1996 HMMWV M998 & Related Models Unit Maintenance Manual Volume 2 – TM 9-2320-280-20-2
The 1996 HMMWV M998 & Related Models Unit Maintenance Manual Volume 2 – TM 9-2320-280-20-2 is a detailed unit-maintenance reference covering chapters 3 through 9 of the three-volume technical manual set. This volume brings together engine-system work, electrical maintenance, transmission and transfer-case procedures, driveline and suspension service, brakes, wheels and steering, and frame maintenance for a broad group of HMMWV utility, armament, TOW, shelter-carrier, heavy-variant, and ambulance configurations. It is arranged around task-based procedures with initial setup information, tools and materials, equipment conditions, warnings and cautions, removal and installation steps, inspections, adjustments, servicing operations, and extensive component illustrations.
File Details
- Manual type: Unit Maintenance Technical Manual
- Document: Army TM 9-2320-280-20-2 / Air Force TO 36A12-1A-2092-1-2 / Marine Corps TM 2320-20/7B
- Volume: Volume 2 of 3, covering Chapters 3 through 9
- Publication date: 31 January 1996
- Change status: Change 2 dated 30 June 1999 is incorporated in the file
- Language: English
- PDF page count: 944 pages
- File format: PDF
Vehicle Coverage
This volume applies across the HMMWV configurations identified on the manual cover, including cargo/troop carriers, winch-equipped variants, heavy variants, armored and supplemental-armor TOW carriers, armament carriers, S250 shelter carriers, and 2-litter and 4-litter ambulance versions. Covered model designations include M998, M998A1, M1038, M1038A1, M1097, M1097A1, M1097A2, M1123, M966, M966A1, M1121, M1036, M1045, M1045A1, M1045A2, M1046, M1046A1, M1025, M1025A1, M1025A2, M1026, M1026A1, M1043, M1043A1, M1043A2, M1044, M1044A1, M1037, M1042, M996, M996A1, M997, M997A1, M997A2, M1035, M1035A1, and M1035A2. Procedures in the manual also distinguish between 6.2L and 6.5L engine applications where required, as well as model-specific configurations such as 3L80 and 4L80-E transmission-related service and the later serpentine-drive arrangements used on specified A2 models and M1123.
Chapters Covered
- Chapter 3 – Engine Systems Maintenance
- Lubrication System Maintenance
- Fuel System Maintenance
- Accelerator System Maintenance
- Exhaust System Maintenance
- Cooling System Maintenance
- Chapter 4 – Electrical System Maintenance
- Generating and Protective Control Box System Maintenance
- Dual Voltage Alternator and Regulator System Maintenance
- Starter and Starting Control System Maintenance
- Instruments, Sending Units, Switches, and Horn Maintenance
- Transfer Case and Transmission Electrical Maintenance
- Lighting System Maintenance
- Battery System Maintenance
- Ambulance Electrical System Maintenance
- Chapter 5 – Transmission and Transfer Case Maintenance
- Transmission Maintenance
- Transfer Case Maintenance
- Chapter 6 – Propeller Shafts, Axles, and Suspension Maintenance
- Propeller Shafts Maintenance
- Front and Rear Axles Maintenance
- Suspension Maintenance
- Chapter 7 – Brake System Maintenance
- Parking Brake System Maintenance
- Service Brake System Maintenance
- Rear Dual Service/Parking Brake System Maintenance
- Chapter 8 – Wheels and Steering Maintenance
- Wheel and Runflat System Maintenance
- Steering Components Maintenance
- Chapter 9 – Frame Maintenance
Taken together, these chapters give a technician a broad unit-maintenance path from routine service and adjustments through component replacement and repair. The manual is not limited to one system: it follows the vehicle from engine oil service, fuel delivery and cooling through charging, starting, lighting, batteries and electrical controls, then continues into transmission and transfer case work, propeller shafts, geared hubs, suspension, brakes, wheel/runflat assemblies, steering and structural frame components.
Engine, Fuel, Cooling and Exhaust Procedures
The engine chapters contain practical maintenance tasks such as engine oil service, oil pan replacement, oil cooler line and cooler assembly work, crankcase depression regulator testing and maintenance, air-cleaner servicing, fuel pump replacement, fuel-tank removal and maintenance, fuel supply/return and vent-line procedures, fuel-filter maintenance and bleeding, injection return-hose work, glow-plug replacement, accelerator linkage adjustment and engine idle-speed adjustment. Cooling-system coverage includes draining and filling, antifreeze preparation guidance, radiator and fan-shroud maintenance, surge-tank service, thermostat and water-pump work, fan-drive procedures, conventional drivebelt adjustment and serpentine-drive maintenance. Exhaust coverage includes tailpipe, muffler, catalytic-converter applications, crossover pipe, manifold heat shields and exhaust-manifold replacement.
The 1996 HMMWV M998 & Related Models Unit Maintenance Manual Volume 2 – TM 9-2320-280-20-2 also includes numerous numerical service values inside the procedures. Examples include specified tightening torques, pressure limits, clearances, coolant-system capacity information, belt tension requirements, engine idle settings for 6.2L and 6.5L applications, and dimensional checks for radiator/fan-shroud alignment. These values are presented alongside the applicable task rather than as detached general guidance, helping the technician use the correct figure in the correct maintenance context.
Electrical and Drivetrain Maintenance
Electrical coverage is especially extensive. The manual includes alternator and regulator work, alternator cables and pulleys, protective-control and distribution boxes, starter and starting controls, instrument and sending-unit work, transfer-case and transmission electrical items, service and blackout lighting, batteries and power cables, wiring-harness connector repair, and a large dedicated ambulance-electrical section. Transmission electrical procedures include 4L80-E items such as the transmission control module, E-PROM, throttle-position sensor, input and output speed sensors, relays and circuit protection, while other procedures distinguish 3L80-related components where applicable.
Mechanical drivetrain chapters cover transmission service, cooler lines, shift controls, transmission mounts and road testing, followed by transfer-case shift linkage, speedometer driven gear, vent line and oil-seal work. Chapter 6 moves into front and rear propeller shafts, universal joints, halfshafts, geared hubs and their seals and bearings, differential venting, steering stops, differential-cover maintenance, stabilizer bars, radius rods, upper and lower ball joints, control arms, coil springs and shock absorbers.
Brakes, Wheels, Steering and Frame
Brake-system procedures address parking-brake adjustment and hardware, service-brake bleeding, pad and caliper maintenance, master-cylinder work, Hydro-Boost replacement, brake lines, brake pedals, proportioning valve and service-brake rotor replacement, plus rear dual service/parking-brake coverage. Wheel and runflat material includes jacking instructions, wheel replacement, tire/wheel/runflat maintenance, bias and radial tire configurations, runflat compressor belts, rim-stud work, tire balancing, front toe-in and rear toe-out alignment. Steering procedures extend through the steering wheel, pitman arm, center link, tie rods, idler arm, steering column and shafts, steering gear, power-steering pump and pulley arrangements, hydraulic hoses, control valve, cooler, system bleeding and relief-valve maintenance.
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “1996 HMMWV M998 & Related Models Unit Maintenance Manual Volume 2 – TM 9-2320-280-20-2” are as follows:
TABLE OF CONTENTSp. 12
LAST CHANGEp. 7
WARNINGp. 2
+TABLES
TABLE 3-1p. 124
TABLE 3-2p. 160
TABLE 8-1p. 827
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+CHAPTERSp. 1
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Chapter 9 completes the volume with frame-related tasks including front bumper and towing-bracket configurations, frame extension, tiedown rings, radiator front mounting bracket, rear bumper and brace components, crossmember brace, towing pintle, lifting shackles, receptacle mounting bracket and transmission-mount crossmember work. The model-specific task headings make it easier to identify which procedure applies to the particular HMMWV configuration being serviced.
Built for Task-by-Task Maintenance Work
Individual procedures typically begin with an initial setup that identifies required tools, materials or parts, personnel requirements where applicable, related manual references and equipment conditions. The maintenance steps then move through clearly separated phases such as removal, cleaning and inspection, testing, adjustment, assembly and installation, with follow-on tasks where additional work is required. The manual makes frequent use of exploded views, component callouts, routing illustrations, installation diagrams and vehicle-level drawings to connect written steps to the actual hardware.
Safety content is integrated throughout the maintenance material. Warnings and cautions address hazards such as hot coolant, diesel fuel, battery electrolyte, electrical shorts, compressed air, wheel inflation, hot exhaust parts and vehicle support. Certain procedures also identify configuration-specific cautions and legacy component issues, so the technician can follow the procedure as written for the applicable vehicle and component arrangement.
Get the Complete Volume 2 Maintenance Reference
Use this 1996 HMMWV M998 & Related Models Unit Maintenance Manual Volume 2 – TM 9-2320-280-20-2 when working on the engine, electrical system, transmission, transfer case, driveline, suspension, brakes, wheels, steering or frame systems covered in Chapters 3 through 9. The depth of the task procedures supports servicing, inspection, adjustment, component removal and installation, repair, testing and diagnosis with the specified sequences and service values close at hand. Correct procedures and specifications matter when a job involves safety-critical brakes, steering, wheel assemblies, drivetrain components, electrical circuits or cooling-system work. The manual is delivered as an instant PDF after payment, with no shipping required; it can be opened on compatible phones, tablets and computers and printed when a paper copy of selected procedures is useful at the workbench or vehicle.
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