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• UNIT, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL
• WARNING SUMMAR Y
• WARNING SUMMARY
• CARBON MONOXIDE (EXHAUST GASES) CAN KILL!
• ADHESIVES AND SEALING COMPOUNDS
• BRAKES
• FIRE EXTINGUISHER
• NBC EXPOSURE
• SLAVE STARTING
• LIST OF EFFECTIVE PAGES/WORK PACKAGES
• Table of Contents
• Table of Contents - Continued
• Table of Contents - Continued
• Table of Contents - Continued
• HOW TO USE THIS MANUAL
• CHAPTER 4 DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE INSTRUCTIONS
• TROUBLESHOOTING INTRODUCTION
• TROUBLESHOOTING SYMPTOM INDEX
• ENGINE TROUBLESHOOTING
• TRANSMISSION TROUBLESHOOTING
• STEERING SYSTEM TROUBLESHOOTING
• Table 1. Steering System Troubleshooting Procedures - Continued.
• Table 1. Steering System Troubleshooting Procedures - Continued.
• AIR CONDITIONING SYSTEM TROUBLESHOOTING AND TESTING
• PERFORMANCE TESTS - CONTINUED
• PERFORMANCE TESTS - CONTINUED
• SAFETY PRECAUTIONS - CONTINUED
• SAFETY PRECAUTIONS - CONTINUED
• AIR CONDITIONING SYSTEM TROUBLESHOOTING LOGIC TREE
• AIR CONDITIONING SYSTEM TROUBLESHOOTING
• Table 5. Problem - Compressor Operates Too Often or Continuously
• POWER PACK REPLACEMENT
• ENGINE/TRANSMISSION REPLACEMENT
• ENGINE MOUNTS REPLACEMENT
• REMOVAL
• REMOVAL - CONTINUED
• INSTALLATION - CONTINUED
• RADIATOR REPAIR
• REMOVAL
• ASSEMBLY - CONTINUED
• FAN CLUTCH REPAIR
• DISASSEMBLY - CONTINUED
• ALTERNATOR REPAIR
• DISASSEMBLY - CONTINUED
• DISASSEMBLY - CONTINUED
• TESTING
• TESTING - CONTINUED
• ASSEMBLY
• ASSEMBLY - CONTINUED
• ASSEMBLY - CONTINUED
• STARTER SOLENOID REPLACEMENT
• REMOVAL - CONTINUED
• STARTER REPAIR
• DISASSEMBLY - CONTINUED
• DISASSEMBLY - CONTINUED
• DISASSEMBLY - CONTINUED
• DISASSEMBLY - CONTINUED
• DISASSEMBLY - CONTINUED
• ASSEMBLY - CONTINUED
• ASSEMBLY - CONTINUED
• ASSEMBLY - CONTINUED
• ASSEMBLY - CONTINUED
• MAIN CAB WIRING HARNESS REPLACEMENT
• REMOVAL - CONTINUED
• REMOVAL - CONTINUED
• REMOVAL - CONTINUED
• REMOVAL - CONTINUED
• REMOVAL - CONTINUED
• REMOVAL - CONTINUED
• REMOVAL - CONTINUED
• INSTALLATION - CONTINUED
• INSTALLATION - CONTINUED
• INSTALLATION - CONTINUED
• INSTALLATION - CONTINUED
• INSTALLATION - CONTINUED
• INSTALLATION - CONTINUED
• INSTALLATION - CONTINUED
• SWITCH PANEL WIRING HARNESS REPLACEMENT
• INSTALLATION - CONTINUED
• TURN SIGNAL/MARKER LIGHT WIRING HARNESS REPLACEMENT
• INSTALLATION - CONTINUED
• TURN SIGNAL (THRU-DECK) WIRING HARNESS REPLACEMENT
• INSTALLATION - CONTINUED
• OVERHEAD CAB WIRING HARNESS REPLACEMENT
• INSTALLATION - CONTINUED
• CHASSIS WIRING HARNESS REPLACEMENT
• INSTALLATION - CONTINUED
• FRONT ANTI-LOCK BRAKE SYSTEM (ABS) WIRING HARNESS REPLACEMENT
• INSTALLATION
• REAR ANTI-LOCK BRAKE SYSTEM (ABS) WIRING HARNESS REPLACEMENT
• INSTALLATION
• TAILLIGHT WIRING HARNESS REPLACEMENT
• INSTALLATION
• ENGINE WIRING HARNESS REPLACEMENT
• INSTALLATION - CONTINUED
• INSTALLATION - CONTINUED
• INSTALLATION - CONTINUED
• RADIO WIRING HARNESS REPLACEMENT
• INSTALLATION - CONTINUED
• COLLISION WARNING SYSTEM (CWS) WIRING HARNESS REPLACEMENT
• INSTALLATION - CONTINUED
• TRANSMISSION OVERHAUL
• DISASSEMBLY
• Removal of Output Shaft and Oil Seal
• Removal of Torque Converter Module
• Removal of Torque Converter Housing Module
• Removal of Control Valve Module
• Removal of Rear Cover Module
• Removal of P2 Planetary Module, C5 Clutch Pack, and P1 Planetary Module
• Removal of Front Support and Charging Pump Module and Rotating Clutch Module - Continued
• Torque Converter Module Disassembly
• Torque Converter Module Disassembly - Continued
• Torque Converter Module Assembly - Continued
• Torque Converter Module Assembly - Continued
• Torque Converter Module Assembly - Continued
• Torque Converter Housing Module Disassembly
• Torque Converter Housing Module Assembly
• Front Support and Charging Oil Pump Module Disassembly
• Front Support and Charging Oil Pump Module Disassembly - Continued
• Front Support and Charging Oil Pump Module Disassembly - Continued
• Front Support and Charging Oil Pump Module Disassembly - Continued
• Front Support and Charging Oil Pump Module Assembly - Continued
• Rotating Clutch Module Disassembly
• Rotating Clutch Module Disassembly - Continued
• Rotating Clutch Module Disassembly - Continued
• Rotating Clutch Module Disassembly - Continued
• Rotating Clutch Module Assembly
• Rotating Clutch Module Assembly - Continued
• C3/C4 Clutch Assembly and Main Housing Module Disassembly
• C3/C4 Clutch Assembly and Main Housing Module Disassembly - Continued
• C3/C4 Clutch Assembly and Main Housing Module Assembly
• C3/C4 Clutch Assembly and Main Housing Module Assembly - Continued
• Main Shaft Module Disassembly
• P1 Planetary Module Disassembly - Continued
• MODULE OVERHAUL - CONTINUED
• P2 Planetary Module Disassembly
• P2 Planetary Module Assembly
• Rear Cover and P3 Planetary Module Disassembly
• Rear Cover and P3 Planetary Module Disassembly - Continued
• Rear Cover and P3 Planetary Module Assembly - Continued
• Control Valve Module Disassembly
• Control Valve Module Disassembly - Continued
• Control Valve Module Disassembly - Continued
• Control Valve Module Disassembly - Continued
• Control Valve Module Assembly
• Control Valve Module Assembly - Continued
• Control Valve Module Assembly - Continued
• Control Valve Module Assembly - Continued
• ASSEMBLY
• ASSEMBLY - CONTINUED
• Installation of Main Shaft Module and Selective Shim Measurement
• Installation of Main Shaft Module and Selective Shim Measurement - Continued
• Installation of Rear Cover Module
• Installation of Torque Converter Housing Module
• Installation of Torque Converter Module and Selective Shim Measurement
• Installation of Torque Converter Module and Selective Shim Measurement
• Installation of Control Valve Module
• Installation of Filters and Breather
• Installation of Output Shaft and Oil Seal
• Table 2. Wear Limits Data.
• Table 2. Wear Limits Data - Continued.
• Table 2. Wear Limits Data - Continued.
• Table 3. Wear Limits and Spring Data.
• Table 3. Wear Limits and Spring Data - Continued.
• FRONT AXLE REPLACEMENT
• REMOVAL - CONTINUED
• INSTALLATION - CONTINUED
• FRONT AXLE CASTER ADJUSTMENT
• ADJUSTMENT - CONTINUED
• TIE ROD MAINTENANCE
• DISASSEMBLY
• INSTALLATION
• FRONT CROSS TUBE ARM REPLACEMENT
• INSTALLATION
• FRONT STEERING ARM REPLACEMENT
• INSTALLATION - CONTINUED
• FRONT STEERING KNUCKLE REPLACEMENT
• REMOVAL - CONTINUED
• INSTALLATION - CONTINUED
• INSTALLATION - CONTINUED
• INSTALLATION - CONTINUED
• INSTALLATION - CONTINUED
• REAR AXLE REPLACEMENT
• REMOVAL - CONTINUED
• REMOVAL - CONTINUED
• INSTALLATION
• INSTALLATION - CONTINUED
• FORWARD-REAR AXLE DIFFERENTIAL CARRIER REPLACEMENT
• REMOVAL
• INSTALLATION
• FORWARD-REAR AXLE DIFFERENTIAL CARRIER REPAIR
• OUTPUT SHAFT REMOVAL AND DISASSEMBLY
• OUTPUT SHAFT REMOVAL AND DISASSEMBLY - CONTINUED
• DIFFERENTIAL CARRIER DISASSEMBLY - CONTINUED
• DIFFERENTIAL CARRIER DISASSEMBLY - CONTINUED
• Remove Oil Filter and Pump
• Remove Oil Filter and Pump. cont'd
• Remove Input Shaft, Forward Bearing, and Shift Collar
• Remove Input Shaft, Forward Bearing, and Shift Collar cont'd
• Remove Shift Unit and Oil Pump Drive Gear
• Remove Shift Unit and Oil Pump Drive Gear cont'd
• Disassemble Interaxle Differential
• Disassemble Interaxle Differential cont'd
• Remove Main Differential and Ring Gear Assembly
• Disassemble Main Differential and Ring Gear Assembly
• Remove Pinion Shaft and Cage Assembly
• CLEANING
• INSPECTION
• REPAIR OR REPLACEMENT - CONTINUED
• Wear Sleeve Replacement cont'd
• REPAIR OR REPLACEMENT - CONTINUED
• DIFFERENTIAL CARRIER ASSEMBLY
• DIFFERENTIAL CARRIER ASSEMBLY
• DIFFERENTIAL CARRIER ASSEMBLY
• DIFFERENTIAL CARRIER ASSEMBLY
• Assemble the Main Differential and Ring Gear Assembly
• Assemble the Main Differential and Ring Gear Assembly cont'd
• Assemble the Main Differential and Ring Gear Assembly cont'd
• Assemble the Main Differential and Ring Gear Assembly cont'd
• Install Main Differential and Ring Gear Assembly
• Adjust the Differential Bearing Preload
• Check Tool Contact
• Check Tool Contact cont'd
• Adjust Drive Gear Thrust Screw
• Assemble lnteraxle Differential
• Assemble lnteraxle Differential cont'd
• Assemble lnteraxle Differential cont'd
• Install Oil Pump Drive
• Assemble the Shift Unit, Fork, and Shaft
• Assemble Input Shaft and Bearings
• Assemble the Oil Pump, Filter, and Cover
• Assemble the Oil Pump, Filter, and Cover cont'd
• Assemble the Oil Pump, Filter, and Cover cont'd
• Assemble and Install Input Shaft Yoke
• Assemble the Gear Cover onto Carrier
• Assemble the Gear Cover onto Carrier cont'd
• Assemble the Gear Cover onto Carrier cont'd
• Adjust Input Bearing End Play
• Adjust Shift Shaft
• OUTPUT SHAFT ASSEMBLY
• OUTPUT SHAFT INSTALLATION - CONTINUED
• REAR-REAR AXLE DIFFERENTIAL CARRIER REPLACEMENT
• REMOVAL
• INSTALLATION - CONTINUED
• REAR-REAR AXLE DIFFERENTIAL CARRIER REPAIR
• DISASSEMBLY - CONTINUED
• DIFFERENTIAL CARRIER DISASSEMBLY (FIG. 1)
• DIFFERENTIAL CARRIER ASSEMBLY
• Install the Pinion and Cage Assembly
• Adjust the Pinion Cage Shim Pack Thickness with Pinion Setting Gage
• DIFFERENTIAL CARRIER ASSEMBLY - CONTINUED
• Assemble the Differential and Gear
• Install the Differential and Gear Assembly
• Check the Amboid Gear Backlash
• Figure 6. Incorrect Contact Patterns
• REAR YOKE AND OIL SEAL REPLACEMENT
• INSTALLATION
• FOOT BRAKE VALVE REPAIR
• DISASSEMBLY - CONTINUED
• DISASSEMBLY - CONTINUED
• DISASSEMBLY - CONTINUED
• DISASSEMBLY - CONTINUED
• ASSEMBLY - CONTINUED
• ASSEMBLY - CONTINUED
• ASSEMBLY - CONTINUED
• AIR DRYER REPAIR
• DISASSEMBLY - CONTINUED
• DISASSEMBLY - CONTINUED
• DISASSEMBLY - CONTINUED
• DISASSEMBLY - CONTINUED
• DISASSEMBLY - CONTINUED
• ASSEMBLY - CONTINUED
• ASSEMBLY - CONTINUED
• ASSEMBLY - CONTINUED
• ASSEMBLY - CONTINUED
• ASSEMBLY - CONTINUED
• BRAKE DRUM REPAIR
• Table 1. Machining Specifications.
• POWER STEERING PUMP REPLACEMENT
• INSTALLATION
• STEERING GEAR REPLACEMENT
• REMOVAL
• INSTALLATION - CONTINUED
• STEERING COLUMN REPLACEMENT
• REMOVAL
• REMOVAL - CONTINUED
• FIFTH WHEEL REPLACEMENT
• REMOVAL
• SLIDE BRACKET AND PLATE REPAIR
• DISASSEMBLY - CONTINUED
• ASSEMBLY
• FIFTH WHEEL TOP PLATE REPLACEMENT
• REMOVAL
• FIFTH WHEEL TOP PLATE REPAIR
• DISASSEMBLY
• DISASSEMBLY - CONTINUED
• DISASSEMBLY - CONTINUED
• ASSEMBLY
• ASSEMBLY - CONTINUED
• ASSEMBLY - CONTINUED
• RAMP REPLACEMENT
• REMOVAL - CONTINUED
• OVERSLUNG CROSSMEMBER REPLACEMENT
• REMOVAL - CONTINUED
• INSTALLATION - CONTINUED
• CAB ALLIGATOR CROSSMEMBER REPLACEMENT
• REMOVAL
• INSTALLATION
• MIDSHIPS ALLIGATOR CROSSMEMBER REPLACEMENT
• REMOVAL - CONTINUED
• REAR SUSPENSION CROSSMEMBER REPLACEMENT
• REMOVAL - CONTINUED
• REMOVAL - CONTINUED
• INSTALLATION - CONTINUED
• REAR CROSSMEMBER REPLACEMENT
• REMOVAL
• REMOVAL - CONTINUED
• REMOVAL - CONTINUED
• INSTALLATION - CONTINUED
• INSTALLATION - CONTINUED
• FRONT CROSSMEMBER REPLACEMENT
• REMOVAL - CONTINUED
• REMOVAL - CONTINUED
• INSTALLATION - CONTINUED
• INSTALLATION - CONTINUED
• Blank page
• FRAME RAIL EXTENSION AND REINFORCEMENT REPLACEMENT
• REMOVAL
• REMOVAL - CONTINUED
• INSTALLATION
• INSTALLATION
• FRONT ENGINE MOUNT SUPPORT REPLACEMENT
• REMOVAL - CONTINUED
• INSTALLATION - CONTINUED
• FRONT CAB MOUNTS REPLACEMENT
• REMOVAL - CONTINUED
• REMOVAL - CONTINUED
• REMOVAL - CONTINUED
• INSTALLATION
• INSTALLATION - CONTINUED
• INSTALLATION - CONTINUED
• REAR CAB MOUNTS REPLACEMENT
• REMOVAL - CONTINUED.
• FRONT SPRING REPLACEMENT
• REMOVAL
• REMOVAL - CONTINUED
• INSTALLATION - CONTINUED
• FRONT SPRING HANGERS REPLACEMENT
• REMOVAL - CONTINUED
• INSTALLATION
• REAR SPRING AND SADDLE ASSEMBLY REPLACEMENT
• INSTALLATION
• REAR SPRING HANGER REPLACEMENT
• INSTALLATION
• TORQUE ROD REPLACEMENT
• INSTALLATION
• EQUALIZING BEAM REPLACEMENT
• REMOVAL - CONTINUED
• REMOVAL - CONTINUED
• INSTALLATION
• INSTALLATION
• Blank page
• EQUALIZING BEAM REPAIR
• INSTALLATION
• CAB BODY REPAIR
• INSPECTION
• INSPECTION - CONTINUED
• Lock Bolt Removal
• Table 2. Drill Sizes for Blind Rivets.
• Table 3. Countersinking Dimensions for 100-Degree Countersunk Blind Rivets.
• Table 5. Calculating Correct Solid Rivet Length.
• Table 6. Correctly and Incorrectly Driven Rivet - Continued.
• Table 7. Rivet Grip Length Determination.
• Rivet Patterns
• Joint Design
• Repair by Patching
• Repair by Insertion
• CAB REPLACEMENT
• REMOVAL
• REMOVAL - CONTINUED
• REMOVAL - CONTINUED
• INSTALLATION - CONTINUED
• INSTALLATION - CONTINUED
• INSTALLATION - CONTINUED
• HOOD SHEET MOLDED COMPOUND (SMC) REPAIR
• REPAIR - CONTINUED
• REPAIR - CONTINUED
• REPAIR - CONTINUED
• REPAIR - CONTINUED
• REPAIR - CONTINUED
• REPAIR - CONTINUED
• CAB DOOR REPLACEMENT
• REMOVAL - CONTINUED
• INSTALLATION - CONTINUED
• CAB DOOR REPAIR
• DISASSEMBLY - CONTINUED
• DISASSEMBLY - CONTINUED
• DISASSEMBLY - CONTINUED
• DISASSEMBLY - CONTINUED
• DISASSEMBLY - CONTINUED
• DISASSEMBLY - CONTINUED
• DISASSEMBLY - CONTINUED
• DISASSEMBLY - CONTINUED
• ASSEMBLY
• ASSEMBLY - CONTINUED
• ASSEMBLY - CONTINUED
• ASSEMBLY - CONTINUED
• ASSEMBLY - CONTINUED
• ASSEMBLY - CONTINUED
• ASSEMBLY - CONTINUED
• ASSEMBLY - CONTINUED
• ASSEMBLY - CONTINUED
• WINDSHIELD REPLACEMENT
• REMOVAL - CONTINUED
• REMOVAL - CONTINUED
• CLEANING AND INSPECTION
• INSTALLATION - CONTINUED
• INSTALLATION - CONTINUED
• INSTALLATION - CONTINUED
• INSTALLATION - CONTINUED
• REAR WINDOW REPLACEMENT
• REMOVAL - CONTINUED
• INSTALLATION - CONTINUED
• INSTALLATION - CONTINUED
• AIR DUCTS REPLACEMENT
• REMOVAL - CONTINUED
• INSTALLATION
• AIR CONDITIONING SYSTEM REFRIGERANT (R-134A) MAINTENANCE
• RECOVERY
• EVACUATING/RECYCLING
• PURGING
• FLUSHING
• CHARGING - CONTINUED
• HEATING, VENTILATION, AIR CONDITIONING (HVAC) UNIT REPLACEMENT
• REMOVAL
• REMOVAL - CONTINUED
• REMOVAL - CONTINUED
• REMOVAL - CONTINUED
• REMOVAL - CONTINUED
• INSTALLATION
• INSTALLATION - CONTINUED
• INSTALLATION - CONTINUED
• INSTALLATION - CONTINUED
• INSTALLATION - CONTINUED
• AIR CONDITIONER EXPANSION VALVE REPLACEMENT
• REMOVAL
• REMOVAL - CONTINUED
• INSTALLATION - CONTINUED
• AIR CONDITIONER EVAPORATOR COIL REPLACEMENT
• REMOVAL - CONTINUED
• REMOVAL - CONTINUED
• INSTALLATION - CONTINUED
• AIR CONDITIONER COMPRESSOR SERVICE
• GENERAL INFORMATION - CONTINUED
• SERVICE - CONTINUED
• AIR CONDITIONER COMPRESSOR REPLACEMENT
• REMOVAL - CONTINUED
• REMOVAL - CONTINUED
• INSTALLATION - CONTINUED
• AIR CONDITIONER RECEIVER-DRYER REPLACEMENT
• REMOVAL - CONTINUED
• INSTALLATION - CONTINUED
• AIR CONDITIONER CONDENSER REPLACEMENT
• REMOVAL - CONTINUED
• INSTALLATION - CONTINUED
• AIR CONDITIONER HOSE REPLACEMENT
• REMOVAL
• INSTALLATION - CONTINUED
• GENERAL MAINTENANCE INSTRUCTIONS
• GENERAL
• Castings, Forgings, and Machined Metal Parts
• DISASSEMBLY AND ASSEMBLY INSTRUCTIONS
• APPLICATION OF ADHESIVES AND SEALING COMPOUNDS
• PUSH-IN AIR TUBE FITTINGS - CONTINUED
• PUSH-IN AIR TUBE FITTINGS - CONTINUED
• SOLDERING - CONTINUED
• LINES AND PORTS
• LOCKWIRE
• MULTIMETER - CONTINUED
• MULTIMETER - CONTINUED
• MULTIMETER - CONTINUED
• MULTIMETER - CONTINUED
• CHAPTER 5 SUPPORTING INFORMATION
• REFERENCES
• REFERENCES - CONTINUED
• MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION
• MAINTENANCE FUNCTIONS - CONTINUED
• EXPLANATION OF COLUMNS IN THE MAC, TABLE 1 - CONTINUED
• MAINTENANCE ALLOCATION CHART (MAC)
• Table 1. MAC for the M915A4 Family of Vehicles - Continued.
• Table 1. MAC for the M915A4 Family of Vehicles - Continued.
• Table 1. MAC for the M915A4 Family of Vehicles - Continued.
• Table 1. MAC for the M915A4 Family of Vehicles - Continued.
• Table 1. MAC for the M915A4 Family of Vehicles - Continued.
• Table 1. MAC for the M915A4 Family of Vehicles - Continued.
• Table 1. MAC for the M915A4 Family of Vehicles - Continued.
• Table 1. MAC for the M915A4 Family of Vehicles - Continued.
• Table 1. MAC for the M915A4 Family of Vehicles - Continued.
• Table 2. Tools and Test Equipment Requirements for the M915A4 Family of Vehicles.
• Table 2. Tools and Test Equipment Requirements for the M915A4 Family of Vehicles - Continued.
• Table 2. Tools and Test Equipment Requirements for the M915A4 Family of Vehicles - Continued.
• Table 3. Remarks for the M915A4 Family of Vehicles.
• ILLUSTRATED LIST OF MANUFACTURED ITEMS
• Table 1. Part Number Index - Continued.
• Table 1. Part Number Index - Continued.
• Table 1. Part Number Index - Continued.
• Table 1. Part Number Index - Continued.
• Table 2. Manufactured Items - Continued.
• Table 2. Manufactured Items - Continued.
• Table 2. Manufactured Items - Continued.
• Table 2. Manufactured Items - Continued.
• Table 2. Manufactured Items - Continued.
• FABRICATED TOOLS
• FABRICATED TOOLS - CONTINUED
• FABRICATED TOOLS - CONTINUED
• TORQUE LIMITS
• Table 1. Torque Limits.
• Table 2. Refrigerant Line Torque Specifications.
• EXPENDABLE AND DURABLE ITEMS LIST
• Table 1. Expendable and Durable Items List .
• Table 1. Expendable and Durable Items List - Continued.
• Table 1. Expendable and Durable Items List - Continued.
• Table 1. Expendable and Durable Items List - Continued.
• Table 1. Expendable and Durable Items List - Continued.
• TOOL IDENTIFICATION LIST
• Table 1. Tool Identification List.
• Table 1. Tool Identification List.
• Table 1. Tool Identification List.
• Table 1. Tool Identification List.
• Figure
• INDEX
• INDEX - Continued
• INDEX - Continued
• INDEX - Continued
• INDEX - Continued
• THE METRIC SYSTEM AND EQUIVALENTS
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• TM-9-2320-303-24-2
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• Distribution
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