NOTE
· Do step (2) if bearing was 2 3
removed.
flush with inside surface of
housing.
(2) Install bearing (3) in housing (2).
1
NOTE
Do steps (3) thru (12) if seals or
actuating shaft were removed.
(3) Position bearing cap (4) in vise with inside
surface up.
CAUTION 7
Seals must be evenly pressed in
bearing cap. Failure to comply
may result in damage to seals.
NOTE
· High--pressure seals must be
6
installed by pressing from inside
of bearing cap to outside.
· Backup washer must be

installed on all steering gears.
5
(4) Install new backup washer (4.1) and new
4
high--pressure seal (5) in bearing cap (4) 4.1
until it rests against shoulder.
(5) Lubricate high--pressure seal (5) with
hydraulic oil. 8
(6) Press actuating shaft (6) into bearing
cap (4).
NOTE
Bearing retainer should be
tightened securely to prevent
actuating shaft end play.
(7) Install bearing retainer (7) on bearing
cap (4).
(8) Install new retaining pin (8) in bearing
cap (4).
27--36
TM 9--2320--360--34--2

surface facing up. 10
NOTE 4 9
Seals are installed lip--side out.
5
(10) Install new seal (9) in bearing cap (4) until it
rests against high--pressure seal (5).
(11) Install new seal (10) in bearing cap (4) until
flush with face of bearing cap (4).
2
(13) Lubricate piston (11) with hydraulic oil and
install in housing (2).
11
NOTE 13
Do steps (14) thru (16) if pinion 12
gear or shaft was removed. 14
(14) Position pinion gear (12) on output

shaft (13).
(15) Install retaining pin (14) through hole in 15
pinion gear (12) into slot on output
shaft (13).
(16) Install roll pin (15) in pinion gear (12).
27--37
TM 9--2320--360--34--2
WARNING 2
Timing marks on piston and 12
pinion must be properly
aligned. Failure to comply 13
will cause steering gear to fail
and loss of vehicle control
which may cause serious
(17) Center timing mark (16) on pinion gear (12)

between timing marks (17) on piston (11)
and install output shaft (13) in housing (2).
11
17 16
18
NOTE
removed during disassembly. 19
flush with face of cover.
(18) Install bearing (18) in cover (19).
20

hydraulic oil and install on cover (19).
(20) Install cover (19) on housing (2) with eight
Tighten to 170--180 lb--ft (231--244 N.m)
19
22 21
27--38
TM 9--2320--360--34--2

hydraulic oil and install on cylinder
head (24).
(22) Align relief valve hole (25) on cylinder head
(24) with relief valve hole (26) in piston (11).
NOTE
Screws for cylinder head are
shorter than screws for bearing
cap. 2
(23) Install cylinder head (24) on housing (2) with 24 11

12 new lockwashers (27) and screws (28).
Torque to 35--45 lb--ft (48--61 N.m).
29
WARNING
keep away from open fire and 23 26
use in well--ventilated areas. 28 27 25
soap and water.

sealing compound.
(25) Install plug (29) in cylinder head (24).

hydraulic oil and install on bearing cap (4).
2
NOTE
Bearing cap is installed on
housing by turning actuating 32
shaft counterclockwise into
piston. 11 31 35 36
(27) Install bearing cap (4) on housing (2).
33
(28) Align relief valve hole (31) in bearing cap (4)
with relief valve hole (32) in piston (11).
(29) Install bearing cap (4) on housing (2) with 12
Tighten to 35--45 lb--ft (47--61 N.m).
(30) Coat threads of plug (35) with pipe thread 30
sealing compound. 4 34
(31) Install plug (35) in bearing cap (4).

(32) Install grease fitting (36) in bearing cap (4).
27--39
TM 9--2320--360--34--2
NOTE
Relief valves have different
lengths. Shorter relief valve
goes in cylinder head.

NOTE
Relief valve must be installed 2
until head is flush with outside 41
face of cylinder head.
4
(34) Install relief valve (38) in cylinder head (24). 41
40
37
NOTE
39
face of bearing cap.
(36) Install relief valve (40) in bearing cap (4).

(37) Install three plugs (41) in housing (2).
(38) Remove housing (2) from vise. 38
24
41
27--40
TM 9--2320--360--34--2
27--5. TEE GEAR BOX REPAIR
This task covers:

INITIAL SETUP

Tee gear box on clean work surface. Adhesive--Sealant (Item 6, Appendix B)
Tools and Special Tools Compound, Sealing, Pipe Thread (Item 28,
Tool Kit, Genl Mech (Item 202, Appendix E) Appendix B)
Caps, Vise Jaw (Item 17, Appendix E) Grease, General Purpose, Lithium Base
Goggles, Industrial (Item 57, Appendix E) (Item 34, Appendix B)
Pan, Drain Oil (Item 102, Appendix E) Cleaning Compound, Solvent (Item 54, Appendix B)
Pliers, Retaining Ring (Item 111, Appendix E) Tags, Identification (Item 56, Appendix B)
Press, Hydraulic (Item 116, Appendix E) Repair Kit, Gear Box (Item 229, Appendix F)
Appendix E)
1
3
8
6
a. Disassembly
(1) Remove three keys (1) from output shaft (2) 9
and pinion shaft (3).
(2) Remove three pipe plugs (4) from 5
housing (5).
(3) Remove vent (6) from pinion end plate (7). 4
(4) Remove four screws (8), pinion end plate

(7), gasket (9), and pinion shaft (3) from
1 2
4
1
4
27--41
TM 9--2320--360--34--2
27--5. TEE GEAR BOX REPAIR (CONT)
(5) Remove four screws (10), front output end

plate (11), gasket (12), and output shaft (2)
from housing (5). Discard gasket.
2
(6) Remove front output end plate (11) from
output shaft (2).
12
11
10
(7) Remove four screws (13), rear output end

plate (14), and gasket (15) from housing (5).
Discard gasket. 15
14
(8) Remove oil seal (16) from front output end

plate (11). Discard oil seal.
13
(9) Position front output end plate (11) in vise
outside surface up. 11
NOTE
Bearing cups and cones are
matched sets. They should be 17
kept together.
16
(10) Remove bearing cup (17) from front output
end plate (11).
(11) Remove front output end plate (11) from
vise.
27--42
TM 9--2320--360--34--2
(12) Remove oil seal (18) from rear output end

plate (14). Discard oil seal.
(13) Position rear output end plate (14) in vise 14
outside surface up.
(14) Remove bearing cup (19) from rear output
end plate (14). 19
(15) Remove rear output end plate (14) from
vise. 18
NOTE
Some tee boxes have machined
shoulder on shaft and no
retaining rings. Skip steps (16)
and (19) if no retaining rings are
present on shaft.
(16) Remove retaining ring (20) from locking
position and slide toward gear (21) on output
shaft (2). 2 21
24
(17) Position output shaft (2) gear side down in
suitable press. 20
CAUTION
Protect shaft from striking floor
while pressing bearing and 23
spacer. Failure to comply may 22
result in damage to output shaft.
(18) Press bearing (22) and spacer (23) from

output shaft (2).
WARNING
injury.
(19) Remove two retaining rings (20 and 24) from 21
output shaft (2). Discard retaining rings.
(20) Position output shaft (2) gear side up in

suitable press.
26
CAUTION
while pressing bearing and gear. 2
damage to output shaft.
(21) Press bearing (25) and gear (21) from
output shaft (2).
(22) Remove woodruff key (26) from output
shaft (2).
27--43
TM 9--2320--360--34--2

27
(23) Remove locknut (27) from pinion shaft (3).
Discard locknut. 28
(24) Position pinion shaft (3) gear side up in
suitable press.
29
CAUTION
while pressing gear from shaft.
damage to shaft.
3
(25) Press pinion gear (28) from pinion shaft (3).
(26) Remove woodruff key (29) from pinion
shaft (3).
30
(27) Position pinion end plate (7) with pinion

shaft (3) threaded end up in suitable press. 7
CAUTION
while pressing from pinion end
plate. Failure to comply may 32
result in damage to pinion shaft.
(28) Press pinion shaft (3), bearing cone (30),
and oil seal (31) from pinion end plate (7).
Discard oil seal.
(29) Position pinion shaft (3) threaded end up in
suitable press. 3
WARNING
injury.
NOTE
Some tee boxes have machined 34
shoulder on shaft and no
7
retaining rings. Skip steps (30)
if no retaining ring is present on
shaft. 34
(30) Remove retaining ring (32) from pinion shaft 33
(31) Press outer bearing cone (30) from pinion
shaft (3).
(32) Remove inner bearing cone (33) and two
bearing cups (34) from pinion end plate (7).
27--44
TM 9--2320--360--34--2
(1) Remove remaining lithium grease from housing.
WARNING
CAUTION
Do not wash machined parts together to avoid damage from parts bumping
together.
CAUTION
Dirt and foreign material in steering system will cause damage and steering
problems.
(4) Clean old gasket material from housing and/or plates
(8) Coat internal parts with light coating of lithium grease.
1 2
c. Assembly
(1) Coat two bearing cones (1 and 2) with
grease.
3
4
(2) Install two bearing cups (3) in pinion end

plate (4).
27--45
TM 9--2320--360--34--2

1
WARNING
Wear eye protection and use care
when installing retaining rings. Re-
4
taining rings are under spring ten-
sion and can act as projectiles when
released causing severe eye injury.
NOTE
Skip step (3) if shaft has machined 2
shoulder instead of retaining ring.
(3) Install new retaining ring (5) on pinion 5

shaft (6).
(4) Position outer bearing cone (1) small side
down on suitable press.
(5) Press pinion shaft (6) threaded end down 6
into outer bearing cone (1).
NOTE
Support inner bearing cone on
press.
(6) Position inner bearing cone (2) and pinion

end plate (4) inner side down on suitable
press.
(7) Press pinion shaft (6) threaded end down
into pinion end plate (4) and inner bearing
cone (2).
(8) Install woodruff key (7) in pinion shaft (6).
(9) Position pinion gear (8) toothed side down
on press.
9
CAUTION 8
Do not bottom out pinion end plate on 7
4
inner bearing cup when installing.
Failure to comply may result in improper
bearing adjustment.
(10) Align slot in gear (8) with woodruff key (7)

6
and press pinion shaft (6) into gear (8).
(11) Position pinion shaft (6) in soft--jawed vise.
NOTE
When properly adjusted, pinion
end plate should rotate freely on
shaft, with no noticeable end
play.
(12) Install locknut (9) on pinion shaft (6).

(13) Remove pinion shaft (6) from vise.
27--46
TM 9--2320--360--34--2
(14) Position pinion end plate (4) in vise.
NOTE
Sharply striking end of pinion 9 4
shaft and locknut with rubber
mallet will enable bearings to
rotate freely with no end play.
6
(15) Strike end of pinion shaft (6) and locknut (9).
(16) Remove pinion end plate (4) from vise. 10
CAUTION
Seal must be evenly pressed in
end plate. Failure to comply
may result in damage to seal.
(17) Install new oil seal (10) on pinion shaft (6)

and pinion end plate (4).
WARNING 12
injury.
NOTE
Skip step (18) if shaft has machined 16
shoulder instead of retaining ring.
(18) Install two new retaining rings (11) on output

14
shaft (12).
12
(19) Install woodruff key (13) on output shaft
(12).
(20) Position gear (14) toothed side up on
suitable press.
(21) Align slot in gear (14) with woodruff key (13)
and install output shaft (12) in gear (14). 14
(22) Position bearing cone (15) small side down

on press.
NOTE
Bearing cone must be pressed
on output shaft until it contacts
gear. 15
(23) Press output shaft (12) into bearing

cone (15).
(24) Install spacer (16) on output shaft (12).
27--47
TM 9--2320--360--34--2
NOTE
Bearing cone should be
positioned with small side down.

on press.
NOTE
spacer and retaining ring. 12
(26) Press output shaft (12) into bearing
cone (17).
(27) Install bearing cup (18) in rear output end 17
plate (19). 19
CAUTION
Seal must be evenly pressed in 18
end plate. Failure to comply
may result in damage to seal. 20
(28) Install new oil seal (20) in rear output end

plate (19).
(29) Install bearing cup (21) in front output end
plate (22). 22
(30) Install new oil seal (23) in front output end
plate (22).
21
(31) Coat two bearing cones (15 and 17) and
bearing cups (18 and 21) with grease. 23
WARNING
Output end plates will fit
either end of housing. Output
end plates and output shaft
must be installed correctly.
Failure to comply will cause
steering gear to operate
backwards, which may cause
serious injury or death.
(32) Install three new gaskets (24) and front 17

output end plate (22) on housing (25) with 15
four screws (26).
12
CAUTION 25
Gear end must be installed first.
Failure to comply will result in 24
backward gear operation.
(33) Install output shaft (12) gear end first in

housing (25).
22
26
27--48
TM 9--2320--360--34--2
(34) Install three new gaskets (24) and rear

output end plate (19) on housing (25) with
four screws (27).
NOTE
Bearings are adjusted by re-
moving gaskets until bearings
bind, then adding one gasket at
a time until shaft rotates freely
with no end play. Number of
gaskets on each end should not 6
vary from other end by more 28
than one.
4
(35) Remove gaskets (24), one at a time, from
front output end plate (22) and rear output
end plate (19) until bearing cones (15 and
17) just bind when turning output shaft (12)
by hand.
(36) Add gaskets (24), one at a time, to front 27
output end plate (22) then rear output end 19 24
plate (19) until output shaft (12) rotates 24
freely with no end play.
NOTE
25
All keyways should face the
mounting side of Tee box when
properly assembled. Gear teeth
should mesh as parts are
assembled.
(37) Align keyways in output shaft (12) and

pinion shaft (6) and install three new gaskets
(24) and pinion end plate (4) on housing (25)
(38) Move gaskets (24), one at a time, from front
output end plate (22) to rear output end
plate (19) until pinion shaft (6) and output
shaft (12) rotate freely with no backlash.
NOTE
To properly adjust backlash, two
gaskets must be moved from
26
front output end plate to rear
output end plate. If there are
not enough gaskets at rear
output end plate to move to front
24
output end plate, further gear 17
adjustment must be made by 12
removing two gaskets from
between pinion end plate and 15
22
housing and repeating steps
(32) through (38).
(39) Move two gaskets (24) from rear output end

plate (19) to front output end plate (22).
27--49
TM 9--2320--360--34--2
WARNING
ventilated areas. If adhesive--
soap and water.
NOTE
Remove and install each end
plate screw separately to ensure
gear adjustment.
(40) Remove four screws (26 and 27) separately

from end plates (19 and 22) and housing
(25); coat threads with adhesive--sealant
and install. Torque to 17 lb--ft (23 N.m).
WARNING
use in well--ventilated areas.
soap and water. 19
CAUTION
Use pipe thread sealing com-
pound sparingly, only on pipe
threads. Do not apply com- 29 25
pound at hose connections.
26
Failure to comply may result in 29
component damage.
(41) Coat threads of three plugs (29) with pipe

(42) Install three plugs (29) in housing (25).
27--50
TM 9--2320--360--34--2
(43) Remove four screws (28), pinion end plate

(4), and three gaskets (24) from housing (25).
NOTE
Two--thirds is approximately
0.25 in. (6 mm) above shaft.
(44) Fill housing (25) two--thirds full with lithium grease.
WARNING
Adhesive--sealant can burn easily, can give off harmful
vapors, and is harmful to skin and clothing. To avoid
injury or death, keep away from open fire and use in
well--ventilated areas. If adhesive--sealant gets on skin

6
NOTE
28
All keyways should face
mounting side of tee box when
properly assembled. Gear teeth 30
should mesh as parts are 4
assembled.
(46) Align keyways in output shaft (12) and

pinion shaft (6) and install three new gaskets
(24) and pinion end plate (4) on housing (25)
WARNING
12
use in well ventilated areas. If
soap and water.
CAUTION
Use pipe thread sealing
compound sparingly, only on
pipe threads. Do not apply
compound at hose connections.
component damage.
31 12
(47) Coat threads of vent (30) with pipe thread
sealing compound and install in pinion end
plate (4).
(48) Install three keys (31) on output shaft (12)
and pinion shaft (6).
27--51
TM 9--2320--360--34--2
27--6. GEAR REDUCER REPAIR
This task covers:

INITIAL SETUP

Gear reducer removed (TM 9--2320--360--20). Adhesive--Sealant (Item 3, Appendix B)
Adhesive--Sealant (Item 6, Appendix B)
Tools and Special Tools Adhesive--Sealant, Permatex No. 1
Tool Kit, Genl Mech (Item 202, Appendix E) (Item 9, Appendix B)
Pan, Oil Drain (Item 102, Appendix E) Cloth, Crocus (Item 16, Appendix B)
Press, Hydraulic (Item 116, Appendix E) Compound, Sealing, Pipe Thread (Item 28,
Puller Kit, Mechanical (Item 124, Appendix E) Appendix B)
Tags, Identification (Item 56, Appendix B)
Repair Kit (Item 228.1, Appendix F)
a. Disassembly
NOTE
Tag and mark housing before
disassembly.
(1) Position drain pan under gear reducer (1).

(1.1) Remove vent (1.1) from reducer (1.2).
(1.2) Remove reducer (1.2) from output
housing (2).
CAUTION
During separation of housing,
do not allow gears to fall.
result.
NOTE
Output housing has three pipe
plugs, Input housing has one
pipe plug.
(2) Remove two nuts (3), screws (4), and input

housing (5) from output housing (2).
(3) Remove input shaft (6) from input
housing (5).
(4) Remove output shaft (7) from output
housing (2).
(5) Remove gasket(s) (8) from housing (2 or 5).
Discard gasket(s).
27--52
TM 9--2320--360--34--2
(6) Remove plug (9) from input housing (5).
(7) Remove two plugs (10) from output

housing (2).
NOTE
Mark location of oil seal and
plug before removing to aid in
installation.
(8) Remove plug (11), oil seal (12) and two

bearing cups (13) from input housing (5).
Discard oil seal.
(9) Remove plug (14), oil seal (15), and two
bearing cups (16) from output housing (2).
Discard oil seal.
(10) Remove two bearing cones (17) from input

shaft (6).
(11) Remove two bearing cones (18) and

shims (19) from output shaft (7).
(12) Position output shaft (7), gear (20) side up,

in suitable press.
CAUTION
Protect output shaft from striking
floor while pressing from gear.
damage to output shaft.
(13) Press output shaft (7) from gear (20).

(14) Remove key (21) from output shaft (7).
WARNING
27--53
TM 9--2320--360--34--2
27--6. GEAR REDUCER REPAIR (CONT)
WARNING
CAUTION
Bearing cones must be air dried or damage to bearing cone will result.
(2) Dry parts, except bearing cones, with compressed air.

(3) Clean old gasket material from housing.
(4) Inspect parts for damage. Replace nonserviceable damaged parts. Remove all
burrs with crocus cloth.
c. Assembly
(1) Install key (1) on output shaft (2).
(2) Position gear (3) on press.
CAUTION
Gears must be centered over
key when installed or damage to
(3) Align slot on gear (3) with key (1) and press
output shaft (2) into gear (3).
on press.
(5) Install shim (5) on output shaft (2). 6
2
NOTE
Bearing cone must be pressed 1
on output shaft until it contacts 7
gear.
3
(6) Press output shaft (2) into bearing cone (4). 5
(7) Position bearing cone (6) small side down 4
on press.
(8) Install shim (7) on output shaft (2).
NOTE
gear.
(9) Press output shaft (2) into bearing cone (6).
27--54
TM 9--2320--360--34--2

on press.
NOTE
Bearing cone must be pressed 10
gear.
9
(11) Press input shaft (9) into bearing cone (8).
8
on press.
NOTE
gear.
(13) Press input shaft (9) into bearing cone (10).
WARNING
soap and water.
CAUTION
Oil seal must be evenly pressed
into housing. Failure to comply
may result in damage to oil seal.
NOTE 14
Plug and oil seal must be
installed in places marked
during removal. 12
(14) Coat plug (11) with adhesive--sealant

(15) Install plug (11) and new oil seal (12) in input 14
housing (13).
13
(16) Install two bearing cups (14) in input
housing (13). 11
27--55
TM 9--2320--360--34--2
27--6. GEAR REDUCER REPAIR (CONT)
WARNING
Adhesive--sealant can burn easily, can give off
harmful vapors, and is harmful to skin and
clothing. To avoid injury or death, keep away
from open fire and use in well--ventilated area.
If adhesive--sealant gets on skin or clothing,
wash immediately with soap and water.
CAUTION
Oil seal must be evenly pressed
into housing. Failure to comply
may result in damage to oil seal.
NOTE
Plug and oil seal must be
installed in places marked
during removal.
(17) Coat plug (14) with adhesive--sealant 19

14
(18) Install plug (14) and new oil seal (15) in 19
output housing (16).
(19) Install two bearing cups (17) in output 15 17
housing (16).
WARNING
Pipe thread sealing compound can 19
burn easily, can give off harmful
vapors, and is harmful to skin and
clothing. To avoid injury or death, 16
keep away from open fire and use in 17
well ventilated areas. If pipe thread
sealing compound gets on skin or
clothing, wash immediately with 18
soap and water.
(20) Coat threads of plug (18) and three
compound.
(21) Install plug (18) in input housing (13).
(22) Install two plugs (19) in output
housing (16).
13
27--56
TM 9--2320--360--34--2
(23) Install input shaft (9) in input housing (13).

(24) Install output shaft (2) in output
housing (16).
(25) Install four new gaskets (20) and input
housing (13) on output housing (16) with
two screws (21) and nuts (22).
NOTE
Bearings are adjusted by
removing gaskets until bearings
bind, then adding one gasket at
a time until shafts rotate freely
and with no end play.
21
(26) Remove gaskets (20), one at a time,
from housings (13 and 16) until bearing
cones just bind.
21
(27) Install gaskets (20), one at a time,
on housings (13 and 16) until
shafts (2 and 9) rotate freely with
no end play.
(28) Remove two nuts (22) and separate 9
housings (13 and 16).
16
WARNING
Adhesive--sealant can burn easily, can give 2
off harmful vapors, and is harmful to skin
and clothing. To avoid injury or death, keep
away from open fire and use in 20 22
well--ventilated area. If adhesive--sealant
gets on skin or clothing, wash immediately 13
22
(29) Coat gaskets (20) and housings (13 and 16)
(30.1) Coat threads of reducer (21.1) and vent (21.2) with

(30.2) Install reducer (21.1) and vent (21.2) on
output housing (16).
(31) Assemble gaskets (20) and housings (13
and 16) with two nuts (22).
Fill gear reducer with oil (LO 9--2320--360--12).
27--57
27--57/(27--58 blank)
TM 9--2320--360--34--2
27--58
TM 9--2320--360--34--2
CHAPTER 28
WINCHES MAINTENANCE
Contents Para Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28--1 28--1
Winch Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28--2 28--2
Drive Motor Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28--3 28--32
Hydraulic Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28--4 28--39
Auxiliary Winch Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28--5 28--49
Power Takeoff Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28--6 28--61
28--1. INTRODUCTION
This chapter contains instructions for repair of winch components at the General Support maintenance level.
28--1
TM 9--2320--360--34--2
28--2. WINCH REPAIR
This task covers:

INITIAL SETUP

Winch drained of lubricant Adhesive--Sealant, Silicone (Item 2, Appendix B)
(TM 9--2320--360--20). Adhesive--Sealant (Item 10.1, Appendix B)
Compound Sealing, Pipe Thread (Item 28,
Compressor Unit, Air (Item 24, Appendix E) Cleaning Compound, Solvent (Item 54, Appendix B)
Goggles, Industrial (Item 57, Appendix E) Brake Seal Kit (Item 297, Appendix F)
Press, Hydraulic (Item 116, Appendix E) Locknuts (2) (Item 93, Appendix F)
Pliers, Retaining Ring (Item 107, Appendix E) Lockwashers (31) (Item 120, Appendix F)
Rods, Threaded (2) (Figure C--14, Appendix C) Lockwashers (18) (Item 124, Appendix F)
Screws, Guide (2) (Figure C--4, Appendix C) Lockwashers (6) (Item 121, Appendix F)
Sling Assemblies (2) (Item 160, Appendix E) Lockwashers (2) (Item 122, Appendix F)
Sling, Endless Strap (Item 161, Appendix E) Lockwashers (2) (Item 129, Appendix F)
Wrench, Torque, 0--300 Lb--In. (Item 235, Lockwashers (2) (Item 130, Appendix F)
Appendix E) Service Kit, Winch (Item 231, Appendix F)
Two
a. Disassembly 4
(1) Remove four nuts (1), lockwashers (2), 3
screws (3), and cable guard (4) from winch
side supports (5 and 6). Discard
lockwashers.
6 5
28--2
TM 9--2320--360--34--2
(2) Remove hose (7) from fitting (8) on valve

solenoid (9). 11
(3) Remove hose (7) from elbow (10) on brake 14 16 15
housing (11).
17
(4) Remove hose (12) from elbow (13) on valve 8
solenoid (9).
(5) Remove hose (12) from elbow (14) on
brake housing (11).
and drive motor (17) from brake housing
13
7 12
10
20
NOTE 19
Right and left sides are disas- 18
sembled the same way. Left
side is shown.
(7) Remove two opposite screws (18) and

lockwashers (19) from clutch end cover (20).
(8) Install two threaded rods (21) in clutch end
19
cover (20) and clutch adapter (22).
18 22
(9) Install two nuts (23) on threaded rods (21).
Tighten nuts until they contact clutch end 21
cover (20). 23
20
(10) Remove four remaining screws (18) and

lockwashers (19) from clutch end cover (20).
19
18
28--3
TM 9--2320--360--34--2
28--2. WINCH REPAIR (CONT)
WARNING
Clutch end cover is under
spring pressure. Loosen nuts 22
slowly and evenly until spring
brace is relieved. Failure to 24
do so may cause injury to
personnel. 20
(11) Loosen two nuts (23) on threaded rods (21)
and remove clutch end cover (20) from
clutch adapter (22).
(12) Remove two nuts (23) and clutch end cover
(20) from two threaded rods (21). 21
23
(13) Remove two threaded rods (21) from clutch
adapter (22).
(14) Remove preformed packing (24) from clutch
end cover (20). Discard preformed packing.
27 22
(15) Remove spring (25) from clutch
adapter (22).
NOTE
Bearing may stay on shaft or in
clutch end cover.
(16) Remove bearing (26) from shaft (27).

(17) Remove thrust ring (28) from clutch drive
gear (29). 25 26 28 29
WARNING
Clutch drive gear and piston
may separate from clutch 32
adapter causing injury to
personnel.
31
NOTE
Location of air fittings on clutch
adapter should be marked on
planetary adapter cover before
removal.

and clutch adapter (22) from planetary 30
22
adapter cover (32). Discard lockwashers.
28--4
TM 9--2320--360--34--2
NOTE
· Tension on cable must be
38
released if clutch drive gear is
stuck on input shaft.
· Do steps (19) thru (21) if clutch
34
drive gear is stuck on input
shaft.
(19) Remove pin (33) from pin (34). 37

(20) Remove pin (34) from cable clevis (35).
(21) Remove cable clevis (35) from cable
clamp (36). 35
(22) Remove two plugs (37) and vent (38) from 37 32
planetary adapter cover (32). 36
33
22
(23) Remove piston (39) with clutch drive gear
(29) from clutch adapter (22). 43
(24) Remove two preformed packings (40) and
preformed packing (41) from piston (39).
Discard preformed packings. 42
40
WARNING
injury.
40
(25) Remove retaining ring (42) from clutch drive
gear (29). Discard retaining ring.
29
(26) Remove piston (39) from clutch drive
gear (29).
(27) Remove two tube fittings (43) from clutch
adapter (22).
28--5
TM 9--2320--360--34--2

32
(28) Loosen 12 screws (44) on planetary adapter 45
cover (32). 44
(45) at the 6 and 12 o’clock positions from
planetary adapter cover (32). Discard
lockwashers.
45
44
(30) Install two guide screws (46) through
planetary adapter cover (32) and ring gear
(47) and into gear end support (48).
WARNING
Support planetary adapter
cover to prevent personnel
injury. 48 47
32 46
(31) Remove 10 remaining screws (44) and
lockwashers (45) from planetary adapter
cover (32). Discard lockwashers.
(32) Slide planetary adapter cover (32) off guide
screws (46) and remove from ring gear (47).
45
44
WARNING
injury.
48
(33) Remove retaining ring (49) and clutch sun 47
gear (50) from input shaft (27). Discard 46
retaining ring.
(34) Remove two guide screws (46) from ring
gear (47) and gear end support (48). 27
49
WARNING
Ring gear weighs approxi-
mately 62 lb (28 kg). Keep out
from under ring gear. Failure
46
to comply may result in
personnel.
(35) Remove ring gear (47) from gear end 50

support (48).
28--6
TM 9--2320--360--34--2
NOTE
Retaining ring is held captive
inside planetary carrier.
(36) Expand retaining ring (51) enough to

disengage planetary carrier (52) from end of
output shaft (53).
WARNING
Planetary carrier weighs
Keep out from under
planetary carrier. Failure to
comply may result in serious
51
(37) Remove planetary carrier (52) from end of 52 53
output shaft (53) with aid of assistant.
WARNING
Outer brake housing is under
3500 lb (1589 kg) of spring
pressure. Loosen six screws
slowly and evenly until spring
force is relieved. Failure to 57
comply may result in serious
NOTE
Steps (38) thru (66) are
performed on motor end of
winch.
(38) Remove six screws (54), lockwashers (55)

and brake housing (11) from brake adapter 57.4 56
(56). Discard lockwashers.
11 55
(39) Remove 12 compression springs (57) from 54
brake adapter (56).
57.3
(39.1) Remove drain cap (57.1), nut (57.2), and 5
hose (57.3) from side support (5).
57.2
(39.2) Remove hose (57.3) from elbow (57.4).
57.1
28--7
TM 9--2320--360--34--2

58
NOTE
Sun gear may stay in carrier in
brake adapter.
61
(40) Remove sun gear (58) from brake shaft (59).
NOTE 59
Brake shaft may have to be
tapped out of brake piston.
60
(41) Remove brake shaft (59) from brake
piston (60).
(42) Remove bearing (61) from brake shaft (59).
11
CAUTION
Carefully pry brake piston from
brake housing. Failure to com-
ply may result in damage to
brake piston.
NOTE
Place brake housing assembly
on work surface, piston side up.
(43) Remove brake piston (60) from brake

housing (11).
63
62
60
64
(44) Remove two preformed packings (62) and
backup ring (63) from brake piston (60).
Discard preformed packings. 65
(45) Remove preformed packing (64) and backup
ring (65) from brake piston (60). Discard
28--8
TM 9--2320--360--34--2
(46) Remove two dowel pins (66) from brake

housing (11).
67
NOTE
Mark order of plates to aid in 68
assembly.
(47) Remove 10 friction disk plates (67) and 9

drive plates (68) from brake housing (11).
(48) Remove bearing (69) from brake
housing (11).
(49) Remove two elbows (10 and 14) from brake
housing (11).
69
66 66
11
14
10
74
74.1
71
56
(50) Remove preformed packing (70) from brake 73
72
adapter (56). Discard preformed packing.
(51) Attach suitable lifting device to ring gear (71)
for support.
(52) Remove 12 screws (72) and lockwashers
(73) from brake adapter (56), ring gear (71),
and motor end support (74). Discard
lockwashers.
(53) Remove brake adapter (56) from ring
gear (71).
(53.1) Remove elbow (57.4) from brake adapter
(5.6). 57.4 70
(53.2) Remove plug (74.1) from brake adapter
(56).
28--9
TM 9--2320--360--34--2
WARNING 76
77 75 71
Ring gear weighs approxi-
mately 62 lb (28 kg). Keep out
from under ring gear. Failure
to comply may result in
personnel.
(54) Place hand on planetary carrier (75) to keep

in place. Remove ring gear (71) from
planetary carriers (75 and 76).
(55) Remove planetary carrier (75) and sun gear
(77) from planetary carrier (76).
75
77
79
WARNING 78
injury.
(56) Remove retaining ring (78) from sun gear

(57) Remove sun gear (77) from planetary
carrier (75).
(58) Remove retaining ring (79) from sun gear
(59) Remove screw (80), lockwasher (81), and 76

retainer plate (82) from planetary carrier (76)
and input shaft (27). Discard lockwasher. 27
82 81 80
28--10
TM 9--2320--360--34--2
27 76
83
(60) Remove planetary carrier (76) from input
shaft (27).
(61) Remove bronze thrust bearing (83) from
input shaft (27).
(62) Remove input shaft (27) from output

shaft (53).
WARNING
Always wear heavy gloves 27
when handling winch cable.
Never let cable run through
hands. Frayed cable can cut
hands severely.
53
NOTE
If cable is still on winch drum, do
84
(63) Wind out winch cable (84). 87
(64) Remove two screws (85) and clamp (86) 91 90
from winch drum (87).
86
WARNING
Use care when removing
cable from drum. End of 85
cable can spring up causing
88
(65) Remove winch cable (84) from winch
drum (87).
89 6
(66) Remove two nuts (88), lockwashers (89),
screw (90), and cable hold down assembly
(91) from winch side support (6). Discard
lockwashers.
28--11
TM 9--2320--360--34--2
92 93 74
(67) Remove two nuts (92), lockwashers (93),

and screws (94) from winch side support (5)
and end supports (48 and 74). Discard 5
lockwashers.
94
48 92 93
74
WARNING
Winch drum weighs 450 lb (204 87 95 96
kg). Keep out from under winch 48
drum. Failure to comply may 6 95 96
result in injury or death to
personnel.
(68) Attach suitable lifting device to winch drum

97
(87) and end supports (48 and 74).
(69) Remove six nuts (95), lockwashers (96), and
screws (97) from winch side support (5) and
end supports (48 and 74). Discard
lockwashers.
(70) Remove side support (5) from end supports 97
(48 and 74). 95
(71) Repeat steps (67), (69), and (70) for 96
remaining side support (6).
95 97
5
96
98
NOTE
5
Right and left side winch cable
clamps are removed the same 99
way. Left side is shown.
(72) Remove two locknuts (98), screws (99), and 43

cable clamp (43) from side support (5).
Discard locknuts.
28--12
TM 9--2320--360--34--2
(73) Support winch drum (87) with wooden

blocks.
87 48
(74) Attach lifting device to gear end
support (48). 53
WARNING
Gear end support weighs 125 lb
(57 kg). Keep out from under
gear end support. Failure to
comply may result in injury or
death to personnel.
(75) Remove gear end support (48) from output

shaft (53) using lifting device.
102 48
(76) Remove seal ring (100) from gear end
support (48). Discard seal ring.
NOTE 100
Do step (77) if bushings fail 101
inspection.
103
(77) Press bronze bushing (101) and bronze
bushing (102) from gear end support (48).
WARNING
injury.
(78) Remove retaining ring (103) from gear end

support (48). Discard retaining ring. 53
74
(79) Attach lifting device to motor end

support (74).
WARNING
Motor end support weighs 125 lb
motor end support. Failure to
death to personnel.
(80) Remove motor end support (74) from output

shaft (53) using lifting device.
28--13
TM 9--2320--360--34--2

(81) Remove seal ring (104) from motor end
support (74). Discard seal ring. 104
105
107
NOTE
Do steps (82) and (84) if 74
bushings fail inspection.
106
(82) Press small bushing (105) from motor end
support (74).
WARNING
injury.
(83) Remove retaining ring (106) from motor end

support (74). Discard retaining ring.
(84) Press large bushing (107) from motor end
support (74).
WARNING
Winch drum weighs 450 lb (204 87
kg). Keep out from under winch
drum. Failure to comply may
result in injury or death to per-
sonnel.
(85) Lower winch drum (87) to ground and

remove lifting device.
(109) from winch drum (87). Discard
lockwashers.
109
108
28--14
TM 9--2320--360--34--2
NOTE
Location of splined end of out-
put shaft is reversed on passen-
ger and driver’s side winches.
For proper assembly, note
which end of drum splines are on.
(87) Slide output shaft (53) with drum keys (110)
out of winch drum (87).
108
NOTE
Drum keys are removed using the 110
screws removed in step (86).
(88) Install two screws (108) into drum
keys (110).
NOTE 87
Turn screws until drum keys are
removed. 108
110
(89) Remove drum keys (110) from output
shaft (53). 53
WARNING
goggles. Use in well-ventilated areas. Use respirator as needed. Accidental ingestion can cause irritation of digestive
tract and respiratory tract, may cause lung and central nervous system damage. Can be fatal if swallowed. Inhalation
of high/massive concentrations can cause coma or be fatal. First aid for ingestion: do not induce vomiting. Seek
immediate medical attention. First aid for skin contact: remove contaminated clothing. Wash skin thoroughly with
soap and water. If symptoms persist, seek medical attention. First aid for eye contact: flush with water for 15 minutes
or until irritation subsides. If symptoms persist, seek medical attention. First aid for inhalation: move to fresh air. If not
breathing, provide artificial respiration. If symptoms persist, seek medical attention. Keep away from open flames and
(1) Clean all parts insolvent cleaning compound.
WARNING
(3) Inspect parts for damage. Replace all damaged parts.
(4) Inspect brake housing and brake adapter seal surfaces for nicks or scratches.
Replace if damaged.
(5) Inspect inner spline of brake shaft for damage. Replace shaft if worn, pitted, spelled,
or if flaking exists on more than 3/8 in. (10 mm) of tooth surface. Inspect outer teeth
for damage that will not allow drive plates to slip freely.
(6) Inspect outside diameters of brake piston. Replace only if outside diameters are
damaged to affect assembly fit or will not provide support for preformed packings or
backup rings.
28--15
TM 9--2320--360--34--2
(7) Inspect disk friction plates for broken or damaged sintered bronze faces. Measure thick-
ness of plate. Replace if damaged, warped, bent, or if overall thickness is less than
0.080 in. (2.03 mm).
(8) Inspect drive plates for bent or warped surface and freedom of movement on brake shaft.
Measure thickness of plate. Replace if damaged, warped or if thickness is 0.055 in. (1.40
mm) or less.
(9) Compress spring to 3/4 in. (19.05 mm) and release. Measure length of spring. Spring must
return to 1 in. (25.4 mm) free length. Replace spring if it does not return to 1 in. (25.4 mm)
free length.
(10) Measure thickness of thrust bearing. Replace thrust bearing if pitted or if worn to less than
0.230 in. (5.84 mm).
(11) Inspect ball bearings and races for damage. Replace galled or pitted races and ball bearings
or ball bearings that do not rotate freely in inner and outer races.
(12) Inspect primary and secondary carrier assembly gear teeth and bearings. Replace assembly
if teeth are worn, pitted, or galled or if bearings have failed.
(13) Inspect sun gear, clutch sun gear, and secondary sun gear for damage. Replace any gear if
teeth faces are worn, galled, pitted, or broken or if flaking has occurred on more than 10% of
any tooth surface.
(14) Inspect bronze bearings for damage. Replace if bearing surface is spalled, pitted, or if inner
diameter is out of round.
(15) Inspect ring gears for damage. Replace ring gear if teeth faces are galled, pitted, spalled, or
broken or if flaking has occurred on more than 10% of any tooth surface.
(16) Inspect planetary carrier assembly for damage. Replace assembly if gears will not rotate
freely or if teeth faces are worn, galled, pitted, or broken or if flaking has occurred on more
than 10% of any tooth surface.
(17) Inspect output shaft for damage. Replace output shaft if journals for bronze bearings are
worn to less than 4.490 in. (114.05 mm) diameter, are galled or scarred enough to damage
bearing, or if tooth faces are worn, galled, pitted, or broken over 10% of any tooth surface.
(18) Inspect relief vent for damage. Replace if spring loaded poppet does not operate freely.
(19) Inspect input shaft for damage. Replace input shaft if splines are damaged to extent that sun
gear will not slide freely or if spline teeth are worn, galled, pitted, broken, or if flaking has
occurred on more than 10% of any tooth surface.
(20) Inspect clutch adapter seal bores for nicks and scratches. Replace if damaged.
(21) Inspect clutch drive gear spline teeth for galling, pitting, breakage, and flaking over 10% of
any tooth surface. Replace if damaged.
(22) Inspect thrust ring for cracks, pitting, galling, and breakage. Replace if damaged.
28--16
TM 9--2320--360--34--2
c. Assembly
(1) Install two keys (1) in keyways on output
shaft (2).
WARNING
Output shaft is installed differ-
ently in winch drum depending
on whether winch is for pas-
senger or driver’s side. For 3
driver’s side winch, splined
4
end of output shaft must be on
cutout end of winch drum. For
passenger’s winch, splined
end of output shaft must be on
end opposite cutout end of 1
winch drum. Failure to comply
may result in improper wind-
ing of cable and injury to 2
personnel.
(2) Align keys (1) with keyways (3) in winch

drum (4) and install output shaft (2) in drum.
1
DRIVER'S SIDE WINCH DRUM PASSENGERS SIDE WINCH DRUM

NOTE
Holes in drum must align with
holes in output shaft. 4
(3) Install two new lockwashers (5) and screws

(6) in winch drum (4) and output shaft (2).
5
6
28--17
TM 9--2320--360--34--2
WARNING
Wear eye protection and use care
when installing retaining rings.
Retaining rings are under spring
tension and can act as projectiles
when released causing severe eye
injury. 11
10
NOTE
Right and left sides are assembled the 8 7
same way. Left side is shown.
9
(4) Install new retaining ring (7) in gear end
support (8).
WARNING
Adhesive--sealant may burn or give
off harmful vapors. It is harmful to
skin and clothing. To avoid injury or
death, keep away from open flame
and use in well--ventilated area. If
adhesive--sealant gets on skin or
clothing, wash immediately with soap
and water.
NOTE
Do steps (4.1) thru (6) if bushings failed
inspection.
(4.1) Coat outside face of bushing (9) and
bushing (10) with adhesive--sealant (Item
10.1, Appendix B).
16
(5) Install large bushing (9) in gear end 15
support (8). 14
(6) Install small bushing (10) in gear end sup-
port (8). 13
(7) Install new seal ring (11) in gear end 12
support (8).
(8) Install new retaining ring (12) in motor end
support (13).
NOTE
Do steps (8.1) thru (10) if bushings
failed inspection.
(8.1) Coat outside face of bushing (14) and
bushing (15) with adhesive--sealant (Item
10.1, Appendix B).
(9) Install large bushing (14) in motor end
support (13).
(10) Install small bushing (15) in motor end
support (13).
(11) Install new seal ring (16) in motor end
support (13).
28--18
TM 9--2320--360--34--2
WARNING
Winch drum weighs 450 lb (204
kg). Keep out from under winch
drum. Failure to comply may
result in injury or death to
personnel.
(12) Attach suitable lifting device to winch

drum (4).
4 8
(13) Raise winch drum (4) and support on blocks to
allow installation of end supports (8 and 13). 2
(14) Attach lifting device to gear end support (8).
WARNING
Gear end support weighs 125 lb
death to personnel.
NOTE
Gear end support is installed on
splined end of output shaft.
(15) Install gear end support (8) on output shaft

(2) while assistant operates lifting device.
(16) Attach lifting device to motor end 2 13

support (13).
WARNING
Motor end support weighs 125 lb
death to personnel.
(17) Install motor end support (13) on output

shaft (2) while assistant operates lifting
device.
28--19
TM 9--2320--360--34--2

23 22 13
NOTE
Right and left side cable clamps
are installed the same way. Left
side is shown.
20
(18) Install cable clamp (17) on side support (18)
with two screws (19) and new locknuts (20). 21
Torque to 200 lb--ft (271 N∙m).
(19) Install side support (18) on end supports (8
and 13) with two screws (21), new
lockwashers (22), and nuts (23). Do not 19
tighten.
17
8 23 22 21
18
13
26 25
8
27 26 25
(20) Install six screws (24), new lockwashers

(25), and nuts (26) on side support (18). 24
(21) Tighten two nuts (23) and six nuts (26) to
200 lb--ft (271 N∙m).
side support (27).
24
26 18
25
26 24
25
28--20
TM 9--2320--360--34--2
4
28 29
(23) Install cable hold down assembly (28) on

winch side support (27) with two screws
(29), new lockwashers (30), and nuts (31).
31
30 27
NOTE
Input shaft is installed from gear
end support. Threaded hole in
end of input shaft must be at
motor end of drum.
(24) Install input shaft (32) in output shaft (2).
32
2
32 35 34
(25) Install bronze thrust bearing (35) on input

shaft (32).
(26) Install planetary carrier (34) on input
shaft (32).
28--21
TM 9--2320--360--34--2
(27) Install retainer plate (35) on planetary carrier

(34) and input shaft (32) with new
lockwasher (36) and screw (37). Torque to
276 lb--in. (31.2 N∙m).
34
32
35 36 37
WARNING
40
41
injury.
(28) Install new retaining ring (38) on sun

gear (39).
(29) Install sun gear (39) in planetary carrier (40).
(30) Insert new retaining ring (41) into planetary
carrier (40) and install on end of sun
gear (39).
34
39
40
(31) Slide planetary carrier (40) with sun gear

(39) into planetary carrier (34).
28--22
TM 9--2320--360--34--2
WARNING
water and seek medical attention.
In case of skin contact, wipe off
and flush with water.
34
(32) Coat both sides of ring gear (42) with 42
40
WARNING
Ring gear weighs 62 lb (28 kg).
Keep out from under ring gear.
NOTE
If gap exists between ring gear
and motor end support, reverse
ring gear.
(33) Install ring gear (42) on planetary carriers
(40 and 34).
WARNING
Pipe thread sealing compound
can burn easily, can give off
harmful vapors, and is harmful to
skin and clothing. To avoid injury
or death, keep away from open
fire and use in well--ventilated 12
area. If pipe thread sealing com- 42.1
pound gets on skin or clothing, 42
wash immediately with soap and
water. 43
44
45
(33.1) Coat threads of plug (42.1) and elbow (42.2)
with pipe thread sealing compound.
(33.2) Install plug (42.1) in brake adapter (43).
(33.3) Install elbow (42.2) in brake adapter (43).
WARNING
Support brake adapter while
installing to prevent injury to
personnel.
NOTE
Holes for fittings in brake adapt-
er must be in the 5 o’clock and 42.2
7 o’clock positions.
(34) Align holes and install brake adapter (43) on
ring gear (42).
(35) Install brake adapter (43) and ring gear (42)
on motor end support (12) with 12 new
to 35 lb--ft (47.5 N∙m).
28--23
TM 9--2320--360--34--2
WARNING
is harmful to skin and cloth- 50 50
47
soap and water.
(36) Coat threads of two elbows (46 and 47) with

NOTE
Elbow hose connections must
face each other.
(37) Install elbow (46) and elbow (47) in brake

housing (48).
(38) Install bearing (49) and two dowel pins (50)
in brake housing (48).
51
54
53
55
51
(39) Install two new preformed packings (51), 52
backup ring (52), new preformed packing
(53), and backup ring (54) on brake
piston (55).
28--24
TM 9--2320--360--34--2
57
58
(40) Install brake shaft (56) in brake housing

(48).
(41) Install 10 friction disk plates (57) and 9 drive
plates (58) on brake shaft (56).
56
48
55
NOTE
Ensure proper alignment and
seating of brake piston to brake
housing. 50
48 50
(42) Align dowel pins (50) and install brake piston
(55) in brake housing (48).
60
59
56
(43) Install bearing (59) on brake shaft (56).
(44) Install sun gear (60) in brake shaft (56).
28--25
TM 9--2320--360--34--2

43
62 61
(45) Install preformed packing (61) and 12

compression springs (62) on brake
adapter (43).
(46) Install brake housing (48) on brake adapter
(43) with six new lockwashers (63) and
screws (64). Torque to 55 lb--ft (74.6 N∙m).
(46.1) Install hose (64.1) on elbow (42.2).
(46.2) Install hose (64.1) on side support (18) with 42.2
nut (64.2).
48 63
(46.3) Install drain cap (64.3) on hose (64.1). 18 64
64.2
64.1
64.3
WARNING
Planetary carrier weighs 100 lb
planetary carrier. Failure to
death to personnel.
(47) Install planetary carrier (65) on output shaft
(2) with aid of assistant.
WARNING
injury.
NOTE 65 2
Retaining ring is located inside
66
planetary carrier.
(48) Install retaining ring (66) on end of output

shaft (2).
28--26
TM 9--2320--360--34--2
(49) Install two guide screws (67) at opposite

positions in gear end support (8).
WARNING
with water. 8
67
(50) Coat both sides of ring gear (68) with 68
WARNING 32
Ring gear weighs 62 lb (28 kg). 70
Keep out from under ring gear.
(51) Align marks made during disassembly and
install ring gear (68) on planetary carrier (65)
and gear end support (8).
(52) Install clutch sun gear (69) on input
shaft (32).
69 65
(53) Install new retaining ring (70) on input
shaft (32). 67
68 71
NOTE 72
Breather hole and drain hole 73
must be in the 12 o’clock and 6
o’clock positions.
(54) Install planetary adapter cover (71) on ring

gear (68) with 10 new lockwashers (72) and
screws (73). Do not tighten.
28--27
TM 9--2320--360--34--2

71
72
73
(55) Remove two guide screws (67) from

planetary adapter cover (71) and install two
new lockwashers (72) and remaining
screws (73).
(56) Tighten 12 screws (73) to 200 lb--ft 67
(271 N∙m).
WARNING
72
soap and water. 74
(57) Coat two tube fittings (74) with pipe thread

sealing compound and install in clutch
adapter (75).
75
WARNING
80
injury. 77
NOTE
Clutch drive gear is secured to
79
input shaft with retaining ring.
(58) Install new retaining ring (76) and piston (77) 80

on clutch drive gear (78).
(59) Install new preformed packing (79) and two
new preformed packings (80) on piston (77). 78
Coat piston with oil.
(60) Install piston (77) on clutch adapter (75).
28--28
TM 9--2320--360--34--2
WARNING
soap and water.
(61) Coat two plugs (81) and vent (82) with pipe
thread sealing compound and install in
planetary adapter cover (71).
81
WARNING
with water. 84 71
81
75
NOTE
Clutch adapter should be
positioned on planetary adapter
cover as marked during
removal.
(62) Coat mating surfaces of planetary adapter

cover (71) and clutch adapter (75) with
75
(63) Install clutch adapter (75) on planetary
adapter cover (71) with six new lockwashers 32
(83) and screws (84). Torque to 276 lb--in.
(31.2 N.m).
86
NOTE
Flat surface of thrust ring faces 85 78
out.
87
(64) Install thrust ring (85) on clutch drive
gear (78).
(65) Install bearing (86) on shaft (32).
(66) Install spring (87) on clutch adapter (75).
28--29
TM 9--2320--360--34--2

(67) Install new preformed packing (88) on clutch
end cover (89).
(68) Install two threaded rods (90) on opposite
ends of clutch adapter (75).
(69) Install clutch end cover (89) on threaded
rods (90).
(70) Install two nuts (91) on threaded rods (90).
Tighten until mating surfaces of clutch end
cover (89) and clutch adapter (75) meet.
88
75
90 89
91
(71) Install four new lockwashers (92) and

screws (93) on clutch end cover (89).
92
93 89
89
92
(72) Remove two nuts (91) and threaded rods
(90) from clutch end cover (89). 93
(73) Install two new lockwashers (92) and screws
(93) on clutch end cover (89).
(74) Tighten six screws (93) to 35 lb--ft
(47.5 N.m).
92
93
91 90
28--30
TM 9--2320--360--34--2
WARNING
with water. 48
(75) Lightly coat edge of bearing housing (94) on 46 96 97
drive motor (95) with thin layer of silicone
94
adhesive--sealant. 99 95
(76) Install drive motor (95) on brake housing
(48) with two new lockwashers (96) and
screws (97).
(77) Install hose (98) on elbow (47) on brake
housing (48).
(78) Install hose (98) on elbow (99) on valve 100
solenoid (100). 102
98 101
(79) Install hose (101) on elbow (46) on brake 47
housing (48).
(80) Install hose (101) on fitting (102) on valve
solenoid (100).
103
104
(81) Install cable guard (103) on winch side

supports (18 and 27) with four screws (104), 27 18
new lockwashers (105), and nuts (106).
105
106
Fill winch with lubricant (LO 9--2320--360--12).
28--31
TM 9--2320--360--34--2
28--3. DRIVE MOTOR REPAIR
This task covers:

INITIAL SETUP

Drive motor on clean work surface. Cloth, Crocus (Item 16, Appendix B)
Jelly, Petroleum (Item 35, Appendix B)
Caps, Vise Jaw (Item 17, Appendix E) Seal Kit (Item 296, Appendix F)
Appendix E)
Appendix E)
a. Disassembly
CAUTION
Clamp drive motor in soft--jawed
vise by mounting flange only.
Clamping drive motor in any
other location will cause
damage. Excessive clamping
will cause damage to drive
motor.
(1) Position drive motor (1) in soft--jawed vise

output shaft down. 2
(2) Remove four screws (2) from drive
motor (1).
3
NOTE 5
Drive motor is made up of 4
several sections. Only valve
6
housing should be removed in
step (3).
7
(3) Carefully lift valve housing (3) straight up to 1
remove from drive motor (1).
(4) Remove seal (4) and preformed packing (5)
from valve housing (3). Discard seal and
preformed packing.
(5) Remove valve (6) from valve plate (7).
28--32
TM 9--2320--360--34--2
(6) Remove balance ring (8) and two balance

ring springs (9) from valve housing (3).
(7) Remove three preformed packings (10) and
four backup rings (11) from balance ring (8).
Discard preformed packings and backup
rings.
9
11
3
9
10
WARNING
Control spool springs are
compressed under plugs.
Remove carefully to prevent
(8) Remove control spool plug (12), preformed 3

packing (13), spring (14), and spring (15)
16
from valve housing (3). Discard preformed 15
packing. 17
18 14
(9) Remove control spool plug (16) and 13
preformed packing (17) from valve housing
21 12
20 22
(10) Remove control spool (18) from valve
housing (3). 19
(11) Remove two check ball plugs (19) and 24

preformed packings (20) from valve housing
(3). Discard preformed packings. 23
22
(12) Remove two springs (21) and check balls
(22) from valve housing (3). 20
21
(13) Remove case drain plug (23) and preformed 19
packing (24) from valve housing (3).
28--33
TM 9--2320--360--34--2
28--3. DRIVE MOTOR REPAIR (CONT)

(14) Remove valve plate (7) from geroler
assembly (25).
32
(15) Remove seal (26) from valve plate (7).
Discard seal.
(16) Remove valve drive (27) from geroler
assembly (25).
7
NOTE
Star and rollers may come out
of geroler assembly. 28 26
(17) Remove geroler assembly (25) from wear
plate (28). 33
27
(18) Remove drive (29) from shaft and bearing 34
assembly (30).
(19) Remove wear plate (28) from bearing
30 25
housing (31).
(20) Remove seal (32) and shaft face seal (33)
from wear plate (28). Discard seals. 29
(21) Remove seal (34) from bearing housing
(31). Discard seal.
31
NOTE
If shaft or bearings are damaged,
replace complete assembly.
(22) Press shaft and bearing assembly (30) from
bearing housing (31).
CAUTION 36
Be careful not to damage seal seats. 35
31
(23) Remove shaft seal (35), backup ring (36),
and dust seal (37) from bearing housing
(31). Discard ring and seals.
37
(1) Use wire brush to remove dirt and debris from motor exterior.
WARNING
28--34
TM 9--2320--360--34--2
WARNING
kPa). Use only with effective chip guarding and personal protective equip-
ment (goggles, shield, and gloves).

air.
(4) Check chamfered area of output shaft. Use
crocus cloth to remove any nicks, burrs, or
sharp edges that could damage shaft during
assembly.
(5) Inspect parts for scratches, burrs, nicks, or
sharp edges, If defects are found, remove
with crocus cloth. If damage cannot be
corrected, replace defective parts.
c. Assembly
(1) Install new dust seal (1) into outer bore of
bearing housing (2) with lip facing out.
(2) Install backup ring (3) into inner bore of
bearing housing (2).
(3) Using shaft seal installation tool, press shaft
seal (4) into inner bore over backup ring (3).
CAUTION
Use protective bullet when in-
stalling shaft to prevent damage
8
to seals. 4
(4) Coat inner edge of dust seal (1) and shaft

seal (4) with petroleum jelly.
(5) Press shaft and bearing assembly (5) into
bearing housing (2). 3 9
CAUTION 1
Clamp bearing housing in
soft--jawed vise by mounting 7
flange only. Clamping bearing
housing in any other location will 5
cause damage. Excessive
clamping will cause damage to
drive motor.
(6) Clamp bearing housing (2) in soft--jawed

vise.
(7) Pour small amount of clean lubricating oil 2
into bearing housing (2) and output shaft (6). 6
(8) Coat seal (7) with petroleum jelly and install
in groove in bearing housing (2).
(9) Install shaft face seal (8) in wear plate (9).
28--35
TM 9--2320--360--34--2

(10) Install wear plate (9) on bearing housing (2).
(11) Coat seal (10) with petroleum jelly and

install in groove in wear plate (9).
(12) Insert drive (11) into bearing housing (2).
2
NOTE 12
Star and rollers must be in place 11
when installing geroler
assembly. 10
(13) Install geroler assembly (12) on wear 9

plate (9).
NOTE
The direction output shaft
rotates is determined by timing.
(14) Locate largest opening pocket in geroler

assembly (12). Mark its position.
15
13 14
(15) Install valve drive (13) in geroler
assembly (12).
12
(16) Coat seal (14) with petroleum jelly and
install in groove in valve plate (15).
(17) Align scribe marks and install valve plate
(15) on geroler assembly (12).
(18) Locate open slot in valve plate (15) that is in 16
line with largest open pocket in geroler
assembly (12).
15
(19) Align any side opening in valve (16) with

open slot in valve plate (15) that is over 13
largest open pocket in geroler
assembly (12).
NOTE 12
Valve will fall into place and rest
flat on valve plate when properly
seated.
(20) Engage valve (16) with valve drive (13) by

rotating it clockwise until spline teeth mesh
(1/2 spline tooth).
28--36
TM 9--2320--360--34--2
(21) Install new preformed packing (17) on case

drain plug (18).
(22) Install case drain plug (18) in valve housing
(19). Torque to 40--60 lb--in. (4.5--6.8 N.m).
(23) Install springs (20 and 21) in control spool (22).
NOTE 26
Valve housing should be 25
positioned with opening facing
you. 21
20
(24) Install control spool (22) with springs (20
and 21) in right port of valve housing (19). 22
23
(25) Install new preformed packing (23) on 24
control spool plug (24).
(26) Install control spool plug (24) in valve housing (19).
19
(27) Install new preformed packing (25) on 18 17
control spool plug (26).
NOTE
Compress springs to install
second plug.
(28) Install control spool plug (26) in valve

housing (19).
(29) Tighten control spool plugs (24 and 26) to
38--46 lb--ft (51--62 N.m).
(30) Install three new preformed packings (27)
and four new backup rings (28) on balance
ring (29).
NOTE
Balance ring springs may be
installed in any two holes that
are directly across from each 30
other.
28
(31) Install two balance ring springs (30) in holes
in valve housing (19).
(32) Coat preformed packings (27) and backup
19
rings (28) with petroleum jelly. 30
NOTE 27
Ensure two index pins are
properly seated in balance ring
before installation.
29
(33) Align two index pins with two remaining
holes in valve housing (19) and install
balance ring (29). Push balance ring (29)
into valve housing (19) until it just touches
springs (30).
28--37
TM 9--2320--360--34--2
(34) Coat seal (31) with petroleum jelly. 32

(35) Install seal (31) and preformed packing (32)
in grooves in valve housing (19).
NOTE
There is a gap between valve 19
housing and valve plate. This 31
gap will close when screws are
tightened.
15
(36) Install valve housing (19) on valve plate
(15).
(37) Install four screws (33) in valve housing
(19). Torque in a crisscross pattern to
38--46 lb--ft (51--62 N.m).
(38) Install two check balls (34) and springs (35)
in valve housing (19).
33
(39) Install new preformed packings (36) on two
check ball plugs (37).
(40) Install plugs (37) in valve housing (19). 34
Torque to 40--60 lb--in. (4.5--6.8 N.m). 35
36
37
19
34
35
36
37
28--38
TM 9--2320--360--34--2
28--4. HYDRAULIC PUMP REPAIR
This task covers:

INITIAL SETUP

Hydraulic pump on clean work surface. Adhesive--Sealant, Silicone (Item 2, Appendix B)
Grease, Automotive and Artillery (Item 32,
Compressor Unit, Air (Item 24, Appendix E) Bearing, Ball (Item 1, Appendix F)
Goggles, Industrial (Item 57, Appendix E) Ring, Retaining (Item 240, Appendix F)
Puller Kit, Mechanical, Slide Hammer Seals, Gasket (6) (Item 294, Appendix F)
(Item 125, Appendix E) Seals, Pocket (36) (Item 318, Appendix F)
Wrench, Torque, 0--600 Lb--Ft (Item 233, Seals, Ring (6) (Item 255, Appendix F)
Appendix E) Seal, Lip (Item 303, Appendix F)
a. Disassembly
NOTE
Leaving two studs in place will aid in disassembly.
When pump is disassembled, housings look the same.
Mark and number housings.
(1) Remove four nuts (1), two long studs (2),

and washers (3) from port end cover (4).
(2) Remove port end cover (4) from gear
housing (5).
(3) Remove gasket seal (6) from gear housing
(5). Discard gasket seal.
(4) Remove two bearings (7) from port end
cover (4) using bearing puller.
(5) Remove ring seal (8) from port end cover
(4). Discard ring seal.
7
8
5
6
3 7
2
4
1
28--39
TM 9--2320--360--34--2
28--4. HYDRAULIC PUMP REPAIR (CONT)

(6) Remove gear housing (5) from bearing
carrier (9).
NOTE
Thrust plate may stay on port
end cover or gear housing.
(7) Remove thrust plate (10) and six pocket

seals (11) from gear housing (5). Discard
pocket seals.
(8) Remove gasket seal (12) from gear housing 13
(9) Remove matched gear set (13 and 14) from
bearing carrier (9).
9
14
11
12
5
10
16
15
pocket seals.
(11) Remove bearing carrier (9) from gear

housing (17).
(12) Remove four bearings (18) and two ring
seals (19) from bearing carrier (9). Discard
ring seals. 19
(13) Remove drive gear connecting shaft (20)
from bearing carrier (9).
20 18
19
17
9
18
28--40
TM 9--2320--360--34--2

(15) Remove gear housing (17) from bearing
carrier (22).
pocket seals.
(18) Remove matched gear set (26 and 27) from
gear housing (17).
24
26 22
25
17
21
23

pocket seals.
28 17
29
28--41
TM 9--2320--360--34--2
(20) Remove bearing carrier (22) from gear

housing (30). 34
(21) Remove four bearings (31) and two ring 32
seals (32) from bearing carrier (22).
33
(22) Remove drive gear connecting shaft (33) 32
from driven gear (34). 30
31
22
31
36
34
(24) Remove key (36) from driven gear (34).
(25) Remove gear housing (30) from shaft end
cover (37).
37
(30). Discard gasket seal. 38
30
seals (40) from gear housing (30). Discard 41
pocket seals.
39
(28) Remove gears (34 and 41) from gear 40
housing (30).
30
NOTE 42
Thrust plate may stay on cover 43
or gear housing.

pocket seals.
28--42
TM 9--2320--360--34--2
(30) Remove two studs (44) from shaft end

cover (37).
46
(31) Remove two bearings (45) and ring seal (46) 37
from shaft end cover (37). Discard ring seal. 45
44
(32) Remove retaining ring (47) from back of

shaft end cover (37). Discard retaining ring.
(33) Remove sealed bearing (48) from shaft end
cover (37). Discard sealed bearing.
(34) Remove seal (49) from shaft end cover (37).
Discard seal.
49 37
48
47
37
(35) Remove plug (50) from shaft end cover (37).
50
WARNING
28--43
TM 9--2320--360--34--2
WARNING
kPa). Use only with effective chip guarding and personal protective equip-
ment (goggles, shield, and gloves).
(2) Dry parts, except bearings, with compressed air.

(3) Inspect parts for cracks, chipping, and warping. If damage is found, replace parts.
2
c. Assembly
NOTE
Ensure directional plug is in
correct hole as shown.
(1) Install plug (1) in shaft end cover (2).
WARNING
with water.
(2) Coat outside edge of new seal (3) with

(3) Install new seal (3) metal side up in back of 2
3
shaft end cover (2).
4
(4) Install new sealed bearing (4) in back of
shaft end cover (2). 5
(5) Install new retaining ring (5) in back of shaft

end cover (2).
2
6
7
NOTE
Notched side of ring seals face
bearings.
(6) Install new ring seal (6) in shaft end

cover (2).
(7) Install two bearings (7) in shaft end 7
cover (2).
28--44
TM 9--2320--360--34--2
(8) Coat six new pocket seals (8) thoroughly

with grease.
(9) Install pocket seals (8) in thrust plate (9). 9
(10) Install thrust plate (9) in gear housing (10). 13
(11) Install driven gear (11) and gear (12) in 11
housing (10).
(12) Install key (13) into driven gear (11).
(13) Install new gasket seal (14) in groove in
2
gear housing (10).
8
NOTE
Marks made during disassembly
should be aligned before 12
assembly.
14
(14) Install gear housing (10), over gears (11 and
12), on shaft end cover (2). 10

gear housing (10).
(16) Install two new ring seals (16) and four
bearings (17) in bearing carrier (18).
with grease.
(18) Install pocket seals (19) in thrust plate (20).
(19) Install thrust plate (20) in bearing 16
carrier (18).
(20) Install bearing carrier (18) on gear 10
16
housing (10). 15
20
19
17
18
17
28--45
TM 9--2320--360--34--2

(21) Coat six new pocket seals (21) thoroughly with grease.
(23) Install thrust plate (22) in bearing carrier (18).
(24) Install drive gear connecting shaft (23) in
(25) Install gear (24) on drive gear connecting shaft (23).
(26) Install gear (25) in gear housing (26).
gear housing (26).
23
25), on bearing carrier (18).
24
18
21
22
25
27
26
(29) Install new gasket seal (28) in groove in gear housing (26).
(30) Install two new ring seals (29) and four bearings (30) in
(31) Coat six new pocket seals (32) thoroughly with
grease.
(33) Install thrust plate (33) in bearing carrier (31). 32
(34) Install bearing carrier (31) on gear
housing (26).
29
26
29 28
33
30
31
30
28--46
TM 9--2320--360--34--2

with grease.
(37) Install thrust plate (35) in gear housing (36).
34
35
36
(38) Install drive gear connecting shaft (37) in

driven gear (24).
(39) Install gear (38) on drive gear connecting
shaft (37).
(40) Install gear (39) in gear housing (36).
gear housing (36).
39), on bearing carrier (31).
24
gear housing (36).
37
38
36 39
26
31
39
40
41
28--47
TM 9--2320--360--34--2
(44) Install new ring seal (42) and two bearings

(43) in port end cover (44).
with grease.
(47) Install thrust plate (46) in port end
cover (44).
(48) Install port end cover (44) on gear
housing (36).
(49) Install four washers (47), two studs (48), two
long studs (49), and four nuts (50). Torque
to 200 ft--lb (271 N.m).
43
42
36
6
46
45
43
47
49 44
50
48
28--48
TM 9--2320--360--34--2
28--5. AUXILIARY WINCH REPAIR
This task covers:

INITIAL SETUP

Auxiliary winch on clean work surface. Compound, Sealing, Pipe Thread (Item 28,
Appendix B)
Caliper Set, Micrometer (Item 15, Appendix E) Lockwashers (7) (Item 122, Appendix F)
Compressor Unit, Air (Item 24, Appendix E) Lockwasher (1) (Item 111, Appendix F)
Gage Set, Telescoping (Item 56, Appendix E) Lockwasher (Item 118, Appendix F)
Goggles, Industrial (Item 57, Appendix E) Lockwasher (Item 120, Appendix F)
Pan, Oil Drain (Item 102, Appendix E) Repair Kit, Winch (Item 232, Appendix F)
Press, Hydraulic (Item 116, Appendix E) Service Kit, Winch (Item 321, Appendix F)
Appendix E)
Appendix E)
a. Disassembly
4
(1) Place auxiliary winch (1) on clean work
surface.
(2) Remove screw (2) from counterbalance 3
valve (3).
(3) Remove four screws (4) and counterbalance
valve (3) from auxiliary winch drive
motor (5).
(4) Remove two screws (6), lockwashers (7), 1
and washers (8) from brake housing 2
assembly (9). Discard lockwashers.
(5) Remove auxiliary winch drive motor (5) with
input shaft (10) from brake housing
assembly (9). 9 10
5
8
7
3
28--49
TM 9--2320--360--34--2
28--5. AUXILIARY WINCH REPAIR (CONT)

(6) Remove preformed packing (11) from drive
motor (5). Discard preformed packing.
(7) Remove input shaft (10) from drive
motor (5).
(8) Remove brake shaft (12) from input
shaft (10).
12 11 5
10
17
WARNING
Loosen capscrews evenly
until spring pressure is com-
pletely relieved. Failure to do 15
so may result in injury to 16
personnel.

9
(14) from brake housing assembly (9).
(10) Remove brake housing assembly (9) with
two springs (15) and thrust plate (16) from
end support (17).
13
18
19
20
19
housing (9). 21
(12) Remove two friction disc plates (19) and
steel brake drive plates (20) from 9
housing (9).
(13) Remove seal (21) from housing (9). Discard
seal.
28--50
TM 9--2320--360--34--2
WARNING
Screw is under spring ten-
sion. Remove screw slowly
to relieve tension and prevent
serious injury.
(14) Remove sockethead screw (22), spring (23),

22 29
washer (24), and shifter arm (25) from end
cover (26). 23
(14.1) Remove preformed packing (25.1) and 28 27
preformed packing (25.2) from end cover 24
(26). Discard preformed packings. 25
(15) Remove sockethead screw (27), lockwasher 25.1
(28), and knob (29) from shifter arm (25). 25.2
WARNING
32
injury.
30
(16) Remove retaining ring (30) from ring
gear (31).
(17) Remove end cover (26) from ring gear (31).
(18) Remove preformed packing (32) from end 38
37
cover (26). Discard preformed packing.
33
36
35
34
26
(19) Remove sun gear (33) from drive
coupling (34).
(20) Remove washer (35), drive gear (36), thrust 41
washer support (37), and thrust washer (38) 40
from end cover (26).
39
(21) Remove drive coupling (34) from end
cover (26).
(22) Remove shifter shaft (39) from end
cover (26). 42
(23) Remove preformed packing (40) from 41
shifter shaft (39). Discard preformed
packing.
(24) Remove two plugs (41) and breather (42)
from end cover (26).
28--51
TM 9--2320--360--34--2

31
(25) Remove secondary carrier assembly (43)

and thrust washer (44) from ring gear (31). 44
(26) Remove thrust washer (44) from secondary 43

carrier assembly (43).
45
46
17
47
and tie bar (47) from end supports (17 and
48). Discard lockwashers.
(28) Pry end supports (17 and 48) from 48
drum (49).
46
45 49
50
51
52
31
(51) from end support (48) and ring gear
(30) Remove ring gear (31) and preformed
packing (52) from end support (48). Discard
preformed packing.
48
17
(31) Remove two seal rings (53) from end
supports (17 and 48). Discard seal rings. 53
28--52
TM 9--2320--360--34--2
NOTE
Do steps (32 and 33) only if
bearings or bushings fail
inspection.
54
49
(32) Remove two bronze bearings (54) from
drum (49).
54
55
26
(33) Remove bronze bushing (55) from end

cover (26).
17
(34) Remove screw (56), lockwasher (57), and

cable hook (58) from end support (17).
58
Discard lockwasher.
57
56
WARNING
28--53
TM 9--2320--360--34--2
WARNING
Compressed air used for cleaning purposes will not exceed
30 psi (207 kPa). Use only with effective chip guarding and
personal protective equipment (goggles, shield, and
gloves).

(3) Clean all sealing surfaces.
(4) Inspect machined surfaces for damage.
(5) Replace oil seals and damaged parts.
(6) Inspect bushing and bearings for pitting, roundness,
and for inside diameter larger than 5/8 in. (16 mm).
(7) Replace bushing or bearings if pitted, out of round,
or smaller than 5/8 in. (16 mm).
c. Assembly 2
NOTE
Do steps (1) and (2) if bushing
and bearings were removed.
(1) Press bronze bushing (1) into end cover (2).
(2) Press two bronze bearings (3) into ends of

drum (4).
3
28--54
TM 9--2320--360--34--2
(3) Install cable hook (5) on end support (6) with

new lockwasher (7) and screw (8).
5 9
7
8
(4) Install two new seal rings (9) on end
supports (6 and 10).
(5) Install new preformed packing (11) in end

support (6). 10
NOTE 13 14
When installing ring gear,
ensure that hole on ring gear for
manual kickout shifter arm is at
top and aligns with tie bar.
(6) Align holes in ring gear (12) with holes in

end support (6) and install ring gear (12) on
end support (6).
(7) Install six new lockwashers (13) and screws
(14) on end support (6) and ring gear (12).
11 6 17
16
NOTE 12
Cable hold down side of drum 6
goes toward motor end of
support.
15
(8) Install end supports (6 and 10) on drum (4).
(9) Install tie bar (15) on end supports (6 and
10) with two new lockwashers (16) and
screws (17). Torque to 50 lb--ft (68 N.m).
10
16
17
28--55
TM 9--2320--360--34--2

(10) Install thrust washer (18) on shaft portion of
secondary carrier assembly (19).
(11) Install secondary carrier assembly (19),
shaft first, on ring gear (12) until flush. 12
NOTE 18
Sun gear is installed with
beveled teeth out.
(12) Install sun gear (20) in secondary carrier 19

assembly (19).
20
(13) Install new preformed packing (21) on shifter

shaft (22).
(14) Install shifter shaft (22) in end cover (2).
(15) Install knob (23) on shifter arm (24) with new
lockwasher (25) and screw (26). 28 29
(15.1) Install new preformed packing (26.1) and
new preformed packing (26.2) on end 27 23
cover (2).
24 25
WARNING
Spring is under pressure 2 26
when compressed. Use care
when installing to prevent
serious injury.
NOTE 21
Arrow on shifter shaft should
point in same direction as shifter 22
arm.
(16) Install shifter arm (24) on shifter shaft (22)

with washer (27), spring (28), and
sockethead screw (29).
(17) Install new preformed packing (30) on end 23
cover (2).
24
NOTE 30
2
Ensure groove around drive
coupling engages boss on 31
shifter shaft.
(18) Install drive coupling (31) in end cover (2).
NOTE
Shifter arm must be turned so
drive coupling lays flat in end
cover.
(19) Turn shifter arm (24) 180 degrees so knob

(23) faces outside end cover (2).
28--56
TM 9--2320--360--34--2
(20) Install thrust washer (32) and drive gear (33) 2

in drive coupling (31).
35 31
36 33
(21) Install input shaft (34), small end first, in 32
drive gear (33) and end cover (2).
(22) Install thrust washer support (35) and thrust
washer (36) on end cover (2).
34
(23) Install input shaft (34) through sun gear (20)

and drum (4).
(24) Install end cover (2) on end support (6). 12
NOTE
Shifter arm must align with hole 20
2 24
in ring gear and tie bar. 4
(25) Turn shifter arm (24) so screw (26) locks in 37 26

hole in ring gear (12).
WARNING
injury.
(26) Install retaining ring (37) on ring gear (12).
40
NOTE
· Open side of seal faces brake 38
housing.
· Seal is installed 2 in. (50 mm) at
a time. Start with outer edge,
then move to inner edge until 39
seal is installed flush with
housing.
(27) Install seal (38) in brake housing (39).

(28) Install new preformed packing (40) in brake
housing (39).
28--57
TM 9--2320--360--34--2
34
(29) Install brake shaft (41) over end of input
shaft (34). 41
CAUTION
Springs must be centered in end
support. Position auxiliary 10
winch so brake shaft points up.
Failure to comply may cause
springs to bind when brake
housing is installed.
42
NOTE
· Springs must be installed so
outside edges do not touch.
· Grooved side of thrust plate
faces out.
(30) Install two springs (42) and thrust plate (43)

in end support (10). 43
41 44
45
44
(31) Install two friction disc plates (44) and steel
brake drive plate (45) on brake shaft (41).
28--58
TM 9--2320--360--34--2
NOTE
· Notches in brake housing must
align with tabs on steel drive
plate.
· Holes in brake housing must
10
align with dowels in end
support.
· Screws should be tightened 46
evenly to uniformly compress
47
spring.
48
(32) Install brake housing (46) on end support
(10) with four new lockwashers (47) and
screws (48). Torque to 45--55 lb--ft
(61--75 N.m).
WARNING
soap and water.
50
(33) Coat threads of two plugs (49) and breather
49
(34) Install two plugs (49) and breather (50) on
end cover (2).
(35) Install new preformed packing (51) on

auxiliary winch drive motor (52).
52
51
28--59
TM 9--2320--360--34--2
57
56
(36) Position auxiliary winch drive motor (52) on
brake housing (46) with two washers (53),
new lockwashers (54), and screws (55).
(37) Install counterbalance valve (56) on auxiliary
winch drive motor (52) with four screws (57).
58
(38) Install screw (58) on counterbalance
valve (56).
46
52
53
54
55
28--60
TM 9--2320--360--34--2
28--6. POWER TAKEOFF REPAIR
This task covers:

INITIAL SETUP

Power takeoff removed (para 17--12). Adhesive--Sealant (Item 6, Appendix B)
Tool Kit, Genl Mech (Item 202, Appendix E) Grease, Automotive and Artillery, (Item 32,
Caps, Vise Jaw (Item 17, Appendix E) Appendix B)
Goggles, Industrial (Item 57, Appendix E) Oil, Lubricating (Item 44, Appendix B)
Pliers, Retaining Ring (Item 106, Appendix E) Cleaning Compound, Solvent (Item 54, Appendix B)
Press, Hydraulic (Item 116, Appendix E) Parts Kit, Clutch (Item 208, Appendix F)
Puller Kit, Mechanical, Gear and Brg Parts Kit, Linear (Item 210, Appendix F)
Appendix E)
1
3
a. Disassembly
2
(1) Remove switch (1) from reducer (2).
(2) Remove reducer (2) from power takeoff
(PTO) housing (3). Discard preformed
packings.
4
(3) Remove elbow (4) from reducer (2).
(4) Remove plug (5) from idler shaft (6).
5 6
8
(5) Remove elbows (7 and 8) from PTO
housing (3).
7
28--61
TM 9--2320--360--34--2
28--6. POWER TAKEOFF REPAIR (CONT)
3 6
(6) Remove setscrew (9) from PTO housing (3).

(7) Tap idler shaft (6) out of PTO housing (3).
(8) Remove two thick thrust races (10), needle 9
thrust bearings (11), thin thrust races (12),
and input gear (13) from PTO housing (3). 10
(9) Remove two needle bearings (14) and 11
spacer (15) from input gear (13).
12
14
15
14
13
12
11
10
16
17
NOTE
Output shaft may remain in PTO
housing or come out with 18
open--end bearing cover.
(10) Remove four screws (16), open--end bearing 3

cover (17), and gasket (18) from PTO
19
17
(11) Remove oil seal (19) from open--end bearing

cover (17). Discard oil seal.
28--62
TM 9--2320--360--34--2
(12) Remove four screws (20), closed--end

bearing cover (21), bearing cover gasket 20
(22), and output shaft (23) from PTO
21
22
23
WARNING
25
injury.
(13) Remove retaining ring (24) and backup plate 21

(25) from closed--end bearing cover (21).
Discard retaining ring.
(14) Remove oil seal (26) from closed--end
bearing cover (21). Discard oil seal.
27 28 23
(15) Press ball bearing (27) and thrust washer
(28) from output shaft (23).
28--63
TM 9--2320--360--34--2
29
23
(16) Remove output gear (29) from output

shaft (23).
30 31
23
(17) Remove two roller bearings (30) and thrust
washer (31) from output shaft (23).
(18) Press ball bearing (32) from output shaft (23).

32
WARNING
Clutch backup cylinder is un- 35
der spring pressure. It must
be clamped in vise to avoid
sudden release of parts. Fail- 33
ure to comply may cause inju-
ry to personnel.
(19) Position clutch backup cylinder (33) and 36

inner clutch gear (34) in vise.
WARNING
rings. Retaining rings are un-
jury.
(20) Remove retaining ring (35) from output shaft

(21) Remove clutch backup cylinder (33), clutch
spring (36), and inner clutch gear (34) from
output shaft (23).
28--64
TM 9--2320--360--34--2
37 38 33
(22) Remove piston (37) from clutch backup

cylinder (33).
(23) Remove preformed packing (38) from piston
(24) Remove eight friction discs (39) and seven 39

clutch plates (40) from inner clutch
gear (34).
40
WARNING
injury.
(25) Remove retaining ring (41) and two

preformed packings (42) from output shaft
(23). Discard retaining ring and preformed 42 41
23
packings.
28--65
TM 9--2320--360--34--2

WARNING

(2) Inspect friction discs for wear. If oil grooves are not visible on any
portion of any friction disc, replace all friction discs.
(3) Inspect clutch spring for breaks or discoloration. Replace spring if
broken or discolored.
(4) Inspect idler shaft, output shaft, and thrust washers for nicks, burrs,
grooves, warps, bends, or other damage. If nicks, burrs, or grooves
cannot be removed with emery cloth, replace part.
(5) Inspect remaining parts for damage. Replace damaged parts.
c. Assembly
WARNING
2
injury.
(1) Install two new preformed packings (1) and
new retaining ring (2) on output shaft (3).
1 3
28--66
TM 9--2320--360--34--2
NOTE
Discs and plates should be
installed alternately starting with 5
friction plates.
(2) Install eight friction discs (4) and seven

clutch plates (5) on inner clutch gear (6).
8 7 9
(3) Coat new preformed packing (7) with
lubricating oil.
NOTE
Lip on seal faces narrow edge
on piston.
(4) Install new preformed packing (7) on clutch

piston (8).
(5) Install clutch piston (8) in backup
cylinder (9).
9 6
10 3
(6) Position inner clutch gear (6), clutch spring
(10), and backup cylinder (9) on output
shaft (3).
(7) Position inner clutch gear (6) and backup
cylinder (9) in vise.
(8) Tighten vise to compress spring (10).
28--67
TM 9--2320--360--34--2
WARNING 9
12
injury.
(9) Install new retaining ring (11) on output shaft

(3) to secure backup cylinder (9).
NOTE
Assembly should be supported
in press by shaft.
(10) Position output shaft (3) in press with

keyway end up.
(11) Press ball bearing (12) on output shaft (3)
until seated.
14 13 3
(12) Install thrust washer (13) and two roller

bearings (14) on output shaft (3).
(13) Align splines on clutch plates (5) with splines

in output gear (15).
3
(14) Install output gear (15) on output shaft (3).
15 5
17 16
3
NOTE
Assembly should be supported
in press by shaft.
(15) Position output shaft (3) in press with

keyway end down.
(16) Press thrust washer (16) and ball bearing
(17) on output shaft (3) until seated.
28--68
TM 9--2320--360--34--2
WARNING
18 21
injury.
(17) Install new oil seal (18), backup plate (19),

and new retaining ring (20) in closed--end
bearing cover (21).
(18) Lightly coat mounting surface of PTO

housing (22) with grease. 23
WARNING 21
Adhesive--sealant may burn
or give off harmful vapors. It
keep away from open flame 24
and use in well--ventilated 3
area. If adhesive--sealant gets
water.

(20) Install new gasket (24), closed--end bearing
cover (21), and output shaft (3) on PTO
housing (22) with four screws (23). Torque
to 214--240 lb--in. (23--27.1 N.m).
(21) Install output shaft (3) on closed--end
bearing cover (21).
25
26
NOTE
Lip on seal faces bearing cover.
(22) Install new oil seal (25) in open--end bearing

cover (26) until flush with outside surface.
28--69
TM 9--2320--360--34--2

(23) Lightly coat mounting surface of PTO
housing (22) with grease.
WARNING
Adhesive--sealant may burn
or give off harmful vapors. It 27
keep away from open flame
and use in well--ventilated 26
area. If adhesive--sealant gets 28
water.
22
adhesive--sealant.
(25) Install new gasket (28) and open--end
bearing cover (26) on PTO housing (22) with
four screws (27). Torque to 214--240 lb--in.
(23--27.1 N.m).
(26) Install needle bearing (29), bearing spacer
(30), and needle bearing (29) in input
gear (31).
(27) Align flat spot on idler shaft (32) with
setscrew hole (33).
NOTE
Slot on idler gear should face
out.
(28) Press idler shaft (32) in PTO housing (22) 22 32

until 0.25 in. (6 mm) shows in opening on
PTO housing (22).
(29) Install thin thrust race (34), thrust bearing
(35), and thick thrust race (36) on idler 33
shaft (32).
36
NOTE
Leave space to install thrust 35
races and thrust bearing. 34
(30) Install input gear (31) on idler shaft (32). 29
30
Press idler shaft through input gear (31). 29
(31) Install thin thrust race (34), thrust bearing
(35), and thick thrust race (36) under input 31
gear (31). 34
35
(32) Install idler shaft (32) completely in PTO 36
housing (22).
(33) Coat threads of setscrew (37) with
adhesive--sealant and install in PTO housing
(22). Torque to 30 lb--in. (3.4 N.m).
28--70
TM 9--2320--360--34--2
WARNING
pound may burn or give off
harmful vapors. It is harmful
to skin and clothing. To avoid
injury or death, keep away 40
from open flame and use in
well--ventilated area. If pipe 39
thread sealing compound
gets on skin or clothing, wash
water.
(34) Coat threads of plug (38), elbows (39 thru

41), reducer (42), and switch (43) with pipe
(35) Install plug (38) on idler shaft (32).
(36) Install elbows (39 and 40) on housing (22).
43
22
42
(37) Install reducer (42) on housing (22).

(38) Install switch (43) in reducer (42). 41
(39) Install elbow (41) on reducer (42).
38 32
Install power takeoff (para 17--12).
28--71/(28--7228--71
blank)
TM 9--2320--360--34--2
28--72
TM 9--2320--360--34--2
CHAPTER 29
STORAGE CONTAINER MAINTENANCE
Contents Para Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29--1 29--1
Shipping and Storage Containers, Engine, Transmission, and Transfer Case Repair . . . . . . . . . . 29--2 29--2
29--1. INTRODUCTION
This chapter contains instructions for repair of storage container components at the General Support maintenance
level.
29--1
TM 9--2320--360--34--2
29--2. SHIPPING AND STORAGE CONTAINERS, ENGINE, TRANSMISSION,

AND TRANSFER CASE REPAIR.
This task covers:

INITIAL SETUP

Engine removed from container (para 3--4). Compound, Sealing, Pipe Thread (Item 28,
Transmission removed from container Appendix B)
(para 7--3). Lockwashers (60) (Item 122, Appendix F)
Transfer case removed from container
(para 8--2).

Appendix E)
a. Disassembly 1
NOTE
All three containers are repaired
in a similar manner. Engine
container is shown throughout
the task.
(1) Remove seal (1) from lower container (2).
29--2
TM 9--2320--360--34--2
3
NOTE 4
5
· Do step (2) for engine container;
do step (3) for transmission and
transfer case containers.
· Position of inner frame(s) should
be marked before removal.
(2) Remove 24 nuts (3), lockwashers (4) and
inner frame (5) from lower container (2).
6
8
(3) Remove four screws (6), lockwashers (7)

and inner frame (8) from lower container (2). 7
2
13
9
NOTE 10
All shear mounts are similar
except for shape. 12
(4) Remove four nuts (9), lockwashers (10),
screws (11), and shear mount (12) from 10
lower container (2). Discard lockwashers.
(5) Remove plug (13) from lower container (2).
29--3
TM 9--2320--360--34--2

AND TRANSFER CASE REPAIR (CONT).
NOTE
Skid legs on engine and
transmission containers do not
have flat washers. 17
(6) Remove two nuts (14), lockwashers (15). 16
four washers (16), two screws (17) and skid
leg (18) form lower container (2). Discard
lockwashers. 2
15
18
14
16
20
25 24
19
(7) Remove cover (19) from upper container
(20). 26
(8) Remove two end balls (21) and cable (22)
from upper container (20) and cover (19).
(9) Remove valve (23), nut (24), washer (25), 21
and gasket (26) from cover (19). 22
23 21
20
NOTE
Number of dehumidification 27
bags may vary due to amount of
units per bag.
(10) Remove 128 units of desiccant (8 to 16

bags) (27) from upper container (20).
29
20
31
30
28
(11) Remove humidity indicator (28), nut (29),

washer (30), and gasket (31) from upper
container (20).
29--4
TM 9--2320--360--34--2
(1) Clean interior and exterior surfaces of container. Use any process or combination of processes which
will accomplish thorough cleaning without damage to container.
(2) Clean all desiccant port covers/assemblies removed from container.
(3) Remove paint scale and rust.
(4) Check interior and exterior of container for dents, cracks, defective welds and other defects. Dents
approximately .75 in. (1.9 cm) or less deep that do not penetrate skin or weaken structure are accept-
able and are not considered defects.
(5) Check inner frame for bends and cracks.
(6) Check mounting brackets for bends and cracks.
(7) Check wire basket for defective tack welds.
(8) Check desiccant port covers/assemblies for damage and reusability.
(9) Check vibration dampener mounts for defects, such as cracking, tearing or evidence of separation of
bonding between metal and elastomer, which may affect the function of the mount.
(10) Inspect skids while on container for weakness and wear.
(11) Inspect installation decal for cracks, tears, illegibility and failure of adhesion.
5
c. Assembly
(1) Install gasket (1) and humidity indicator (2)
3
on upper container (3) with washer (4) and
nut (5).
1
4
2
NOTE
Desiccant comes in bags of
eight units each or 16 units
each. The minimum units for
engine is 128 units,
transmission and transfer case
is 48 units.
(2) Install appropriate units of desiccant (8 to 16

6
bags) (6).
29--5
TM 9--2320--360--34--2

AND TRANSFER CASE REPAIR (CONT).
5
10 11
9
(3) Install gasket (7) and valve (8) in cover (9)
with washer (10) and nut (11). 7
(4) Install cover (9) on upper container (5) with
cable (12) and two balls (13).
NOTE
13
Skid legs on engine and
8
transmission containers do not 12
have flat washers. 13
(5) Install skid leg (14) on lower container (15)

with two screws (16), four washers (17), two
new lockwashers (18), and nuts (19).
Torque to 31--37 lb--ft (42--50 N∙m).
20
WARNING 16
19
soap and water.
(6) Coat threads of pipe plug (20) with pipe

thread compound and install in lower
container (15).
24
23
21
22
NOTE
All shear mounts are similar
except for shape.
(7) Install shear mount (21) on lower container 15

(15) with four screws (22), new lockwashers
(23) and nuts (24).
29--6
TM 9--2320--360--34--2
NOTE 27
Do step (8) for engine container, 26
25
do step (9) for transmission and
transfer case containers.
(8) Install inner frame (25) in lower container

(15) with 24 new lockwashers (26) and nuts
(27).
15
29
28
(9) Install inner frame (28) with four screws (29) 30

and new lockwashers (30).
15
31
(10) Install seal (31) on lower container (15).
15
Change 29--7
29-1-7/(29--8 blank)
TM 9--2320--360--34--2
29--8
T M 9 --2320 --360 --34 --2
APPENDIX A
REFERENCES
A--1. S C OP E
T his appendix lists all forms , field manuals , technical manuals , and other publications referenc ed in this manual.
A --2. P UBLICATIONS INDE X

T he following index s hould be cons ulted frequently for lates t changes or revis ions and for new publications
relating to material covered in this tec hnical manuals .
Cons olidated Index of Army Public ations and Blank F orms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA P am 25 --30
A--3. F OR MS
T he following forms pertain to this manual. S ee DA Pam 25 --30 for index of blank forms . See DA P am 750-8,
T he Army Maintenanc e Management Sy s tem (TAMMS) , for ins tructions on the us e of maintenanc e forms
pertaining to this material.
F ield Organiz ations Unit Status Repor t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 220 --1
Rec ommended Changes to DA Public ations and Blank F orms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA F orm 2028
Rec ommended Changes to Equipment Tec hnical P ublications . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2028
Equipment Ins pection and Maintenanc e Works heet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA F orm 2404
Maintenanc e R eques t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA F orm 2407
Equipment Contr ol R ec ord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA F orm 2408 --9
Quality Deficienc y R eport (Categor y II) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SF 368
A --4. OTHER PUBLICATIONS

The following publications contain information pertinent to the HET Tractor and associated equipment.
a. Department of Ar my Pamphle ts
The Army Maintenance Management System (TAMMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Pam 750-8
b. Field Manua ls
First Aid for Soldiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 4-25.11
Nuclear, Biological, and Chemical (NBC) Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FM 3-11.4
Nuclear, Biological, and Chemical (NBC) Decontamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 3-11.5
c. Lubr ic ation Order

Lubrication Order for Truck, Tractor, M1070, 8 x 8,
Heavy Equipment Transporter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LO 9--2320--360--12
d. Technic al Bulle tins

Pre--Embarkation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 9--2300--281--35
Warranty Technical Bulletin for Truck, Tractor, M1070, 8 x 8,
Heavy Equipment Transporter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 9--2320--360--14
Equipment Improvement Report and Maintenance Digest: TACOM Equipment . . . . . . . . . . . . . . . TB 43--001--39
Cooling Systems: Tactical Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 750--254
A--1
T M 9 --2320 --360 --34 --2
A --4. OTHER P UBLICATIONS (CONT)

e. Technical Manuals
Operator’s Manual for Truck, Trac tor, M1070, 8 x 8,

Heav y E quipment Trans porter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T M 9--2320 --360 --10
Hand Rec eipt Manual for Truck, Trac tor, M1070, 8 x 8,
Heav y E quipment Trans porter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T M 9--2320 --360 --10 --HR
Unit Maintenanc e Manual for Truck, Trac tor, M1070, 8 x 8,
Heav y E quipment Trans porter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T M 9--2320 --360 --20
Equipment Improvement Repor t and Maintenanc e S ummary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T M 43 --1043
Pr ocedures for Des truction of Tank --Automotive Equipment
to Pr event Enemy Us e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T M 750 --244 --6
A--2
TM 9--2320--360--34--2
APPENDIX B
EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST
B--1. SCOPE
This appendix lists expendable and durable items that you will need to operate and maintain the HET Tractor.
This listing is for information only and is not authority to requisition the listed items. These items are authorized to
you by CTA 50--790, Expendable/Durable Items (except medical, class V repair parts, and heraldic items), or CTA
8--100, Army Medical Department Expendable/Durable Items.
B--2. EXPLANATION OF COLUMNS

a. Column (1) -- Item Number. This number is assigned to the entry in the listing and is referenced in the
narrative instructions to identify the item, e.g., “Oil, Lubricating (Item 42, Appendix B).”
b. Column (2) -- Level. This column identifies the lowest level of maintenance that requires the item.
c. Column (3) -- National Stock Number. This is the national stock number assigned to the item which you
can use to requisition it.
d. Column (4) -- Item Name, Description, Commercial and Government Entity Code (CAGEC), and Part
Number. This provides the other information you need to identify the item.
e. Column (5) -- Unit of Measure. This code shows the physical measurement or count of an item, such as
gallon, dozen, gross, etc.
Section II. EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST

(1) (2) (3) (4) (5)
National
Item Stock
Number Level Number Description U/M
1 O 8040--00--273--8717 Adhesive (81348) MMM--A--121 pt

2 O 8040--00--843--0802 Adhesive--Sealant, Silicone, RTV, General Purpose oz
(MIL--A--46106A) (01139) 108
2.1 F Adhesive--Sealant (05972) 510 ml
3 O 5330--01--325--6993 Adhesive--Sealant (05972) 515 ml
4 F Adhesive--Sealant (51517) 518 ml
5 O 8030--00--148--9833 Adhesive--Sealant (MIL--S--46163) (05972) 271 ml
6 O 8040--01--250--3969 Adhesive--Sealant (05972) 242 ml
7.1 H Adhesive--Sealant (05972) 601 ml
B--1
TM 9--2320--360--34--2
Section II. EXPENDABLE/DURABLE SUPPLIES AND

MATERIALS LIST (CONT)
(1) (2) (3) (4) (5)
National
Item Stock

9 F Adhesive--Sealant, Permatex No. 1 ml
10 F Adhesive--Sealant, Permatex No. 2 ml
10.1 F Adhesive--Spray (04963) 77 oz
8040--00--938--6860 17 oz. can
11 C Antifreeze, Arctic Type (MIL--A--11755) (81349)
6850--00--243--1992 1 gal can gl
6850--00--174--1806 55 gal drum gl
12 C 6850--00--181--7940 Antifreeze, Permanent, Glycol, Inhibited gl
(MIL--A--46153) (81349)
13 F Caps, Shipping and Sealing
14 O Cement, General Purpose, Synthetic Base
(MIL--A--4003) (81349)
15 C 7930--00--634--3935 Chips, Soap (81348) P--S--579
16 F Cloth, Crocus
17 F Clips, Wire (45152) 27886AX
18 O 8030--00--597--5367 Compound, Antiseize, High Temperature lb
(MIL--A--907) 2--1/2 lb can
19 F Compound, Gasket--Forming
20 F 5970--00--166--5697 Compound, Insulating, Electrical, Embedding
(MIL--C--47233)
21 F Compound, International, No. 2
(72582) 5198563
22 F Compound, Retaining (MIL--R--46082)
8030--00--181--7603 50 cc cc
8030--00--181--7529 250 cc cc
22.1 Compound, Sealing (MIL--S--45180C) Type III pt
(7A756) Permatex 3D
23 F Compound, Sealing, Lubricating, Wicking, Thread--
Locking, Anaerobic, Single Component
(MIL--S--46163), Type I, Grade K
B--2
TM 9--2320--360--34--2

(1) (2) (3) (4) (5)
National
Item Stock

(MIL--S--46163), Type I, Grade
(MIL--S--46163), Type II, Grade N
(MIL--S--46163), Type II, Grade O
27 F Compound, Sealing and Lubricating
28 O 8030--01--166--0675 Compound, Sealing, Pipe Thread
(05972) 567
50 ml ml
250 ml ml
29 F Connector, Electrical, Butt (34072) 04618 ea
30 F Dye, Prussian Blue
31 O 9150--00--223--4004 Grease, Anticorrosion (Molybdenum) (MIL--G--21164) lb
(81349)
32 C Grease, Automotive and Artillery (GAA)
(MIL--G--10924) (81349)
9150--00--065--0029 2--1/4 oz tube oz
9150--00--935--1017 14 oz cartridge oz
9150--00--190--0904 1 lb can lb
9150--00--190--0905 5 lb can lb
9150--00--190--0907 35 lb can lb
33 F Grease, Ball Bearing
34 F 9150--01--091--9336 Grease, General Purpose, Lithium Base
34.1 F 9150--01--145--1259 Grease, High Temperature DOD--G--85733 (81349) qt
35 F Jelly, Petroleum
36 F 9505--00--191--3680 Lockwire
37 C Oil, Fuel, Diesel, DF--1, Winter (VV--F--800) (81348)
9140--00--286--5286 Bulk gl
9140--00--286--5287 5 gal can gl
9140--00--286--5288 55 gal drum, 16 gage gl
9140--00--286--5289 55 gal drum, 18 gage gl
B--3
TM 9--2320--360--34--2

(1) (2) (3) (4) (5)
National
Item Stock
38 C Oil, Fuel, Diesel, DF--2, Regular (VV--F--800) (81348)

9140--00--286--5294 Bulk gl
9140--00--286--5295 5 gal can gl
9140--00--286--5296 55 gal drum, 16 gage gl
9140--00--286--5297 55 gal drum, 18 gage gl
39 F Oil, Hydraulic
40 C Oil, Lubricating Gear, GO 75 (MIL--L--2105C)
9150--01--035--5390 1 qt can qt
9150--01--035--5391 5 gal drum gl
41 C Oil, Lubricating Gear, GO 80/90 (MIL--L--2105C)
9150--01--035--5392 1 qt can qt
9150--01--035--5393 5 gal drum gl
9150--01--035--5394 55 gal drum gl
42 O Oil, Lubricating OEA ICE, Subzero (MIL--L--46167)
9150--00--402--4478 1 qt can qt
9150--00--402--2372 5 gal drum gl
9150--00--491--7197 55 gal drum, 16 gage gl
43 O Oil, Lubricating 15W/40 (MIL--L--2104)
9150--01--152--4117 1 qt can qt
9150--01--152--4118 5 gal drum gl
9150--01--152--4119 55 gal drum gl
44 C Oil, Lubricating, OE/HDO 10 (MIL--L--2104)
9150--00--189--6727 1 qt can qt
9150--00--186--6668 5 gal drum gl
55 gal drum, 16 gage gl
9150--00--191--2772 55 gal drum, 18 gage gl
45 F Oil, Lubricating, OE/HDO 15 (MIL--L--2104)

1 qt can qt
46 C Oil, Lubricating, OE/HDO 30 (SAE 30) (MIL--L--2104)
9150--00--186--6681 1 qt can qt
9150--00--188--9858 5 gal drum gl
9150--00--265--9436 55 gal drum, 16 gage gl
9150--00--189--6729 55 gal drum, 18 gage gl
47 C Oil, Lubricating, OE/HDO 40 (MIL--L--2104)
9150--00--189--6730 1 qt can qt
9150--00--188--9862 5 gal drum gl
9150--00--405--2987 55 gal drum, 16 gage gl
B--4
TM 9--2320--360--34--2

(1) (2) (3) (4) (5)
National
Item Stock
48 F Oil, Lubricating, OE/HDO 50 (MIL--L--2104)

1 qt can qt
5 gal drum gl
55 gal drum, 16 gage gl
49 F 5350--00--186--8818 Paper, Abrasive, Garnet, P--P--121
50 F Plastigage
51 O 7920--00--205--1711 Rags, Wiping, Cotton and Cotton--Synthetic lb
(A--A--531)
52 F 2090--00--372--6064 Repair Kit, Glass Reinforced Plastic Laminate ea
53 F Rope, 50 ft ft
54 C Cleaning Compound, Solvent (MIL-PRF-680)
6850--01-474-2319 1 gal can (Type II) gl
6850--01-474-2318 1 gal can (Type III) gl
55 F Spray, Adhesive
56 O 8135--00--178--9200 Tags, Identification (MIL--T--12755) pk/1000 mx
57 O 5970--00--644--3167 Tape, Insulation, Electrical (MIL--T--50886) ft
58 F Tape, Masking, A--A--883 ft
59 F Tape, Plastic ft
60 O 5975--01--273--8133 Ties, Cable, Plastic (96906) MS3367
(MIL--S--29190)
B--5/(B--6 B-
blank)
-5
TM 9--2320--360--34--2
B--6
TM 9--2320--360--34--2
APPENDIX C
ILLUSTRATED LIST OF MANUFACTURED ITEMS
This appendix includes complete instructions for making items authorized to be manufactured or fabricated at the
direct support and general support maintenance levels.
A part number index in alphanumeric order is provided for cross--referencing the part number of the item to be
manufactured to the figure which covers fabrication criteria.
All bulk materials needed for manufacture of an item are listed by part number or specification number in a tabular
list on the illustration.
Section II. MANUFACTURED ITEMS PART NUMBER INDEX
PART NO. DESCRIPTION FIGURE NO.

1525--6 HOSE ASSEMBLY C--1
2BG623 REMOVER, BEARING SHELL C--10
2BH944 EYES, LIFTING (1/2 IN.) C--8
2HD798 YOKE HOLDER C--15
2SK742 FIXTURE, TURBOCHARGER HOLDING C--17
25806AX9 WIRE, SAFETY C--2
ADAPTER, CONSTANT VELOCITY U--JOINT BEARING
CAP REMOVAL TOOL C--19
BEARING CONE INSTALLER, POWER DIVIDER C--21
CONE INSTALLER, PINION BEARING C--20
BLOCKS, WOODEN C--3
EYE, LIFTING (10 MM) C--9
FIXTURE, IDLER GEAR HOLDING C--18
GUIDE SCREWS C--4
HOOK, WIRE C--6
JET EXTRACTOR C--11
PLATE, STEEL, 3/16 IN. C--12
PLATE, STEEL, 1/16 IN. C--13
PLYWOOD C--5
PRELOAD GAGE, DIFFERENTIAL CARRIER C--16
SHIM C--7
TEMPLATE, STEERING RADIUS C--22
THREADED ROD (3/8 IN.) C--14
C--1
TM 9--2320--360--34--2
Section III. MANUFACTURED ITEMS ILLUSTRATIONS
CUTOFF
LENGTH
A BULK HOSE STOCK B
(1) Fabricate from bulk hose stock listed in table C--1.

(2) Using fine--toothed hacksaw, cut hose to length required in table C--1.
(2.1) Clean debris from inside hose and around hose end.
(3) Place fitting A in vise and screw hose counterclockwise until hose bottoms in fitting. Back off one--
quarter turn.
(4) Place fitting B in vise and screw hose counterclockwise until hose bottoms. Back off one--quarter
turn.
Figure C--1. Hose Assembly
Table C--1. Hose Assembly
CUTOFF
HOSE ASSY BULK HOSE LENGTH
PN PN IN. (CM) FITTING A FITTING B
1525--6 FS332--6 12 (30) ADAPTER 5113191 ADAPTER 5113191
C--2
TM 9--2320--360--34--2
CUTOFF
LENGTH
BULK WIRE STOCK
(5) Fabricate from bulk wire stock listed in table C--2.

(6) Using wire cutters, cut to required length.
Figure C--2. Safety Wire
Table C--2. Safety Wire

CUTOFF LENGTH
HARNESS ASSY PN BULK WIRE PN IN. (MM)
25806AX9 MS20995--S41 9 (229)
(1) Fabricate from MML751 lumber stock.

(2) Using saw and standard planing machine, cut stock to size required in table C--3.
Figure C--3. Wooden Blocks
Table C--3. Wooden Blocks
PARAGRAPH NO. FINISHED DIMENSIONS OF BLOCK

IN. (CM)
3--10, 4--4, 19--11, 20--2 1--1/2 x 1--1/2 x 12 (3.8 x 3.8 x 30)

5--6 2 x 4 x 9 (5 x 10 x 23)
14--9 4 x 4 x 24 (10 x 10 x 61)
14--11 2 x 4 x 14.5 (5 x 10 x 37)
2 x 4 x 16.5 (5 x 10 x 42)
2 x 4 x 21 (5 x 10 x 53)
19--7 1--1/2 x 3--1/2 x 24 (3.8 x 9 x 61)
22--17 3--1/2 x 3--1/2 x 12 (9 x 9 x 30)
25--2 1--1/2 x 3--1/2 x 12 (3.8 x 9 x 30)
C--3
TM 9--2320--360--34--2
LENGTH (FROM TABLE C-4)
SCREW SIZE
(1) Fabricate from grade 5 screw of lengths shown in table C--4. (FROM TABLE C-4)
(2) Using hacksaw, cut off screw head.
(3) Using file or grinder, remove any sharp edges.
(4) All dimensions are in inches (millimeters).
Figure C--4. Guide Screws
Table C--4. Guide Screws

LENGTH
PARAGRAPH SCREW SIZE IN. (MM)
3--5 and 11--6 1/2--13 2--3/8 (60)
3--5 and 13--7 1/2--13 2--1/2 (64)
7--4 1/2--20 3 (76)
28--2 3/4--10 6--1/2 (165)
(1) Fabricate from 48 x 72 x 3/4 in. exterior grade plywood.

(2) Using saw, cut to 48 x 29 x 3/4 in. (122 x 73.6 x 1.9 cm).
Figure C--5. Plywood
C--4
TM 9--2320--360--34--2
1/2 1/8 (3.2)

(13)
5-1/2 (140) OR LONGER
(1) Fabricate from 1/8 in. (3.2 mm) diameter steel welding rod or equivalent stiff wire.
(2) Using cutting pliers, cut welding rod to 6 in. (150 mm) length or longer.
(3) Using machinist’s vise, bend 1/2 in. (13 mm) length of rod 90 degrees.
Figure C--6. Wire Hook
30 3/32
(762) (2.38)
3
(76.2)
(1) Fabricate from flat shim stock 0.02 x 3/32 x 30 in. (0.5 x 2.38 x 762 mm).
(2) Cut shim stock into ten 3 in. (76.2 mm) pieces.
Figure C--7. Shims
C--5
TM 9--2320--360--34--2
5/8 R.
(16)
7 - 16 1
Threads (25)
(1) Fabricate from 1/2 x 6 in. (13 x 152 mm) cold rolled steel.
(2) Thread size is 7--16 x 1 in. (25 mm) long.
(3) Heat unthreaded end and bend over 1--1/4 (32 mm) diameter rod.
(4) All dimensions are inches (millimeters).
Figure C--8. Lifting Eyes (PN 2BH944)
5/8 R.
(16)
10 - 1.5 mm 1
Threads (25)
(1) Fabricate from 1/2 x 6 in. (13 x 152 mm) cold rolled steel.
(2) Thread size is 10--1.5 x 25 mm (1 in.) long.
(3) Heat unthreaded end and bend over 1--1/4 (32 mm) diameter rod.
(4) All unlabeled dimensions are inches (millimeters).
Figure C--9. Lifting Eye (10 mm)
C--6
TM 9--2320--360--34--2
1/2 (13)
1/8 (3.2) 4-1/2

(114)
2.25 R. (57)
15 (381)
(1) Fabricate from 3/8 in. (9.5 mm) diameter cold rolled steel.
(2) Heat and flatten 4--1/2 in. (114 mm) length of round stock until end is 1/8 x 1/2 x 4--1/2 in.
(3.2 x 13 x 114 mm).
Figure C--10. Bearing Shell Remover (PN 2BG623)
3-1/8
(79)
1
(25)
3/8
(10)
(1) Fabricate from 3/8 in. (10 mm) thick mild steel stock.
(2) Using hacksaw, cut steel stock to dimensions shown.
Figure C--11. Jet Extractor
C--7
TM 9--2320--360--34--2
6 (152)
1 (25)
3/16 (4.8)
(1) Fabricate from 3/16 x 1 x 6 in. (4.8 x 25 x 152 mm) or longer flat steel stock.
(2) Using hacksaw, cut steel stock to 6 in. (152 mm) length.
Figure C--12. 3/16--Inch Steel Plate
6 (152)
1 (25)
1/16 (1.6)
(1) Fabricate from 1/16 x 1 x 6 in. (1.6 x 25 x 152 mm) or longer flat steel stock.
(2) Using hacksaw, cut steel stock to 6 in. (152 mm) length.
Figure C--13. 1/16--Inch Steel Plate
C--8
TM 9--2320--360--34--2
5 (127)
Notch
3/8 - 16 Thread
(1) Fabricate from 3/8 in. --16 threaded steel rod.

(2) Using hacksaw, cut rod to 5 in. (127 mm) length.
(4) Using hacksaw, cut screwdriver--size notch in one end of rod.
Figure C--14. Threaded Rod (3/8 inch)
2-1/8 (54)
4-1/8 (105) 4-3/16 (106)
2 (51)
6-1/4 (159)
1 (25)
1 (25)
8-5/16 (211)
10-1/2 (267)
46-1/2 (1181)
1/2 (13) Stock
(1) Fabricate from 1/2 in. (13 mm) thick mild steel stock.
(2) Using torch, cut steel stock to dimensions shown.
(3) Using grinder, remove rough edges.
Figure C--15. Yoke Holder (PN 2HD798)
C--9
TM 9--2320--360--34--2
.34 (8.64)
.63 (16)
.31 (7.87)
3.5 (89)
.25 (6.35) 3.06 (78)
11(279)
(1) Fabricate from 1/4 in. (6 mm) thick, 1/2 in. (13 mm) wide, mild steel stock.
(2) Using hacksaw, cut steel stock to 14 1/2 in. (36.8 cm).
(3) Using machinist’s vise, bend steel stock 900 where indicated.
(4) Drill .344 in. (8.73 mm) hole where indicated.
Figure C--16. Differential Carrier Preload Gage.
C--10
TM 9--2320--360--34--2
(1) Fabricate from 3/4 in. (19 mm) exterior grade plywood.
(2) Drill 1--1/2 in. (38 mm) diameter hole in center of base.
(3) Drill four 1/2 in. (13 mm) diameter holes in corners of base.
(4) Draw a circle with a 1--5/8 in. (41 mm) radius.
(5) Route four 1/2 x 3/4 in. (13 x 38 mm) slots in base into circle as shown.
(6) Fabricate two 1--15/16 x 2--1/2 x 1--1/4 in. (49 x 63.5 x 32 mm) fingers from plywood.
(7) Grind bottom of fingers 23/32 in. (18 mm) wide and 7/16 in. (11 mm) high. Contour front surface of
fingers to fit turbine wheel blades.
Figure C--17. Turbocharger Holding Fixture (PN 2SK742)
C--11
TM 9--2320--360--34--2
NOTE
Required stock:
Mild steel plate, 0.75 x 6.13 x 4 in. (19 x 156 x 102 mm)
Mild steel plate, 0.25 x 4 x 4 in. (6.35 x 102 x 102 mm)
Nut, 3/8--16 (MS51967--8)
Bolt, 3/8--16 x 3--1/4 (MS90725--71)
.50 (12.7) DIA. THRU
.75
(19)
2
(50.8)
1
(25.4)
2 (50.8)
(1) Cut 0.75 x 2 x 2 in. (19 x 50.8 x 50.8 mm) steel plate.
(2) Drill 0.50 in. (12.7 mm) hole through center of steel plate.
.50 (12.7) DIA. THRU

.75
(19)
.94
(23.9)
4
(102)
2
(50.8)
2 1.50 (38.1) DIA. THRU

(50.8)
4 (102)
(4) Cut 0.75 x 4 x 4 in. (19 x 102 x 102 mm) steel plate.
(5) Drill 1.50 in. (38.1 mm) hole through center of steel plate.
(6) Drill 0.50 in. (12.7 mm) hole in steel plate.
Figure C--18. Idler Gear Holding Fixture
C--12
TM 9--2320--360--34--2
.25
(6.35)
2.06 .50 (12.7)
(52.3) DIA. THRU
1.06
(26.9)
4
(102)
1.38 (35.1)
1 1.13
(25.4) (28.7) .50 (12.7) DIA. THRU
(TWO PLACES)
4 (102)
(8) Cut 0.25 x 4 x 4 in. (6.35 x 102 x 102 mm) steel plate.
(9) Drill three 0.50 in. (12.7 mm) holes through center of steel plate.
(11) Assemble parts using 3/8--16 x 3--1/4 in. bolt and 3/8--16 nut.
Figure C--18. Idler Gear Holding Fixture (Cont)
C--13
TM 9--2320--360--34--2
1 (25)
1 (25)
1.75 (44.45)
4 (102)
2.25 (57.15)
1 (25)
10 mm THREAD
(1) Fabricate from 1 in. (25 mm) mild steel round stock; 4 in. (102 mm) long.
(2) Turn down 2.1/4 in. (57.15 mm) to .39 in. (10mm).
(3) Tap 1 in. (25mm) of 10 mm diameter shaft with 10 mm by 1 in. (25 mm) threads.
(4) Drill 5/8 in. (16 mm) hole 1 in. (25 mm) deep in 1 in. (25 mm) end.
(5) Tap 1 in. (25 mm) of 3/4 in. by 16 diameter hole in 1 in. (25 mm) end.
Figure C--19. Adapter, Constant Velocity U--joint Bearing Cap Removal Tool
C--14
TM 9--2320--360--34--2
3 (7.6)
6 1/2 (16.5)
1/2 (1.3)
(1) Fabricate from 3 in. (7.6 cm) OD steel tube.
(2) Using hacksaw, cut tubing to 6 1/2 in. (16.5 cm) in length.
(3) Cut 3 in. (7.6 cm) diameter circle from 1/2 in. (1.3 cm) steel plate.
(4) Weld steel plate on one end of steel tube.
(6) All dimensions are in inches (centimeters).
Figure C--20. Pinion Bearing Cone Installer (PN 2HE491)
4 (10.2)
4 1/4 (10.8)
1/2 (1.3)
(1) Fabricate from 4 in. (10.2 cm) OD steel tube.

(2) Using hacksaw, cut tubing to 4 1/4 in. (10.8 cm) in length.
(3) Cut 4 in. (10.2 cm) diameter circle from 1/2 in. (1.3 cm) steel plate.
(4) Weld steel plate on one end of steel tube.
(6) All dimensions are in inches (centimeters).
Figure C--21. Power Divider Bearing Cone Installer (PN 2HE497)
C--15
TM 9--2320--360--34--2
(1) Fabricate from 1/8 in. (3.2 mm) aluminum plate.

(2) Cut aluminum plate to 11 X 17 in. (28 X 43 cm).
(4) Using punch or awl, scribe a line 3/4 in. (1.9 cm) from bottom of plate.
(5) Scribe second line 90 degrees from first line, 8 1/2 in. (22 cm) form edge of plate
(6) Using compass, scribe lines at 7 1/2 degrees, 10 1/2 degrees, 34 1/2 degrees and 37 1/2 degrees
from line made in step (4).
(7) Repeat step (6) for other side of template.
(8) Using letter punches, identify the 34 1/2 and 37 1/2 degree lines as ”FRONT” and the 7 1/2 and 10
1/2 degree lines and ”REAR”.
Figure C--22. Steering Radius Template
C--16
C--17
TM 9--2320--360--34--2
C--17/(C--18 blank)
FRONT FRONT
36o ±1 1/2 o 36o ±1 1/2 o REAR
REAR
9 o ±1 1/2 o 9 o ±1 1/2 o
TM 9--2320--360--34--2
C--18
TM 9--2320--360--34--2
APPENDIX D
TORQUE VALUES
D--1. GENERAL
This appendix provides general torque limits for screws used on the HET Tractor. Special torque limits are shown
in the maintenance procedures for applicable components. Use the general torque limits given in this appendix
when specific torque limits are not given in the maintenance procedure. These general torque limits cannot be
applied to screws that retain rubber components. The rubber components will be damaged before the torque limit
is reached. If a special torque limit is not given in the maintenance instruction, tighten the screw or nut until it
touches the metal bracket, then tighten it one more turn.
D--2. TORQUE LIMITS

Table D--1 lists dry torque limits. Dry torque limits are used on screws that do not have lubricants applied to the
threads. Table D--2 lists wet torque limits. Wet torque limits are used on screws that have high pressure
lubricants applied to the threads. Table D--3 lists dry torque limits for metric screws. Table D--4 lists wet torque
limits for flange nuts.
D--3. USE OF TORQUE TABLES

(1) Measure the diameter of the screw you are
installing.
(2) Count the number of threads per inch.
(3) Under the heading DIAMETER look down the column until you find the diameter of the screw. (There
are usually two lines beginning with the same diameter.)
NOTE
Step (4) is not required for metric screws.
(4) Under the heading THREADS PER INCH, find the number of threads per inch that matches the
number you counted in step (2).
(5) To find the grade of the screw, match the markings on the head to the correct picture under
CAPSCREW HEAD MARKINGS on the torque table.
(6) Look down the column under the picture your found in step (5) until you find the torque limit (lb--ft or
N.m) for the diameter and threads per inch of the screw.
D--1
TM 9--2320--360--34--2
Table D--1. Torque Limits for Dry Fasteners
CAPSCREW HEAD MARKINGS
NOTE
Manufacturer’s marks may vary.
These are all SAE Grade 5. SAE GRADE SAE GRADE SAE GRADE SAE GRADE
NO. 2 NO. 5 NO. 6 OR 7 NO. 8
DIAMETER THREADS TORQUE
PER INCH
IN. MM LB--FT N .M LB--FT .
NM LB--FT N .M LB--FT N.M
1/4 6.35 20 5 7 8 11 10 14 12 16
1/4 6.35 28 6 9 10 14 12 16 14 19
5/16 7.94 18 11 15 17 23 21 28 25 34
5/16 7.94 24 12 16 19 26 24 33 25 34
3/8 9.53 16 20 27 30 41 40 54 45 61
3/8 9.53 24 23 31 35 47 45 61 50 68
7/16 11.11 14 30 41 50 68 60 81 70 95
7/16 20 35 47 55 75 70 95 80 108
1/2 12.70 13 50 68 75 102 95 129 110 149
1/2 20 55 75 90 122 100 136 120 163
9/16 14.29 12 65 88 110 149 135 183 150 203
9/16 18 75 102 120 163 150 203 170 231
5/8 15.88 11 90 122 150 203 190 258 220 298
5/8 18 100 136 180 244 210 285 240 325
3/4 19.05 10 160 217 260 353 320 434 380 515
3/4 16 180 244 300 407 360 488 420 597
7/8 22.23 9 140 190 400 542 520 705 600 814
7/8 14 155 210 440 597 580 786 660 895
1 25.40 8 220 298 580 786 800 1085 900 1220
1 12 240 325 640 868 860 1166 1000 1356
1--1/8 25.58 7 300 407 800 1085 1120 1519 1280 1736
1--1/8 12 340 461 880 1193 1260 1709 1440 1953
1--1/4 31.75 7 420 570 1120 1519 1580 2142 1820 2468
1--1/4 12 460 624 1240 1681 1760 2387 2000 2712
1--3/8 34.93 6 560 759 1460 1980 2080 2820 2380 3227
1--3/8 12 640 868 1680 2278 2380 3227 2720 3688
1--1/2 38.10 6 740 1003 1940 2631 2780 3770 3160 4285
1--1/2 12 840 1139 2200 2983 3100 4204 3560 4827
D--2
TM 9--2320--360--34--2
Table D--2. Torque Limits for Wet Fasteners
NOTE
Manufacturer’s marks may vary.
These are all SAE Grade 5. SAE GRADE SAE GRADE SAE GRADE SAE GRADE
NO. 2 NO. 5 NO. 6 OR 7 NO. 8
DIAMETER THREADS TORQUE
PER INCH
IN. MM LB--FT N .M LB--FT .
NM LB--FT N .M LB--FT N.M
1/4 6.35 20 4 6 6 8 8 11 9 12
1/4 6.35 28 5 7 7 9 9 12 10 14
5/16 7.94 18 8 11 13 18 16 22 18 24
5/16 7.94 24 9 12 14 19 18 24 20 27
3/8 9.53 16 15 20 23 31 30 41 35 47
3/8 9.53 24 17 23 25 34 30 41 35 47
7/16 11.11 14 24 33 35 47 45 61 55 75
7/16 20 25 34 40 54 50 68 60 81
1/2 12.70 13 35 47 55 75 70 95 80 108
1/2 20 40 54 65 88 80 108 90 122
9/16 14.29 12 50 68 80 108 100 136 110 149
9/16 18 55 75 90 122 110 149 130 176
5/8 15.88 11 70 95 110 149 140 190 170 231
5/8 18 80 108 130 176 160 217 180 244
3/4 19.05 10 120 163 200 271 240 325 280 380
3/4 16 140 190 220 298 280 380 320 434
7/8 22.23 9 110 149 300 407 400 542 460 624
7/8 14 120 163 320 434 440 597 500 678
1 25.40 8 160 217 440 597 600 814 680 922
1 12 170 231 480 651 660 895 740 1003
1--1/8 25.58 7 220 298 600 814 840 1139 960 1302
1--1/8 12 260 353 660 895 940 1275 1080 1464
1--1/4 31.75 7 320 434 840 1139 1100 1492 1360 1844
1--1/4 12 360 488 920 1248 1320 1790 1500 2034
1--3/8 34.93 6 420 570 1100 1492 1560 2115 1780 2414
1--3/8 12 460 624 1260 1709 1780 2414 2040 2766
1--1/2 38.10 6 560 760 1460 1980 2080 2820 2360 3200
1--1/2 12 620 841 1640 2224 2320 3146 2660 3607
D--3
TM 9--2320--360--34--2
Table D--3. Torque Limits for Dry Metric Fasteners
METRIC GRADE METRIC GRADE METRIC GRADE

8.8 10.9 12.9
DIAMETER TORQUE
IN. MM LB--FT N .M LB--FT N .M LB--FT N .M
0.157 4 2 3 3 4 4 5
0.197 5 4 5 6 8 7 9
0.237 6 7 9 10 14 11 15
0.276 7 11 15 16 22 20 27
0.315 8 18 24 25 34 29 39
0.394 10 32 43 47 64 58 79
0.473 12 58 79 83 113 100 136
0.552 14 94 127 133 180 159 216
0.630 16 144 195 196 266 235 319
0.709 18 190 258 269 365 323 438
0.788 20 260 353 366 496 440 597
0.867 22 368 499 520 705 678 919
0.946 24 470 637 664 900 794 1077
1.064 27 707 959 996 1351 1235 1675
1.182 30 967 1311 1357 1840 1630 2210
Table D--4. Torque Limits for Wet Flange Nuts
SPIRALOCK FLANGE DIAMETER THREADS TORQUE

NUT MARKINGS PER INCH
GRADE 8 IN. MM LB--FT N. M
1/4 6.35 20 15 20
5/16 7.94 18 25 34
3/8 9.65 16 45 61
1/2 12.70 13 110 149
5/8 15.75 11 210 285
3/4 19.05 10 375 508
D--4
TM 9--2320--360--34--2
APPENDIX E
COMMON TOOLS, SUPPLEMENTS, AND
SPECIAL TOOLS/FIXTURES LIST
E--1. INTRODUCTION
This appendix lists common tools, supplements, and special tools/fixtures that are required for
maintenance tasks performed at the organizational maintenance level.
E--2. EXPLANATION OF COLUMNS

a. Column (1) -- Item Number. This number is assigned to the entry in the listing and is
referenced in the narrative instructions to identify the item, e.g., “Adapter Tool, Transfer Case End
Play (Item 8, Appendix E).”
b. Column (2) -- Item Name. This column contains the nomenclature for the item.
c. Column (3) -- National Stock Number. This is the national stock number assigned to the
item which you can use to requisition it.
d. Column (4) -- Part Number. This provides the Government, manufacturer, or vendor part
number for the item.
e. Column (5) -- Reference. This column contains the shop catalog (SC), technical manual,
or other publication which provides an illustration and description of the item, or lists whether the
item is fabricated.
E--1
T M 9 --2320 --360 --34 --2
Section II. C OM MON TOOLS, SUPPLEMENTS A ND

SPECIAL TOOLS/FIXTURES L IST
(1)
ITEM NATIONAL PA R T
NUMBER ITEM NAME STOCK NUMBER NUMBER REFERENCE
0.1 ADAPTER, DIF F E RENTIAL 5340-01-384-6264 J 39929 T M 9--2320 --360 --34P

MAINTENANCE ST AND
1 ADAPTER, IMPELLER, SLIP 5935 --01 --297 --2481 J 33765 T M 9--2320 --360 --34P
T EST
2 ADAPTER, R ADIA TO R 4910 --01 --170 --4929 J 29003 --A T M 9--2320 --360 --34P
3 ADAPTER, S OCKET WRENCH, 5120 --00 --144 --5207 B107 10M SC 4910 --95 --A31
1/2 IN. F E MALE -- 3/4 IN. MALE
4 ADAPTER, S OCKET WRENCH, 5120 --00 --227 --8088 5H-131
5 ADAPTER, S OCKET WRENCH, 5120 --00 --240 --8702 5523A54 SC 4910 --95 --A31
6 ADAPTER, S OCKET WRENCH, 5120 --00 --227 --8104
3/4 IN. F E MALE -- 1 IN. MALE
6.1 ADAPTER KIT , TRANSFER 4910-01-385-6779 J 39911 T M 9--2320 --360 --34P
CASE
7 ADAPTER PLA T E, ENGINE 4910 --00 --146 --9624 J 33850 T M 9--2320 --360 --34P
STAND
8 ADAPTER TO OL, T RANSFER 3040-01-362-1105 1976890U T M 9--2320 --360 --34P
CASE END P LAY
9 ALIGNMENT T OOL, F IF T H 5120 --01 --115 --1161 J 24221 T M 9--2320 --360 --34P
CLUTCH
9.1 BIT SET , SCREWDRIVER 5120 --01 --170 --4454 38699 SC 4910 --95 --CL --A72
10 BOLTS, PULLER 5120 --01 --185 --6811 J 26901 --A T M 9--2320 --360 --34P
11 BRACKET , LIFTING 5120 --01 --115 --1159 J 24209 T M 9--2320 --360 --34P
12 BRACKET , LIFTING, 5120 --01 --116 --6049 J 24365 T M 9--2320 --360 --34P
F LYWHEEL
13 BRACKET , LIFTING, MAIN 5120 --01 --115 --1157 J 24196
SHAFT
14 BRUSH, WIRE 7920 --00 --291 --5815 8078883 SC 4910 --95 --A31
15 CALIPER SET , MICROMETER, 5210 --00 --554 --7134 GGG --C --105 SC 4910 --95 --A63
0--6 IN.
16 CALIPER, VERNIER, 0--6 IN. 5210 --01 --113 --1548 6240 SC 4910 --95 --A31
17 CAPS, VISE J AW (4 IN. BRASS 5120 --00 --221 --1506 404 --4 SC 4910 --95 --A31
OR CO PPER)
18 CLAMP SET , C YLINDER LINER 4910 --01 --158 --3984 J 24565 --02 T M 9--2320 --360 --34P
HOLDDOWN
E--2
T M 9 --2320 --360 --34 --2
Sect ion II. C OM MON TOOLS, SU PPLEMENTS, A ND

SPECIAL TOOLS/FIXTURES L IST
(1) (2) (3) (4) (5)

ITEM NATIONAL PA R T
NUMBER ITEM NAME STOCK NUMBER NUMBER REFERENCE
19 COMPRESSOR PISTON RING 8120-01-192-9428 RCL30 T M 9--2320 --360 --34P

20 COMPRESSOR, RING 5120 --00 --223 --8848 SC 4910 --95 --A63
21 COMPRESSOR SET , C ENTER 4310 --01 --247 --7126 J 24208 --D T M 9--2320 --360 --34P
SUPPORT
22 COMPRESSOR SET , C LUTCH 5120 --01 --048 --3129 J 24204 T M 9--2320 --360 --34P
SPRING
23 COMPRESSOR, SPRING 5120 --01 --048 --2160 J 24219 T M 9--2320 --360 --34P
24 COMPRESSOR UNIT , AIR 4310 --00 --542 --4566 MIL --C --52980 SC 4910 --95 --CL --A31
25 COMPRESSOR, VALV E 5120 --00 --733 --8888 J 7455 --A T M 9--2320 --360 --34P
SPRING
25.1 CONTACT T EST SET
26 COVER, K ING P IN PRELOAD 2HE225 T M 9--2320 --360 --34P
27 CRIMPER, T ERMINAL J 35123 T M 9--2320 --360 --34P
30 CROWBAR 5120 --00 --224 --1390 SC 4910 --95 --CL --A72
31 DELETED
32 DIAL INDICA T OR, MAGNETIC 5120 --00 --402 --9619 J 7872 T M 9--2320 --360 --34P
33 DRILL SET , T WIST , 1/16--1/2 IN. 5133 --00 --293 --0983 800434 SC 4910 --95 --A31
BY 64T HS
34 DRILL, ELECTRIC, P OR TABLE, 5130 --00 --889 --8993 1070 SC 4910 --95 --A31
1/4 IN.
35 DRILL, ELECTRIC, P OR TABLE, 5130 --00 --204 --2718 SC 4910 --95 --CL --A02
1/2 IN.
36 DRILL, T WIST , 5/8 IN. 5133 --00 --228 --1327 10040 SC 4910 --95 --A31
37 EXPANDER, SEAL 5120 --00 --336 --0445 J 4239 T M 9--2320 --360 --34P
38 EXTRACT OR SET , S CREW 5120 --00 --610 --1888 A--A--283 SC 4910 --95 --A31
SZ 1--9
39 EXTRACT OR, K ING P IN 2HE226 T M 9--2320 --360 --34P
40 EYE, LIFTING 2BH944 Appendix C , F ig. C --4
41 FIXTURE, HOLDING, IDLER 5180 --01 --167 --4285 2SK900 Appendix C , F ig.
G EAR C--18
42 FIX T URE , LIFTING 4910 --00 --456 --7620 J 22062 --01 T M 9--2320 --360 --34P
E--3
TM 9--2320--360--34--2
Section II. COMMON TOOLS, SUPPLEMENTS, AND

(1) (2) (3) (4) (5)

ITEM NATIONAL
NUMBER ITEM NAME STOCK NUMBER PART REFERENCE
NUMBER
43 FIXTURE, PTO GEAR 4910--01--158--3969 J26899 TM 9--2320--360--34P

REMOVER
44 FIXTURE, TEST, HEAD 4910--01--158--3985 J28454 TM 9--2320--360--34P
45 FIXTURE, TRANSMISSION 5120--01--115--1165 J24310 TM 9--2320--360--34P
HOLDING
45.1 GAGE, BRAKE DRUM 5210--00--861--9117 8500--50
MICROMETER
46 GAGE, CLEARANCE 5120--01--048--2161 J24192 TM 9--2320--360--34P
47 GAGE, CYLINDER LINER 5120--01--093--3710 J24898 TM 9--2320--360--34P
DEPTH
48 GAGE, DEPTH, MICROMETER 5210--00--619--4045 445BZ--6RL SC 3470--95--CL--A02
49 GAGE, DIAL, CYLINDER BORE 5120--01--070--4543 J5347--B TM 9--2320--360--34P
50 GAGE, FEELER 5210--00--267--3095 667 SC 4910--95--A31
51 GAGE, PISTON GROOVE 5120--01--028--1109 J24599 TM 9--2320--360--34P
52 DELETED
53 GAGE, SEAL RING GROOVE 5120--01--133--6888 J29198--3 TM 9--2320--360--34P
54 GAGE SET, CYLINDER 4910--01--148--1236 J7334--E TM 9--2320--360--34P
COMPRESSION
55 GAGE SET, PISTON FEELER 5210--00--116--1631 J5438--01 TM 9--2320--360--34P
56 GAGE SET, TELESCOPING 5210--00--473--9350 GGG--G--17 SC 4910--95--A63
57 GOGGLES, INDUSTRIAL 4940--00--269--7912 A--A--1814 SC 4910--95--CL--A31
58 GRINDING KIT, VALVE SEAT, 4910--00--473--6437 1750 SC 4910--95--CL--A63
ELECTRIC
59 GRINDING MACHINE, VALVE 4910--00--540--4679 K403CM SC 4910--95--CL--A63
FACE
60 GUIDE PIN SET J24315 TM 9--2320--360--34P
61 GUIDE SCREWS 5120--00--629--9781 J1927--01 TM 9--2320--360--34P
62 GUIDE SLEEVE 2HE234 TM 9--2320--360--34P
63 HAMMER, HAND: 5120--01--065--2211 57--534 SC 4910--95--A31
NONSPARKING
(SOFT--FACED)
E--4
TM 9--2320--360--34--2

(1) (2) (3) (4) (5)

ITEM NATIONAL
NUMBER
64 HAMMER, SLIDE 5120--01--355--3010 2HE227 TM 9--2320--360--34P

64.1 HAMMER, SLIDE TYPE 5120--01--112--2165 J6125--1B TM 9--2320--360--34P
65 HANDLE, INSTALLER 5120--00--977--5578 J7079--2 TM 9--2320--360--34P
66 HANDLE, DRIVER 5120--00--677--2259 J8092 TM 9--2320--360--34P
67 HANDLE, DRIVER 5129--01--054--4048 J24202--4 TM 9--2320--360--34P
68 HEATER, GUN TYPE 4940--00--561--1002 500A SC 4910--95--A31
69 HOIST, HAND OPERATED 1730--00--906--1352 TM 9--2320--360--10
70 HOLDER, STATOR ROLLER 5120--01--115--1158 J24218--2 TM 9--2320--360--24P
71 HOLDING FIXTURE, 2SK742 Appendix C, Fig. C--8
TURBOCHARGER
72 HYDRAULIC TEST KIT 3SK867 TM 9--2320--360--34P
73 INDICATOR, DIAL 4910--00--779--7103 J8165--2 TM 9--2320--360--34P
74 INDICATOR, DIAL 5120--00--794--9178 J5959--01 SC 4910--95--CL--A31
75 INSTALLER, BEARING J24447 TM 9--2320--360--34P
76 INSTALLER, BRIDGE GUIDE 5120--00--999--8616 J7482 TM 9--2320--360--34P
77 INSTALLER, BUSHING 4910--01--158--3986 J24201 TM 9--2320--360--34P
78 INSTALLER, FRONT SUPPORT 5120--01--115--1160 J24197 TM 9--2320--360--34P
NEEDLE BEARING
79 INSTALLER, MANUAL SHAFT 5120--01--115--1161 J26282 TM 9--2320--360--34P
OIL SEAL
80 INSTALLER, OIL SEAL 5120--00--937--7267 J8501 TM 9--2320--360--34P
81 INSTALLER, OIL SEAL, 5120--01--054--4042 J24202--1A TM 9--2320--360--34P
OUTPUT
82 INSTALLER, OUTPUT SHAFT 5120--01--158--3946 J25562 TM 9--2320--360--34P
BEARING
83 INSTALLER, SEAL 4910--01--176--4230 J21112--B TM 9--2320--360--34P
84 INSTALLER AND STAKING 5120--00--048--3124 J24200 TM 9--2320--360--34P
SET, COLLECTOR RING
85 INSTALLER, VALVE GUIDE 5120--00--999--8617 J21520 TM 9--2320--360--34P
E--5
TM 9--2320--360--34--2

(1) (2) (3) (4) (5)

ITEM NATIONAL
NUMBER
86 INSTALLER, VALVE SEAT 5120--01--048--3118 J24357 TM 9--2320--360--34P

INSERT
87 INSTALLER, WATER NOZZLE 5120--01--048--3119 J24857--A TM 9--2320--360--34P
88 INSTALLER, WATER PUMP 5120--00--033--8902 J25257 TM 9--2320--360--34P
DRIVE GEAR
89 INSTALLER, WATER PUMP J38858 TM 9--2320--360--34P
SEAL
90 JACK, FLOOR (DOLLY TYPE), 4910--00--289--7233 93660 SC 4910--95--A31
10--TON
91 JACK, HYDRAULIC, 12 TON 5120--00--224--7330 5025209--111-- SC 4910--95--A31
10
92 JACK KIT, HYDRAULIC HAND 5120--00--595--8387 A--A--312 SC 4910--95--A31
93 JACKSTAND, 7--TON 4910--00--251--8013 306 SC 4910--95--A31
94 LATHE, BRAKE DRUM 4910--01--028--9849 4100 SC 4910--95--A31
95 LIFT, TRANSMISSION AND 4910--00--585--3622 9037--20BM SC 4910--95--A62
DIFFERENTIAL
96 LIFTING BRACKET 5120--01--116--6048 J24195 TM 9--2320--360--34P
97 LIFTING TOOL, REAR J24408--A TM 9--2320--360--34P
PLANETARY
98 MULTIMETER 6625--01--139--2512 T00377 SC 4910--95--A31
99 MULTIPLIER, TORQUE 5120--01--122--9393 GA185 SC 4910--95--A31
100 NUT, 1/4 IN. MS51967--2
100.1 NUT, 1/2 IN. MS51967--14
101 NUT, 5/8 IN. 5310--00--763--8920 MS51967--20
102 PAN, OIL DRAIN 4910--00--387--9592 450 SC 4910--95--A31
103 DELETED
104 DELETED
105 PLIERS, RETAINING RING J28507 TM 9--2320--360--34P
106 PLIERS, RETAINING RING 5120--00--288--9717 176L129P8 SC 4910--95--A31
107 PLIERS, RETAINING RING 5120--00--293--0046 SC 4910--95--A31
E--6
TM 9--2320--360--34--2

(1) (2) (3) (4) (5)

ITEM NATIONAL
NUMBER
108 PLIERS, RETAINING RING 5120--00--293--0048 0100 SC 4910--95--A31

110 PLIERS, RETAINING RING 5120--00--293--0186 J6843--01 SC 4910--95--A31
111 PLIERS, RETAINING RING 5120--00--595--9551 407 SC 4910--95--A31
112.1 PLUG FF9767--08S
113 PLUG PIPE, 1/2 IN. 4730--01--318--6246 219P--8 TM 9--2320--360--34P
114 PLUG PIPE, 1/4 IN. 4730--01--082--1017 444693 TM 9--2320--360--34P
115 PLUG SET, RADIATOR 4910--00--273--3660 2005S--S SC 4910--95--CL--A76
115.1 PLUMB BOB 5120--00--234--8949 GGG--P--501
116 PRESS, HYDRAULIC, 60--TON 3444--00--449--7295 26A49 SC 4910--95--A31
117 PRESSURE TESTER, 4910--01--170--4928 J24460--01 TM 9--2320--360--34P
RADIATOR
118 PROTECTOR, FORWARD 5120--01--048--2157 J24216--01 TM 9--2320--360--34P
CLUTCH PISTON INNER SEAL
119 PROTECTOR, SEAL 5120--00--048--2156 J24210 TM 9--2320--360--34P
120 PULLER, 3--LEG 5120--00--740--3345 J4871 TM 9--2320--360--34P
121 PULLER ASSEMBLY, VALVE J23479--492 TM 9--2320--360--34P
SEAT
122 PULLER, BRIDGE 5120--01--143--4492 J8433--1 TM 9--2320--360--34P
123 PULLER, CAMSHAFT GEAR 5120--00--219--8397 J1902--B TM 9--2320--360--34P
124 PULLER KIT, MECHANICAL, 5180--00--423--1596 PE12 SC 4910--95--A31
GEAR AND BRG
125 PULLER KIT, MECHANICAL, 5180--00--313--9496 1178 SC 4910--95--A62
SLIDE HAMMER
126 REAMER SET, SUN GEAR 5110--01--150--9755 J 28489 TM 9--2320--360--34P
BUSHING
127 RECONDITIONING SET, 2910--01--146--9616 J22525--B TM 9--2320--360--34P
INJECTOR TUBE
128 RELINER, BRAKE AND 4910--00--173--5310 MILR13495 SC 4910--95--A31
CLUTCH
E--7
TM 9--2320--360--34--2

(1) (2) (3) (4) (5)

ITEM NATIONAL
NUMBER
129 REMOVAL TOOL, FILTER 5120--00--865--0933 SC 4910--95--CL--A72

130 REMOVER ASSEMBLY, 4910--01--158--3892 J24563--A TM 9--2320--360--34P
CYLINDER LINER
131 REMOVER, BROKEN BRIDGE 5120--00--999--8615 J7453 TM 9--2320--360--34P
GUIDE
132 REMOVER/INSTALLER, 4110--01--158--3996 J26598--A TM 9--2320--360--34P
CONVERTER PUMP SNAP
RING
133 REMOVER/INSTALLER, CORE 5120--01--130--8864 J23019 TM 9--2320--360--34P
PLUG
134 REMOVER/INSTALLER, 5120--01--048--2180 J25275 TM 9--2320--360--34P
WATER INLET ADAPTER
135 REMOVER AND INSTALLER, 5120--00--494--1846 7950177 TM 9--2320--360--34P
PISTON RING
136 REMOVER, PULLEY, CAM 5120--00--733--8890 J7932 TM 9--2320--360--34P
GEAR AND WATER PUMP
137 REMOVER/SETTER, STUD 5120--00--293--0050 SC 4910--95--A31
138 REMOVER/SETTER, STUD, 5120--00--596--0980 SC 4910--95--A31
1/4 IN., 1/2 IN. DRIVE
139 REMOVER SET, VALVE 5120--00--999--8614 J7091--01 TM 9--2320--360--34P
BRIDGE GUIDE
140 REMOVER, TERMINAL J35689--A TM 9--2320--360--34P
141 REMOVER, TERMINAL J33095 TM 9--2320--360--34P
142 REMOVER TOOL, BEARING 5120--01--117--2523 J28557
143 REMOVER, VALVE GUIDE 5120--00--733--8880 10919987
143.1 REMOVER, VALVE PIN 5120--01--048--3128 J24412--2 TM 9--2320--360--34P
144 RETAINER TOOL, PISTON PIN 5120--00--127--7757 J23762--A TM 9--2320--360--34P
145 SCALE, SPRING, 0--50 LB 6670--00--254--4634 AAA--S--133 SC 4910--95--CL--A74
146 SCREW, 1/4 IN. X 3 IN. MS90728--18
147 SCREW, 5/16--18 X 2 IN. MS90728--44
148 SCREW, 5/16--18 x 2--1/4 IN. MS90728--40
E--8
TM 9--2320--360--34--2

(1) (2) (3) (4) (5)

ITEM NATIONAL
NUMBER
148.1 SCREW, 1/2 IN. X 3--1/2 IN. MS90728--121

149 SCREW, 5/8 IN. X 4--1/2 IN. 5305--00--724--7264 MS90728--174
150 SCREW, CAP, HEX, 5/8 IN. X 5305--00--724--7254 MS90728--172
4 IN.
151 SCREW, CAP, HEX, 1/4--20 X 5305--00--068--0509 MS90728--10
1--1/4 IN.
152 SCREW, FORCING 5305--01--142--9397 J22214--4 TM 9--2320--360--34P
153 SCREW, SHEET METAL, MS51850--48
NO. 8 X 1 IN.
154 SEAL DRIVER, CTI 2HE232 TM 9--2320--360--34P
155 SEAL DRIVER, CTI 2HE233 TM 9--2320--360--34P
156 SEAL INSTALLER, FRONT 5120--00--936--4377 J9783 TM 9--2320--360--34P
CRANKSHAFT
157 SET, CYLINDER HEAD GUIDE 4910--01--162--3630 J24748 TM 9--2320--360--34P
STUD
158 SHAFT, DUMMY, TRANSFER 1975300 TM 9--2320--360--34P
CASE
159 SLEEVE, PULLER 4910--01--385--2795 J25007--4 TM 9--2320--360--34P
160 SLING ASSEMBLY 3940--01--209--6008 TM 9--2320--360--10
161 SLING, ENDLESS STRAP 3940--00--675--5002 TM 9--2320--360--10
162 SOCKET, 3--1/8 IN., 1--1/2 IN. 5130--00--234--1890 IM1005 SC 4910--95--A31
DRIVE
163 SOCKET, 33 MM, 3/4 IN. DRIVE 07533M TM 9--2320--360--34P
163.1 SOCKET, 55 MM J39938 TM 9--2320--360--34P
163.2 SOCKET, 63 MM J39939 TM 9--2320--360--34P
164 SOCKET, DEEP WELL, 9/16 IN., 5120--00--243--7348 A--A--1394 SC 4910--95--A31
1/2 IN. DRIVE
165 SOCKET, PIPE PLUG PPM408 TM 9--2320--360--34P
166 SOCKET, POWER STEERING E12--V TM 9--2320--360--34P
E--9
TM 9--2320--360--34--2

(1) (2) (3) (4) (5)

ITEM NATIONAL
NUMBER
167 SOCKET SET, DEEP WELL, 5120--00--596--8622 SC 4940--95--CL--B20

12 POINT, 1/2 IN. DRIVE
168 SOCKET, SOCKETHEAD, 5120--01--024--0168 LAW124A TM 9--2320--360--34P
169 SOCKET, SOCKETHEAD 5120--00--243--1676 172396PC5
SCREW, 1/2 IN., 1/2 IN. DRIVE
170 SOCKET, SOCKETHEAD 5120--00--516--4979 4080--08
171 SOCKET, SOCKETHEAD 5120--00--596--8508 SC 4910--95--A31
SCREW, 1/4 IN,, 1/2 IN. DRIVE
172 SOCKET, SOCKETHEAD 5120--00--683--8597 4080--12 SC 4910--95--A31
172.1 SOCKET, SOCKETHEAD 5120--00--596--1199 SC 4910--95--A31
173 SOCKET, SOCKETHEAD 5120--01--079--8033 SAM14A SC 4910--95--A31
SCREW, 14 MM, 1/2 IN. DRIVE
174 SOCKET, SOCKETHEAD 5120--01--104--5346 SAM12A SC 4910--95--A31
175 SOCKET, SOCKETHEAD 5320--01--104--5345 SC 4910--95--A31
176 SOCKET, SPANNER 2HE229 TM 9--2320--360--34P
180 SQUARE, COMBINATION, 5210--00--540--3513 GGGS656 SC 3470--95--CL--A02
PROTRACTOR HEAD
181 STAND, ENGINE 4910--00--808--3372 J29109 TM 9--2320--360--34P
182 STAND, MAINTENANCE, 4910--00--241--3329 SC 4910--95--A63
AUTOMOTIVE AXLE
183 DELETED
184 STE/ICE--R 4910--01--222--6589 12259266
185 STRAIGHT EDGE 6675--00--224--8807 SC 4910--95--A63
186 SWAGING TOOL 4910--01--158--3971 J28525 TM 9--2320--360--34P
E--10
TM 9--2320--360--34--2

(1) (2) (3) (4) (5)

ITEM NATIONAL
NUMBER
187 SWAGING TOOL, SUN GEAR 4910--01--158--3970 J26997--A TM 9--2320--360--34P

188 TAPE, MEASURING, 50 FT 5210--00--234--6745 GGG--T--106 SC 4910--95--A31
189 TAPE, MEASURING, 12 FT 5210--00--287--3335 SC 3470--95--CL--A02
190 TESTER, SPRING 6635--01--170--5001 J29196 TM 9--2320--360--34P
191 TESTER, VACUUM GAGE, 6685--01--061--4253 J--23987--B TM 9--2320--360--34P
LEAK DETECTOR SET
192 TESTING KIT, CYLINDER 5180--01--252--9800 2SK737 TM 9--2320--360--34P
BLOCK PRESSURE
193 THREADING SET, SCREW, NC 5120--00--448--2362 GGG--T--330 SC 4910--95--A31
THREAD
194 GAGE, INJECTOR, 1.520 IN. 5220--01--348--1638 J25502 TM 9--2320--360--34P
195 TOOL, ALIGNMENT, BLOWER 4910--01--158--3991 J33001 TM 9--2320--360--34P
SHAFT
196 TOOL, ALIGNMENT, SRS/TRS 5120--01--343--1001 J34729 TM 9--2320--360--34P
196.1 TOOL, ALIGNMENT, SRS/TRS 5120--01--343--1001 J39815 TM 9--2320--360--34P
197 TOOL, CRANK POSITION J34930--A TM 9--2320--360--34P
TIMING
198 TOOL, LIFTING 5120--01--159--1736 J33079 TM 9--2320--360--34P
199 TOOL KIT, AUTOMOTIVE FUEL 5180--00--754--0655 SC 5180--95--CL--B08
AND ELECTRICAL SYSTEM
REPAIR
200 TOOL KIT, BODY AND FENDER 5180--00--754--0063 SC 5180--90--CL--N34
REPAIR
201 TOOL KIT, ELECTRICAL 5180--00--876--9336 7550526 SC 4910--95--A31
REPAIR
202 TOOL KIT, GENERAL 5180--00--177--7033 SC5180--90--C SC 5180--90--CL--N26
MECHANICS L--N26
203 TOOL KIT, FAN CLUTCH 4910--01--163--1340 3--462--902-- TM 9--2320--360--34P
OVERHAUL 24460
204 TOOL SET, BLOWER SERVICE 5180--00--936--4376 J6270--G TM 9--2320--360--34P
205 TOOL SET, FUEL PUMP 5180--00--219--8407 J1508--E TM 9--2320--360--34P
206 V--BLOCKS 3460--00--725--5076 AA51150TY2S SC 4910--95--A63
TASZ2
E--11
TM 9--2320--360--34--2

(1) (2) (3) (4) (5)

ITEM NATIONAL
NUMBER
207 VISE, MACHINISTS, 4 IN. JAW, 5120--00--239--1439 504M2 SC 4910--95--A31

6 IN. OPENING
208 WASHER, FLAT, 1/4 IN. MS23183--48
208.1 WASHER, FLAT, 1/2 IN. MS27183--17
209 WASHER, FLAT, 5/8 IN. 5310--00--003--9174 MS27183--21
210 WASHER, FLAT, 5/16 IN. 5310--00--081--4219 MS27183--12
211 WIRE BRUSH, BRASS 5130--00--937--7281 J7944 TM 9--2320--360--34P
212 WIRE TWISTER, PLIER 5130--00--542--4171 SC 4910--95--A31
212.1 WRENCH, ADJUSTABLE, 5120--00--264--3793 WA615 SC 4910--95--A31
AUTOMOBILE
213 WRENCH, COMBINATION, 5120--00--277--8833 1244 SC 4910--95--A31
1--3/8 IN.
214 WRENCH, COMBINATION, 5120--00--277--8834 A--A--1358 SC 4910--95--A31
1--1/2 IN.
1--1/4 IN.
1--5/16 IN.
217 WRENCH, COMBINATION, 5120--01--957--3115 CL64 TM 9--2320--360--34P
2 IN.
218 WRENCH, CROW’S FOOT, 5120--00--222--7975 SC 4910--95--A31
9/16 IN., 3/8 IN. DRIVE
220 WRENCH, CROW’S FOOT, 5120--00--224--7288 A1650--013 SC 4910--95--A31
222 WRENCH, FUEL LINE NUT, 5120--00--019--5232 J8932--B TM 9--2320--360--34P
1/2 IN. DRIVE
223 WRENCH, IMPACT, ELECTRIC, 5120--00--889--9020 SC 4910--95--A62
1 IN.
224 WRENCH, OPEN--END, 5120--00--081--9099 ANSI B107.6 SC 4910--95--A31
1--5/8 IN. & 1--13/16 IN.
E--12
TM 9--2320--360--34--2

(1) (2) (3) (4) (5)

ITEM NATIONAL
NUMBER
225 WRENCH, OPEN--END, 5120--00--081--9100 ANSI B107.6 SC 4910--95--A31

1--7/8 IN. & 1--11/16 IN.
226 WRENCH, OPEN--END, 1 IN. & 5120--00--187--7133 SC 4910--95--A31
1--1/8 IN.
227 WRENCH, OPEN--END, 5120--00--277--2693 SC 4910--95--A31
15/16 IN. & 1--1/16 IN.
228 WRENCH SET, IMPACT 5130--00--221--0607 WW650 SC 4910--95--A31
229 WRENCH SET, LINE 5120--00--985--9866 SC 4910--95--A31
230 WRENCH SET, SOCKET, 1 IN. 5120--00--081--2309 A--A--1392 SC 4910--95--A31
DRIVE
231 WRENCH SET, SOCKET, 5120--00--204--1999 GGG--W--641 SC 4910--95--A31
3/4 IN. DRIVE
232 WRENCH SET, SOCKET, 5120--00--322--6231 51200017510 SC 4910--95--A31
3/8 IN. DRIVE
233 WRENCH, TORQUE, 5120--00--221--7983 TE602A SC 4910--95--A31
0--600 LB--FT, 3/4 IN. DRIVE
234 WRENCH, TORQUE, 5120--00--230--6380 TE--12A SC 4910--95--A31
0--150 LB--IN., 3/8 IN. DRIVE
235 WRENCH, TORQUE, 5120--00--247--2536 F3001 SC 4910--95--A31
0--300 LB--IN., 1/2 IN. DRIVE
236 WRENCH, TORQUE, 5120--00--640--6364 A--A--2411 SC 4910--95--A31
0--175 LB--FT, 1/2 IN. DRIVE
237 WRENCH, TORQUE, 5120--01--112--9532 TQSC6A SC 4910--95--A31
0--75 LB--IN., 1/4 IN. DRIVE
238 WRENCH, TORQUE, QJR2100E TM 9--2320--360--34P
CLICK--TYPE, 15--100 LB--FT,
3/8 IN. DRIVE
239 WRENCH, TORQUE, QJR3250A TM 9--2320--360--34P
CLICK--TYPE, 30--250 LB--FT,
1/2 IN. DRIVE
240 WRENCH, WHEEL BEARING 5120--01--144--5322 AS1910 SC 4910--95--CL--A74
ADJUSTING NUT, 3--1/2 IN.
E--13
E--13/(E--14 blank)
TM 9--2320--360--34--2
E--14
TM 9--2320--360--34--2
APPENDIX F
MANDATORY REPLACEMENT PARTS
F--1. SCOPE
This appendix lists mandatory replacement parts you will need to maintain the HET Tractor.
F--2. EXPLANATION OF COLUMNS

a. Column (1) -- Item Number. This number is assigned to each entry in the listing and is referenced
in the Initial Setup of the applicable task under Materials/Parts.
b. Column (2) -- Nomenclature. Name or identification of the part.
c. Column (3) -- Part Number. The manufacturer’s part number.
d. Column (4) -- National Stock Number. The National stock number of the part.
Section II. MANDATORY REPLACEMENT PARTS LIST

(1) (2) (3) (4)
ITEM NATIONAL STOCK
NO. NOMENCLATURE PART NUMBER NUMBER
1 BEARING, BALL 391 0381 040 3110--01--284--1460
2 BEARING SHELL 23501025 3120--01--336--3064
3 BOLT KIT, BEAM HANGER A--11784
4 BOLT KIT, BUSHING A--5332 5306--01--344--7993
5 BUSHING XB--02949
6 CAP, VALVE SPRING 5111337 2815--00--529--8193
7 CLAMP 5137620 5340--01--114--5623
8 CLAMP 5143999 4730--00--080--5799
9 CONNECTOR 23500514 2990--01--298--9350
9.1 CROSS V75750400 2520--01--352--9164
10 CYLINDER KIT 23503830 2590--01--361--8202
11 FASTENER, RATCHET PC47516 5305--01--222--4344
12 FILTER, FUEL 25010778 2910--01--022--8183
13 FUEL PIPE, JUMPER 8928632
14 GASKET D346--177 5330--00--364--3550
15 GASKET MS52000--3 5330--00--939--0666
16 GASKET 0601--38260 5330--01--352--7495
F--1
TM 9--2320--360--34--2
Section II. MANDATORY REPLACEMENT PARTS LIST (CONT)

(1) (2) (3) (4)
ITEM NATIONAL STOCK
17 GASKET 14079550 5330--00--107--3925
18 GASKET 2DD219
19 GASKET 23016681 5330--01--328--7635
20 GASKET 23018625 5330--01--243--5148
21 GASKET 23046658
22 GASKET 23501587 5330--01--058--0587
23 GASKET 23502937 5330--01--353--9547
24 GASKET 244956
25 GASKET 328951--6X 5330--00--781--7774
26 GASKET 423617 5330--01--336--8786
27 GASKET 5100404 5330--01--054--2398
28 GASKET 5100638 5330--01--058--0586
29 GASKET 5104081 5330--01--078--7186
30 GASKET 23515145 5330--01--079--9963
31 GASKET 5104507
32 GASKET 5117242 5330--00--911--4628
33 GASKET 5117243 5330--00--735--4289
34 GASKET 5117254 5330--00--745--7831
35 GASKET 5117269 5330--00--735--4291
36 GASKET 5117332 5330--00--725--2301
37 GASKET 5117535 5330--00--844--2907
38 GASKET 5117734 5330--00--745--7776
39 GASKET 5117993 5330--00--973--1415
40 GASKET 5120224 5330--00--862--6929
41 GASKET 5121714 5330--00--745--7669
42 GASKET 5121835 5330--00--847--4967
43 GASKET 5123570 5330--00--915--2835
44 GASKET 5123638 5330--00--862--6934
F--2
TM 9--2320--360--34--2

(1) (2) (3) (4)
ITEM NATIONAL STOCK
45 GASKET 5123812 5330--00--892--1764
46 GASKET 5126499 5330--00--736--0228
47 GASKET 5136678 5330--00--198--7953
47.1 GASKET 5137221
48 GASKET 5138659 5330--00--769--4882
49 GASKET 23520012 5330--00--915--4511
50 GASKET 5144874 5330--01--348--3331
51 GASKET 23520287 5330--01--447--1706
52 GASKET 5144901 5330--01--054--2399
53 GASKET 5145581
54 GASKET 5148810 5330--01--058--0585
55 GASKET 5161003 5330--00--599--5577
56 GASKET 5167380 5330--00--641--4504
57 GASKET 60598 5310--00--663--7617
58 GASKET 6750186 5330--00--537--2388
59 GASKET 6839213 5330--01--049--0552
60 GASKET 79031 5330--01--078--2825
61 GASKET 8922442 8030--01--338--7640
62 GASKET 8923492 5330--01--037--4129
63 GASKET 8923512 5330--01--206--3264
64 GASKET 8923791 5330--01--088--5982
65 GASKET 8923792 5330--01--206--3265
66 GASKET 8924266 5330--01--270--1161
67 GASKET 8925778 5330--01--247--2474
68 GASKET 23511304 5330--00--758--2863
69 GASKET 97706 5330--01--078--2826
70 GASKET, FUEL PUMP TO ENGINE 5150193 5330--00--212--6290
71 GASKET/SEAL KIT 5518191 5330--01--329--2074
71.1 ISOLATOR 23512307 5342--01--414--2177
72 KEY 8928545 5315--01--304--9174
F--3
TM 9--2320--360--34--2

(1) (2) (3) (4)
ITEM NATIONAL STOCK
73 KEYWASHER 8926285 5310--01--233--1338
74 LINING, BRAKE N2000J1466 2530--01--342--2980
75 LOCKNUT AN365--1024A 5310--00--208--1918
76 LOCKNUT MS21045--7 5310--00--274--9364
77 LOCKNUT MS35691--93 5310--00--997--6903
78 LOCKNUT MS51922--21 5310--00--959--1488
79 LOCKNUT TLA--3410--S--GRC 5310--00--269--6340
80 LOCKNUT TLA--3816--S--GRC 5310--01--222--9097
80.1 LOCKNUT TLA--5811--GRC 5310--01--082--6166
81 LOCKNUT T893R 5310--01--288--1116
82 LOCKNUT V75502830 5310--01--344--6738
83 LOCKNUT V75503336 5310--01--344--6740
84 LOCKNUT XB--FW--25 5310--01--199--3419
85 LOCKNUT XB--HNH--58--C 5310--01--199--9463
86 LOCKNUT 110310A 5310--01--159--8178
87 LOCKNUT 110311A 5310--01--111--0645
88 LOCKNUT 110312A 5310--01--150--5918
89 LOCKNUT 115307A 5310--01--151--1036
90 LOCKNUT 117212 5310--00--568--6077
91 LOCKNUT 1244954--2 5310--00--074--1387
92 LOCKNUT 1333510 5310--01--340--5671
93 LOCKNUT 1488--G 5310--01--358--3664
94 LOCKNUT 1571850 5310--01--288--5096
95 LOCKNUT 1598030 5310--01--342--8595
96 LOCKNUT 1600460 5310--01--346--9445
97 LOCKNUT 192481 5310--01--058--3353
98 LOCKNUT 26175 5310--00--429--3127
99 LOCKNUT 5149163 2835--01--015--5419
100 LOCKNUT 76985 5310--00--432--3959
101 LOCKNUT 79024 5310--01--077--9437
F--4
TM 9--2320--360--34--2

(1) (2) (3) (4)
ITEM NATIONAL STOCK
102 LOCKNUT 8925752 5310--01--268--6783
103 LOCKNUT 9004--94
104 LOCK PLATE 57022 5340--01--127--5636
105 LOCKSTRIP 6880899 5340--01--056--0037
106 LOCKWASHER L58 5310--00--820--6653
107 LOCKWASHER MS27183--15 5310--00--809--4061
108 LOCKWASHER MS27183--17 5310--00--809--5997
109 LOCKWASHER MS27183--21
111 LOCKWASHER MS35333--44 5310--00--194--1483
115 LOCKWASHER MS35338--41 5310--00--045--4007
116 LOCKWASHER MS35338--42 5310--00--045--3299
117 LOCKWASHER MS35338--43 5310--00--045--3296
118 LOCKWASHER MS35338--44 5310--00--582--5965
119 LOCKWASHER MS35338--45 5310--00--407--5966
120 LOCKWASHER MS35338--46 5310--00--637--9541
121 LOCKWASHER MS35338--47 5310--00--209--0965
122 LOCKWASHER MS35338--48 5310--00--584--5272
123 LOCKWASHER MS35338--49 5310--00--167--0860
124 LOCKWASHER MS35338--51 5310--01--584--7888
125 LOCKWASHER MS35338--52 5310--00--754--2005
126 LOCKWASHER MS35338--63 5310--00--582--5965
127 LOCKWASHER MS35338--8 5310--00--261--7340
128 LOCKWASHER MS45904--60 5310--00--080--9786
129 LOCKWASHER MS51848--12 5310--00--688--2195
130 LOCKWASHER MS51848--14 5310--00--171--1735
F--5
TM 9--2320--360--34--2

(1) (2) (3) (4)
ITEM NATIONAL STOCK
131 LOCKWASHER NWA18 5310--01--344--8254
132 LOCKWASHER SA--1600--4
132.1 LOCKWASHER 093078423
132.2 LOCKWASHER 095002434
132.3 LOCKWASHER 0400139971
133 LOCKWASHER 1484FX 5310--01--354--9949
134 LOCKWASHER 103323
135 LOCKWASHER 1613
136 LOCKWASHER 237757 5305--01--133--7193
137 LOCKWASHER 2434 5310--00--775--5139
138 LOCKWASHER 2523 5310--00--775--5182
139 LOCKWASHER 3231 5310--00--032--1814
140 LOCKWASHER 5141367 5310--01--340--3936
141 LOCKWASHER 5177769 5310--00--209--1543
142 LOCKWASHER 5584 5310--00--775--5125
143 LOCKWASHER 6769636 5310--00--776--7670
144 LOCKWASHER 78328 5310--00--172--1991
145 MOUNTING PARTS KIT 328170--203X
146 NUT V75503561 5310--01--344--6313
147 NUT V88350222 5310--01--345--5495
148 NUT 6772182
149 NUT, ADJUSTING V75502102 5310--01--344--6280
150 NUT, ADJUSTING V88140038 5310--01--344--6279
151 NUT, NYLON 97--4196--1
152 NUT, TRISTOP V75503716 5310--01--357--3768
153 OVERHAUL KIT, BLOWER 23514202 2990--01--136--7514
154 OVERHAUL KIT, CYLINDER HEAD 5199674 5330--01--053--1845
155 OVERHAUL KIT, FAN CLUTCH 3--34867 2930--01--K49--9523
156 PACKING, PREFORMED 8925981 5330--01--207--7789
157 PACKING, PREFORMED FF9446--12 5330--01--115--8226
F--6
TM 9--2320--360--34--2

(1) (2) (3) (4)
ITEM NATIONAL STOCK
159 PACKING, PREFORMED FF9446--10
160.1 PACKING, PREFORMED FF9446--18
164 PACKING, PREFORMED FF9449--21 5330--01-- 269--4323
165.1 PACKING, PREFORMED M053225163
166 PACKING, PREFORMED V75500858 5330--01--350--6007
167 PACKING, PREFORMED V75502787 5330--01--354--4160
167.1 PACKING, PREFORMED XA--2265
168 PACKING, PREFORMED Z053095777 5330--01--304--3453
168.1 PACKING, PREFORMED Z053074979
173 PACKING, PREFORMED 2AL343 5330--01--145--4573
174 PACKING, PREFORMED 2--219N674--70 5330--00--013--7784
175 PACKING, PREFORMED 2--27153 5330--01--334--1602
178 PACKING, PREFORMED 22617--14
F--7
TM 9--2320--360--34--2

(1) (2) (3) (4)
ITEM NATIONAL STOCK
181.1 PACKING, PREFORMED 22617--24
182.1 PACKING, PREFORMED 22617--6
184 PACKING, PREFORMED 262331
186 PACKING, PREFORMED 3--924N552--90 5330--01--038--3074
187 PACKING, PREFORMED 427682
194.1 PACKING, PREFORMED 853181952
196 PACKING, PREFORMED 9600--G 5330--01--351--2728
197.1 PACKING, PREFORMED 9612 5331--01--357--0846
202 PARTS KIT RNT--26--C
203 PARTS KIT RNT--26--EG
204 PARTS KIT RNT--26--H
205 PARTS KIT SN--3711--AL
206 PARTS KIT SN--3711--T
207 PARTS KIT, AIR FLOW 289352 2530--01--134--1834
F--8
TM 9--2320--360--34--2

(1) (2) (3) (4)
ITEM NATIONAL STOCK
208 PARTS KIT, CLUTCH 328970X 2520--01--325--3336
209 PARTS KIT, COMPRESSOR RNT26A 4310--01--231--2807
210 PARTS KIT, LINEAR 328971X 3040--01--221--8889
211 PIN 274889 5315--00--823--4333
212 PIN 5106909 5315--01--089--6864
213 PIN 5175641 5315--00--829--0381
214 PIN, COTTER MS24665--291 5315--00--019--0777
215 PIN, COTTER MS24665--267
216 PIN, COTTER MS24665--283 5315--00--842--3044
217 PIN, COTTER MS24665--291
218 PIN, COTTER MS24665--353 5315--00--839--5822
219 PIN, COTTER MS24665--360 5315--00--298--1499
220 PIN, COTTER MS24665--493 5315--00--018--7988
221 PIN, COTTER MS24665--624 5315--00--059--0217
222 PIN, COTTER MS24665--625 5315--00--209--7273
223 PIN, COTTER MS24665--627 5315--00--013--7308
224 PIN, COTTER MS24665--683 5315--00--234--1673
225 PIN, RETAINING 6831774 5315--00--108--1112
226 PIN, ROLL 2451151 5315--01--162--4130
227 PIN, SPRING 456299 5315--01--297--7378
227.1 PISTON AND ROD KIT 882957
228 PLUG 5151272 5340--00--841--9141
228.1 REPAIR KIT 0223--01251--022
229 REPAIR KIT, GEARBOX 02--23--01260--150 3010--01--102--2040
230 REPAIR KIT, WATER PUMP 5149407 2930--01--143--1352
231 REPAIR KIT, WINCH 9426--G 5330--01--356--5147
232 REPAIR KIT, WINCH 9443--G
233 RETAINING KIT, PITMAN ARM 1790632K 2530--01--340--4080
234 RING, RETAINING MS16625--1175 5365--00--804--5827
235 RING, RETAINING 2--21267 5365--01--151--5087
F--9
M 9-- 2320--360--34--2

(1) (2) (3) (4)
ITEM NATIONAL STOCK
236 RING, RETAINING 2--21272 5365--01--151--4985
237 RING, RETAINING 2--25578 5360--01--336--6734
238 RING, RETAINING 274613 5365--00--349--8518
239 RING, RETAINING 3359--G 5365--01--350--6035
240 RING, RETAINING 3912686063 5365--00--768--8563
241 RING, RETAINING 5149154 5365--01--015--5414
242 RING, RETAINING 5198049 5365--00--930--3257
243 RING, RETAINING 6758779 5365--00--582--2641
244 RING, RETAINING 8922407 5365--01--166--6633
245 RING, RETAINING 8922605 5365--01--173--3437
246 RING, RETAINING 9414876 5365--01--084--5352
247 RING, RETAINING 9420905 5365--01--084--5353
248 RING, SEAL 001332 5330--01--173--6825
249 RING, SEAL 23503769 5330--00--166--8396
250 RING, SEAL 23011454 5365--01--084--5258
251 RING, SEAL 23011455 2520--01--149--3273
252 RING, SEAL 23014631 5330--01--173--3413
253 RING, SEAL 23019652 5330--01--247--8519
254 RING, SEAL 23045519 5330--01--280--7491
255 RING, SEAL 3912585006 5330--01--212--2222
256 RING, SEAL 5101160 5330--01--058--0281
257 RING, SEAL 5103544 5330--01--088--6596
258 RING, SEAL 5148502 5365--01--062--0943
259 RING, SEAL 5197583 5330--00--930--3254
260 RING, SEAL 5198936 5365--01--016--0443
261 RING, SEAL 6758740 5330--00--582--0456
262 RING, SEAL 6770492 5330--00--999--3760
263 RING, SEAL 6772321 5330--00--999--3754
264 RING, SEAL 6833980 5330--01--236--1753
265 RING, SEAL 6834542 5330--01--088--5847
F--10
TM 9--2320--360--34--2

(1) (2) (3) (4)
ITEM NATIONAL STOCK
266 RING, SEAL 6836796 5330--01--336--6709
267 RING, SEAL 6836799 5330--01--145--0697
268 RING, SEAL 6836800 5330--01--336--2998
269 RING, SEAL 6880389 5330--01--141--9579
270 RING, SEAL 8922140 5330--00--764--1659
271 RING, SEAL 8927189 5330--01--054--2267
272 RING, SEAL 8928676 5330--01--346--0486
273 RING KIT, SEAL, BUTT JOINT 23014441 5330--01--087--6849
274 RING, TEFLON, PISTON T--560--0330--001 3040--01--341--2340
274.1 ROTATING GROUP KIT 882954
275 SCREW MS90725--61
276 SCREW MS90728--172
276.1 SCREW Z112007092
277 SCREW 115217A 5306--01--156--5429
277.1 SCREW 23512308 5306--01--411--6384
278 SCREW 5121466 5306--00--894--2381
279 SCREW 8927581 5305--01--242--1783
280 SCREW 9409011 5306--00--940--9011
281 SCREW, ANCHOR 23045343 5306--01--245--9837
282 SCREW, NYLON PATCH 5103534 5306--01--078--4981
283 SCREW, NYLON PATCH 8925603 5306--01--297--6987
284 SCREW, SELF--LOCKING 5101196 5306--01--120--3659
285 SCREW, SELF--LOCKING 9431456 5306--01--147--1202
286 SEAL A11507 4330--00--846--8177
286.1 SEAL M054097799
287 SEAL NA1205V1556 5330--01--344--0636
288 SEAL N1779J1024 5330--01--345--4721
289 SEAL V75503661 5330--01--344--0637
290 SEAL 2AG460 5330--01--328--6014
290.1 SEAL 23504641 5330--01--336--2997
291 SEAL 5102098 5330--01--058--5220
F--11
TM 9--2320--360--34--2

(1) (2) (3) (4)
ITEM NATIONAL STOCK
292 SEAL 8922045 5330--01--K49--9394
293 SEAL, CTI V88900213 5330--01--342--7860
294 SEAL, GASKET 3912884019 5330--01--340--8159
295 SEALING KIT V88510253 5330--01--345--0157
295.1 SEAL KIT SK--10--2
295.2 SEAL KIT SK2--10V--4
296 SEAL KIT 61267 5330--01--355--3582
296.1 SEAL KIT 882955
297 SEAL KIT, BRAKE 9868--G 5330--01--230--3723
298 SEAL KIT, CARTRIDGE VALVE 9692--G 5330--01--169--0769
299 SEAL KIT, PLUG 70035--G 4820--01--351--5840
300 SEAL KIT, PLUG 9432--G 5340--01--344--8463
301 SEAL KIT, SOLENOID VALVE SV08--31 4810--01--356--4018
302 SEAL KIT, VALVE CARTRIDGE 9638--G 5330--01--346--1534
303 SEAL, LIP 3912883058 5330--01--298--3042
304 SEAL, OIL G13824 5330--00--725--1511
305 SEAL, OIL V75503484 5330--01--344--8263
306 SEAL, OIL V75503486 5330--01--344--8935
307 SEAL, OIL 23010610 2840--01--141--9503
308 SEAL, OIL 23016947 5330--01--245--0159
309 SEAL, OIL 415023--SSR 5330--01--340--9882
310 SEAL, OIL 415304 5330--01--033--2697
311 SEAL, OIL 471965 5330--01--336--8738
312 SEAL, OIL 23516871
313 SEAL, OIL 5107223 5330--01--083--3063
314 SEAL, OIL 23512418 5330--00--961--9801
315 SEAL, OIL 6773311 5330--00--999--3752
316 SEAL, OIL 71246 5330--01--187--3640
317 SEAL, OIL 8929750 5330--01--324--0437
318 SEAL, POCKET 3912882086 5330--00--809--1052
F--12
TM 9--2320--360--34--2

(1) (2) (3) (4)
ITEM NATIONAL STOCK
319 SEAL, QUAD RING 2369031 5330--01--K49--9511
320 SEAL, VALVE GUIDE 8921209 5330--00--992--0695
321 SERVICE KIT 9427--G 2590--01--344--5749
321.1 SHAFT BEARING KIT 882956
322 SHIM 5100703 5365--01--082--1972
322.1 SHIM KIT V86010048 5310--01--345--2637
323 SNAP CLIP H360--4--2 5340--01--151--8391
324 SNAP CLIP H360--6--2 5340--01--224--8368
324.1 SNAP CLIP H360--13--12
324.2 SNAP CLIP H360K2593
325 SOCKET, CONTACT 1203 4051 5940--01--342--0712
326 SPACER 59808BX 5365--01--156--0026
327 SPINDLE 12267808 5315--01--091--0784
328 SPINDLE 6831679 5315--01--112--8641
329 TERMINAL 12084563 5999--01--321--1925
330 TERMINAL 12089305 5999--01--319--7394
331 U--BOLT ASSEMBLY 2--94--28X 5306--00--097--9701
332 WASHER 23013841 5310--01--245--9859
333 WASHER 6839761 5310--01--084--1768
333.1 WASHER, COPPER SEAL 23513842
334 WASHER, COPPER 5152148
334.1 WASHER, FIBER Z082073500
335 WASHER, KEY 7520854 5310--00--264--1888
336 WASHER, LOCKING V88350241 5310--01--346--0138
337 WASHERS, PRESSURE 5125108 5310--00--785--3961
338 WASHER, RETAINING 3909063 5310--01--143--0542
338.1 WASHER, SEAL XA--1470
339 WASHER, THRUST 23047365 3120--01--318--2070
340 WASHER, THRUST 6835321 3120--01--084--4607
341 WASHER, THRUST 29519114
F--13
TM 9--2320--360--34--2

(1) (2) (3) (4)
ITEM NATIONAL STOCK
342 WASHER, THRUST 6881352 3120--01--056--2112
343 WASHER, THRUST 6881638 3120--01--053--1819
344 deleted
345 WIRE SEAL 12010293 5975--01--226--8078
346 WIRE SEAL 12015323 5975--01--310--5011
347 YOKE BEARING KIT 923987
F--14
TM 9--2320--360--34--2
SUBJECT INDEX
Paragraph,
Subject Figure, Table
Number
A
Adapter Housing and Second Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--18
Air Compressor Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26--2
Auxiliary Steering Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27--2.1
Auxiliary Winch Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28--5
Axle Differential Repair
Axle No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24--2
Axle No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25--2
Axle No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25--3
Axle No. 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25--4
B
Blower Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20--2
C
Cam Follower and Push Rod Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--11
Camshaft and End Bearing Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--12
Center Shaft Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--15
Center Support Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--15
Common Tools, Supplements, and Special Tools/Fixtures List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E
Compressor Repair, Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26--2
Connecting Rod Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--10
Containers, Storage Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29--2
Control Console Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17--7
Crankshaft
Cover, Front Oil Seal, and Oil Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--14
End Play Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--8, T19--3
Journal Diameter Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--8, T19--1
Journal Width Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--8, T19--2
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--8
Cylinder Head
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--7
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--7
D
Differential Repair
Axle No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24--2
Axle No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25--2
Axle No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25--3
Axle No.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25--4
Drive Motor Repair, Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28--3
Durable/Expendable Supplies and Materials List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B
Index--1
TM 9--2320--360--34--2
SUBJECT INDEX (CONT)

Paragraph,
Number
E
Engine
Block Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--4
Block Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--4
Blower Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20--2
Brake Retarder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--15
Cam Follower and Push Rod Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--11
Camshaft and End Bearing Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--12
Cylinder Head Repair/Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--7
End Plate Repair, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--6
End Plate Repair, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--5
Flywheel Housing Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--9
General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--2
Idler Gear Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--13
Main Bearing and Crankshaft Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--8
Oil Pump, Crankshaft Cover, and Oil Seal Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--14
Piston, Connecting Rod, and Liner Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--10
Stand, Engine Installation/Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--3
Turbocharger Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20--3
Water Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21--2
End Plate
Repair, Engine Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--5
Repair, Engine Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--6
Exhaust Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--7
Expendable/Durable Supplies and Materials List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B
F
Fifth Clutch Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--9
First Clutch Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--17
First Shift Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--13
Flywheel Assembly/Lockup Clutch Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--4
Flywheel Housing Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--9
Forms and Publications, Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Forward Clutch and Turbine Shaft Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--8
Fourth Clutch Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--10
Front
End Plate Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--5
Steering Gear Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27--3
Support Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--7
Fuel Injector Tube Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--7
G
Gear Reducer Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27--6
General Maintenance Instructions
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--2
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--2
Index--2
TM 9--2320--360--34--2

Paragraph,
Number
H
Hydraulic Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28--4
I
Idler Gear Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--13
Illustrated List of Manufactured Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
L
Liner Repair (Cylinder) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--10
Lockup Clutch Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--4
Lockup Cutoff Valve Body Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--11
Lubrication Pump Repair, Transfer Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23--3
M
Main Bearing and Connecting Rod
Journal Diameter Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--8, T19--1
Journal Width Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--8, T19--2
Main Bearing and Crankshaft Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--8
Main Control Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--14
Mandatory Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F
Manufactured Items, Illustrated List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
Materials and Supplies List, Expendable/Durable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B
P
Parts, Mandatory Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F
Piston, Connecting Rod, and Liner Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--10
Piston Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--10
Planetary Gearing, Shafts, and Third Clutch Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--16
Power Takeoff Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28--6
Publications and Forms, Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
R
Rear
Cover and First Clutch Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--17
End Plate Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--6
Steering Gear Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27--4
References, Forms and Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Index--3
TM 9--2320--360--34--2

Paragraph,
Number
S
Second Clutch Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--18
Special Tools/Fixtures List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E
Spring Load--Length/Height Specifications
Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--7, T23--2
Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--7, T23--1
Steering
Gear Reducer Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27--6
Gear Repair, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27--3
Gear Repair, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27--4
Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27--2
Pump Repair, Auxiliary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27--2.1
Tee Gear Box Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27--5
Supplements, Common and Special Tools/Fixtures List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E
Supplies and Materials List, Expendable/Durable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B
T
Tee Gear Box Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27--5
Third Clutch Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--16
Tools, Supplements, and Special Tools/Fixtures List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E
Torque Converter
Housing/Front Support Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--7
Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--6
Spring Load--Height Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--7, T23--1
Stator Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--5
Torque Values, Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D
Transfer Case
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23--2
Lubrication Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23--3
Transmission
Adapter Housing Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--18
Center Support Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--15
Control Valve Repair, Main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--14
Fifth Clutch Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--9
First Clutch Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--17
First Shift Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--13
Flywheel Assembly/Lockup Clutch Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--4
Fourth Clutch Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--10
Forward Clutch and Turbine Shaft Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--8
General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--2
Housing Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--19
Lockup Clutch Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--4
Lockup Cutoff Valve Body Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--11
Planetary Gearing, Shafts, and Third Clutch Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--16
Rear Cover Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--17
Second Clutch Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--18
Stand, Transmission Installation/Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--3
Third Clutch Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--16
Index--4
TM 9--2320--360--34--2

Paragraph,
Number
T (CONT)
Transmission (Cont)
Trimmer Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--12
Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (see Torque Converter)
Trimmer Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--12
Turbine Shaft Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--8
Turbocharger Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20--3
U
Upper Shift Rod Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23--2
V
Valve
Bridge Guide Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--7
Guide Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--7
Seat Insert Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--7
Spring Load--Height Specifications, Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--7, T22--1
Spring Load--Height Specifications, Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--7, T22--2
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--7
W
Water Nozzle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--7
Water Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21--2
Winch
Auxiliary, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28--5
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28--2
Drive Motor Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28--3
Hydraulic Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28--4
Power Takeoff Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28--6
Index--5/(Index--6 blank)
TM 9-2320-360-34-2
By Order of the Secretary of the Army:
GEORGE W. CASEY, JR.

General, United States Army
Chief of Staff
Official:
JOYCE E. MORROW
Administrative Assistant to the
Secretary of the Army
0702307
Distribution:
To be distributed in accordance with the initial distribution number (IDN) 380755,

requirements for TM 9-2320-360-34-2.
RECOMMENDED CHANGES TO PUBLICATIONS Use Part II (reverse) for Repair Parts and DATE
AND BLANK FORMS Special Tool Lists (RPSTL) and Supply
Catalogs/Supply Manuals (SC/SM). Date you filled out
For use of this form, see AR 25-30; the proponent agency is ODISC4.
this form.
TO: (Forward to proponent of publication or form) (Include ZIP Code) FROM: (Activity and location) (Include ZIP Code)
AMSTA-LC-LPIT / TECH PUBS, TACOM-RI
1 Rock Island Arsenal Your mailing address
Rock Island, IL 61299-7630
PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER DATE TITLE Heavy Equipment Transporter, M1070, Direct
TM 9-2320-360-34-2 31 May 2007 Support/General Support Maintenance
ITEM PAGE PARA- LINE FIGURE TABLE RECOMMENDED CHANGES AND REASON
NO. NO. GRAPH NO. * NO. NO. (Provide exact wording of recommended changes, if possible).
0004 4-7 Wrong POC is listed.

00-2
*Reference to line numbers within the paragraph or subparagraph.

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION SIGNATURE
Your Name Your Signature
DA FORM 2028, FEB 74 REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. USAPPC V3.00
TO: (Forward direct to addressee listed in publication) FROM: (Activity and location) (Include ZIP Code) DATE
AMSTA-LC-LPIT / TECH PUBS, TACOM-RI Your address Date you filled out this
1 Rock Island Arsenal form
PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
PUBLICATION NUMBER DATE TITLE Heavy Equipment Transporter,
TM 9-2320-360-34-2 31 May 2007 M1070, Direct Support/General Support
Maintenance
TOTAL NO.
PAGE COLM LINE NATIONAL STOCK REFERENCE FIGURE ITEM OF MAJOR
NO. NO. NO. NUMBER NO. NO. NO. ITEMS RECOMMENDED ACTION
SUPPORTED
PART III – REMARKS (Any general remarks or recommendations, or suggestions for improvement of publications and blank
forms. Additional blank sheets may be used if more space is needed.)
Your Name Your Signature

USAPPC V3.00
Catalogs/Supply Manuals (SC/SM).
1 Rock Island Arsenal
PUBLICATION/FORM NUMBER DATE Heavy Equipment Transporter, M1070, Direct
TITLE

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, PLUS SIGNATURE
EXTENSION
Maintenance
TOTAL NO.
SUPPORTED
USAPPC V3.00
Catalogs/Supply Manuals (SC/SM).
PUBLICATION/FORM NUMBER DATE TITLE Heavy Equipment Transporter, M1070, Direct

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, PLUS SIGNATURE
EXTENSION
Maintenance
TOTAL NO.
SUPPORTED
USAPPC V3.00
THE METRIC SYSTEM AND EQUIVALENTS
LINEAR MEASURE SQUARE MEASURE
1 Centimeter = 10 Millimeters = 0.01 Meters = 0.3937 Inches 1 Sq Centimeter = 100 Sq Millimeters = 0.155 Sq Inches
1 Meter = 100 Centimeters = 1000 Millimeters = 39.37 Inches 1 Sq Meter = 10,000 Sq Centimeters = 10.76 Sq Feet
1 Kilometer = 1000 Meters = 0.621 Miles 1 Sq Kilometer = 1,000,000 Sq Meters = 0.386 Sq Miles
WEIGHTS CUBIC MEASURE
1 Gram = 0.001 Kilograms = 1000 Milligrams = 0.035 Ounces 1 Cu Centimeter = 1000 Cu Millimeters = 0.06 Cu Inches
1 Kilogram = 1000 Grams = 2.2 Lb 1 Cu Meter = 1,000,000 Cu Centimeters = 35.31 Cu Feet
1 Metric Ton = 1000 Kilograms = 1 Megagram = 1.1 Short Tons
LIQUID MEASURE TEMPERATURE
1 Milliliter = 0.001 Liters = 0.0338 Fluid Ounces 5/9 (oF -- 32) = oC

1 Liter = 1000 Milliliters = 33.82 Fluid Ounces 212o Fahrenheit is equivalent to 100o Celsius
90o Fahrenheit is equivalent to 32.2o Celsius
32o Fahrenheit is equivalent to 0o Celsius
9/5 Co + 32) = Fo
APPROXIMATE CONVERSION FACTORS
TO CHANGE TO MULTIPLY BY
Inches . . . . . . . . . . . . . . . . . . . . . . . . . Centimeters . . . . . . . . . . . . . 2.540
Feet . . . . . . . . . . . . . . . . . . . . . . . . . . . Meters . . . . . . . . . . . . . . . . . 0.305
Yards . . . . . . . . . . . . . . . . . . . . . . . . . Meters . . . . . . . . . . . . . . . . . 0.914
Miles . . . . . . . . . . . . . . . . . . . . . . . . . . Kilometers . . . . . . . . . . . . . . 1.609
Square Inches . . . . . . . . . . . . . . . . . . Square Centimeters . . . . . . 6.451
Square Feet . . . . . . . . . . . . . . . . . . . . Square Meters . . . . . . . . . . 0.093
Square Yards . . . . . . . . . . . . . . . . . . . Square Meters . . . . . . . . . . 0.836
Square Miles . . . . . . . . . . . . . . . . . . . Square Kilometers . . . . . . . 2.590
Acres . . . . . . . . . . . . . . . . . . . . . . . . . Square Hectometers . . . . . 0.405
Cubic Feet . . . . . . . . . . . . . . . . . . . . . Cubic Meters . . . . . . . . . . . . 0.028
Cubic Yards . . . . . . . . . . . . . . . . . . . . Cubic Meters . . . . . . . . . . . . 0.765
Fluid Ounces . . . . . . . . . . . . . . . . . . . Milliliters . . . . . . . . . . . . . . . 29.573
Pints . . . . . . . . . . . . . . . . . . . . . . . . . . Liters . . . . . . . . . . . . . . . . . . 0.473
Quarts . . . . . . . . . . . . . . . . . . . . . . . . . Liters . . . . . . . . . . . . . . . . . . 0.946
Gallons . . . . . . . . . . . . . . . . . . . . . . . . Liters . . . . . . . . . . . . . . . . . . 3.785
Ounces . . . . . . . . . . . . . . . . . . . . . . . . Grams . . . . . . . . . . . . . . . . 28.349
Pounds . . . . . . . . . . . . . . . . . . . . . . . . Kilograms . . . . . . . . . . . . . . 0.454
Short Tons . . . . . . . . . . . . . . . . . . . . . Metric Tons . . . . . . . . . . . . . 0.907
Pound--Feet . . . . . . . . . . . . . . . . . . . . Newton--Meters . . . . . . . . . 1.356
Pounds per Square Inch . . . . . . . . . Kilopascals . . . . . . . . . . . . . 6.895
Miles per Gallon . . . . . . . . . . . . . . . . Kilometers per Liter . . . . . . 0.425
Miles per Hour . . . . . . . . . . . . . . . . . . Kilometers per Hour . . . . . . 1.609
TO CHANGE TO MULTIPLY BY
Centimeters . . . . . . . . . . . . . . . . . . . . Inches . . . . . . . . . . . . . . . . . 0.394
Meters . . . . . . . . . . . . . . . . . . . . . . . . Feet . . . . . . . . . . . . . . . . . . . 3.280
Meters . . . . . . . . . . . . . . . . . . . . . . . . Yards . . . . . . . . . . . . . . . . . . 1.094
Kilometers . . . . . . . . . . . . . . . . . . . . . Miles . . . . . . . . . . . . . . . . . . . 0.621
Square Centimeters . . . . . . . . . . . . . Square Inches . . . . . . . . . . 0.155
Square Meters . . . . . . . . . . . . . . . . . . Square Feet . . . . . . . . . . . 10.764
Square Meters . . . . . . . . . . . . . . . . . . Square Yards . . . . . . . . . . . 1.196
Square Kilometers . . . . . . . . . . . . . . Square Miles . . . . . . . . . . . . 0.386
Square Hectometers . . . . . . . . . . . . Acres . . . . . . . . . . . . . . . . . . 2.471
Cubic Meters . . . . . . . . . . . . . . . . . . . Cubic Feet . . . . . . . . . . . . . 35.315
Cubic Meters . . . . . . . . . . . . . . . . . . . Cubic Yards . . . . . . . . . . . . . 1.308
Milliliters . . . . . . . . . . . . . . . . . . . . . . . Fluid Ounces . . . . . . . . . . . . 0.034
Liters . . . . . . . . . . . . . . . . . . . . . . . . . . Pints . . . . . . . . . . . . . . . . . . . 2.113
Liters . . . . . . . . . . . . . . . . . . . . . . . . . . Quarts . . . . . . . . . . . . . . . . . 1.057
Liters . . . . . . . . . . . . . . . . . . . . . . . . . . Gallons . . . . . . . . . . . . . . . . . 0.264
Grams . . . . . . . . . . . . . . . . . . . . . . . . . Ounces . . . . . . . . . . . . . . . . 0.035
Kilograms . . . . . . . . . . . . . . . . . . . . . . Pounds . . . . . . . . . . . . . . . . . 2.205
Metric Tons . . . . . . . . . . . . . . . . . . . . Short Tons . . . . . . . . . . . . . . 1.102
Newton--Meters . . . . . . . . . . . . . . . . . Pound--Feet . . . . . . . . . . . . 0.738
Kilopascals . . . . . . . . . . . . . . . . . . . . Pounds per Square Inch . . 0.145
Kilometers per Liter . . . . . . . . . . . . . Miles per Gallon . . . . . . . . . 2.354
Kilometers per Hour . . . . . . . . . . . . . Miles per Hour . . . . . . . . . . 0.621
PIN: 072603-000
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TRANSFER CASE 22- 1

FRONT AXLE 24- 1

STEERING SYSTEM 27- 1

WINCHES MAINTENANCE 28- 1

SUBJECT INDEX INDEX- 1

HEADQUARTERS, DEPARTMENT OF THE ARMY

The following precautions must be taken whenever using CARC paint:

LIST OF EFFECTIVE PAGES

Dates of issue for original pages are:

Original...................................... 31 May 2007

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 661 CONSISTING OF THE

* Zero In This Column Indicates An Original Page.

Technical Manual HEADQUARTERS

DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL

TRUCK, TRACTOR, M1070, 8 X 8,

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 --1

CHAPTER 20 FUEL SYSTEM MAINTENANCE

Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 --1

CHAPTER 21 COOLING SYSTEM MAINTENANCE

Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 --1

CHAPTER 22 TRANSMISSION MAINTENANCE

Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 --1

*Supersedes TM 9-2320-360-34-2 dated 31 March 1994

TABLE OF CONTENTS (CONT)

CHAPTER 23 TRANSFER CASE MAINTENANCE

Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23--1

CHAPTER 24 FRONT AXLE MAINTENANCE

CHAPTER 25 REAR AXLES MAINTENANCE

Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25--1

CHAPTER 26 BRAKE SYSTEM MAINTENANCE

Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26--1

CHAPTER 27 STEERING SYSTEM MAINTENANCE

Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27--1

CHAPTER 28 WINCHES MAINTENANCE

Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28--1

CHAPTER 29 STORAGE CONTAINER MAINTENANCE

Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29--1

APPENDIX A REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--1

APPENDIX B EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST

Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B--1

APPENDIX C ILLUSTRATED LIST OF MANUFACTURED ITEMS

Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C--1

APPENDIX D TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--1

TABLE OF CONTENTS (CONT)

APPENDIX E COMMON TOOLS, SUPPLEMENTS, AND SPECIAL

Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E--1

Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F--1

SUBJECT INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index--1

Contents Para Page

Section II. SERVICE UPON RECEIPT

19--2. GENERAL MAINTENANCE INSTRUCTIONS (CONT)

Section III. MAINTENANCE PROCEDURES

19--3. ENGINE TO ENGINE STAND INSTALLATION/REMOVAL

This task covers:

Equipment Conditions Tools and Special Tools (Cont)

(3) Remove plastic cable tie (7) from engine

19--3. ENGINE TO ENGINE STAND INSTALLATION/REMOVAL (CONT)