M35A3 M35A3C M36A3 2-1/2-Ton 6X6 Truck DS/GS Maintenance Manual TM 9-2320-386-24-1-2 Vol 2

Description

M35A3 M35A3C M36A3 2-1/2-Ton 6X6 Truck DS/GS Maintenance Manual TM 9-2320-386-24-1-2 Vol 2

File Details

• Manual Type: Unit, Direct Support, and General Support Maintenance Manual (Technical Manual)
• Document Number: TM 9-2320-386-24-1-2 / TO 36A12-1B-1122-2
• Volume: 2 of 2 (contains Chapters 4 through 9, work packages 0289 00 through 0395 00, plus rear matter)
• Date: 1 May 2001 (Change 1: 19 October 2003)
• Language: English
• Page Count: 762
• File Format: PDF
• Models Covered: M35A3 (W/O Winch NSN 2320-01-383-2047, W/Winch NSN 2320-01-383-3850); M35A3C (W/O Winch NSN 2320-01-383-2050, W/Winch NSN 2320-01-383-2049); M36A3 (W/O Winch NSN 2320-01-383-2048, W/Winch NSN 2320-01-383-2046)
• Distribution: Statement A – Approved for public release; distribution is unlimited

Chapters Covered

• Chapter 4 – Direct Support Troubleshooting
  • Section I: Introduction to Troubleshooting
  • Section II: Direct Support Troubleshooting Procedures (Mechanical Troubleshooting symptom index covering engine, fuel system, cooling system, transmission, transfer case, differential, tires and wheels, steering gear, winch, and winterization kits)
• Chapter 5 – Direct Support Maintenance
  • Section I: Power Plant Maintenance (Power Plant Replacement, Engine and Container Replacement, Preparing Replacement Engine for Installation, Starting Repaired or Replaced Engine)
  • Section II: Engine Maintenance (Rear Mounting Pads, Mounts and Support, Cylinder Head In-Vehicle, Vibration Damper, Crankshaft Pulley and Front Oil Seal, Crankshaft Rear Seal, Rear Seal Cover, Flywheel Housing, Camshaft Roller Followers and Covers, Rocker Arm Assembly and Pushrod, Timing Gear Cover, Valve Clearance Check and Adjustment, Oil Pan, Oil Pump, Oil Cooler, Oil Filter Base, Air Inlet Elbow/Manifold Cover/Manifold, Exhaust Manifold)
  • Section III: Fuel System Maintenance (Fuel Injector Replacement, Fuel Injection Control Linkage, Fuel Injector Synchronization, Fuel Injector Timing, Fuel Setting Adjustment, Fuel Transfer Pump Repair, Turbocharger Replacement, Governor Replacement)
  • Section IV: Engine Cooling System Maintenance (Water Pump Repair)
  • Section V: Electrical System Maintenance (Front Wiring Harness Replacement, STE/ICE-R Wiring Harness Replacement, Rear Wiring Harness Replacement)
  • Section VI: Transmission Maintenance (Transmission and Container Replacement, Transmission In-Vehicle Replacement, Transmission Out-of-Vehicle Replacement, Flexplate and Hub Replacement, Output Oil Seal Replacement)
  • Section VII: Transfer Case Maintenance
  • Section VIII: Front and Rear Axle Maintenance (Front Axle Replacement, Forward-Rear and Rear-Rear Axle Replacement, Differential Oil Seal Replacement)
  • Section IX: Wheel Maintenance (Rear Wheel Ring Adapter Maintenance)
  • Section X: Steering System Maintenance (Steering Gear Replacement)
  • Section XI: Body and Cab Maintenance (Fiberglass Hood Repair, Windshield Glass Replacement, Cargo Body Replacement)
• Chapter 6 – General Support Maintenance Instructions
  • Section I: Engine Maintenance (Valve Maintenance, Cylinder Head Repair, Valve Guide Maintenance, Valve Seat Maintenance, Camshaft Maintenance, Camshaft Bearing Sleeves Maintenance, Pistons and Connecting Rods Maintenance, Piston Cooling Tubes Replacement, Timing Gear Housing and Idler Gear Replacement, Crankshaft and Bearing Sleeves Maintenance)
  • Section II: Transmission Maintenance (Transmission Maintenance Introduction, Mounting Transmission on Holding Fixture, Torque Converter Maintenance, Transmission Governor Maintenance, Transmission Oil Pan and Filter Replacement, Transmission Control Valve Replacement, Modulator Valve Maintenance, Transmission Manual Select Shaft and Seal Replacement, Transmission Oil Pump Maintenance, Forward Clutch and Turbine Shaft Maintenance, Fourth Clutch Maintenance, Third Clutch Maintenance, Center Support Maintenance, Planetary Gearing Maintenance, Second Clutch Maintenance, First Clutch Maintenance, Transmission Output Shaft Seal and Bearing Replacement)
• Chapter 7 – General Maintenance
  • General Maintenance Procedures (Cleaning, Inspection, Repair, Assembly, Disassembly)
  • Illustrated List of Manufactured Items (Guide Screw, Shim Stock, Checking Gauge, Air Adapter Repair Fixture, In-Vehicle Seal Installer, Transmission Lifting Bracket)
  • Torque Limits (Dry Fasteners, Wet Fasteners, Metric Fasteners, Tubing Application Tightening Assembly Instructions, Torque Wrench Adapters, Conversion Formula)
  • Wiring Diagram Introduction

  IMAGES PREVIEW

  

  

  

• Chapter 8 – Shipment and Limited Storage
  • General Preparation of Vehicle for Shipment
  • Loading and Movement of Vehicle
  • Limited Storage
• Chapter 9 – Supporting Information
  • References
  • Maintenance Allocation Chart (MAC) Introduction and Chart
  • Expendable and Durable Items List
  • Tool Identification List
  • Mandatory Replacement Parts

This M35A3 M35A3C M36A3 DS/GS maintenance manual is the second volume of a two-part technical manual set covering the 2-1/2-ton, 6×6, M44A3 Series Trucks (Diesel). Volume 2 picks up where Volume 1 leaves off, delivering the complete Direct Support and General Support maintenance procedures that a unit or field maintenance shop needs to keep these trucks operational. The troubleshooting chapter alone is worth the price of admission, providing a symptom-driven diagnostic approach that walks a mechanic through engine will not crank, engine cranks but will not start, poor acceleration, excessive black smoke, transmission shift problems, transfer case issues, differential noise, steering play, winch faults, and heater malfunctions. Each malfunction is paired with step-by-step test or inspection procedures and corrective actions, with references to the exact work package where the repair is performed.

The Direct Support Maintenance chapter is the heart of this volume, covering the power plant, engine, fuel system, cooling system, electrical system, transmission, transfer case, front and rear axles, wheel maintenance, steering system, and body and cab. You get complete removal and installation procedures for the engine and transmission as a power plant assembly, cylinder head in-vehicle maintenance, crankshaft pulley and front oil seal, rear seal and cover, flywheel housing, camshaft roller followers, rocker arm assemblies and pushrods, timing gear cover, valve clearance adjustment, oil pan and pump, oil cooler, fuel injectors, fuel injection control linkage, synchronization and timing, fuel setting adjustment, transfer pump, turbocharger, governor, water pump, wiring harnesses, transmission in-vehicle and out-of-vehicle replacement, transfer case, front and rear axles, differential oil seals, rear wheel ring adapter, steering gear, fiberglass hood, windshield glass, and cargo body.

The General Support Maintenance chapter goes deeper into component overhaul, covering valve maintenance including facing and guide reaming, cylinder head repair, camshaft and bearing sleeves, pistons and connecting rods, timing gear housing and idler gear, crankshaft and bearing sleeves. The transmission section in Chapter 6 is extensive, covering torque converter maintenance with end play and leak testing, governor, oil pan and filter, control valve disassembly and assembly with detailed adjusting ring position notes, modulator valve, manual select shaft and seal, oil pump with thrust washer selection, forward clutch and turbine shaft, fourth, third, second, and first clutch maintenance, center support with piston and seal service, planetary gearing, and output shaft seal and bearing replacement. This M35A3 M35A3C M36A3 transmission overhaul information is critical for units that need to rebuild the AT1545P or AT545 automatic transmission in-house rather than replacing it.

The General Maintenance chapter provides the foundation for all the procedures, with detailed cleaning, inspection, repair, assembly, and disassembly instructions. The illustrated list of manufactured items shows you how to fabricate the guide screw, shim stock, checking gauge, air adapter repair fixture, in-vehicle seal installer, and transmission lifting bracket. The torque limits chapter gives you dry, wet, and metric fastener torque values, plus tubing tightening instructions and the torque wrench adapter conversion formula so you can calculate corrected dial readings when using adapters. The Maintenance Allocation Chart in Chapter 9 tells you exactly which maintenance level is authorized to perform each function, and the Expendable and Durable Items List, Tool Identification List, and Mandatory Replacement Parts list make sure you have the right consumables, tools, and replacement parts on hand.

What This M35A3 M35A3C M36A3 Maintenance Manual Enables You to Do

With this TM 9-2320-386-24-1-2 Volume 2 in your shop, you can diagnose and repair the diesel engine, fuel system, cooling system, electrical system, automatic transmission, transfer case, front and rear axles, steering system, brakes, and body components on the M35A3, M35A3C, and M36A3 trucks. You can pull the power plant, separate the transmission, replace the cylinder head, set valve clearance, synchronize and time the fuel injectors, adjust the fuel setting, rebuild the transmission control valve, service the torque converter, replace the transfer case, pull the front or rear axle, replace differential oil seals, service the rear wheel ring adapter, replace the steering gear, repair the fiberglass hood, replace windshield glass, and swap out the cargo body. The troubleshooting procedures give you a logical path from symptom to solution, so you are not guessing or throwing parts at a problem. The torque limits and specifications ensure you tighten every fastener correctly and set every adjustment to the right value. The MAC tells you what maintenance your level is authorized to perform, and the mandatory replacement parts list tells you what must be replaced during each job.

Why Correct Procedures and Specifications Matter for These Trucks

The M35A3, M35A3C, and M36A3 are heavy-duty tactical trucks that operate in demanding conditions. An improperly torqued cylinder head, a fuel injector that is out of sync or out of time, a transmission control valve that is assembled with adjusting rings in the wrong position, or a torque converter that is not properly seated can lead to catastrophic failure, injury to personnel, or damage to equipment. The warnings throughout this manual are there for a reason, and the step-by-step procedures are written to prevent mistakes that could cost you an engine, a transmission, or a truck. Having the correct maintenance manual means you follow the same procedures that the Army and Air Force use to keep these trucks running, which is especially important when a vehicle is deadlined and needs to get back into service.

Instant PDF Delivery – No Shipping, No Waiting

This M35A3 M35A3C M36A3 Unit, Direct Support, and General Support Maintenance Manual is delivered as an instant PDF download. There is no physical book to ship, no waiting for delivery, and no shipping cost. You can access the file immediately after payment, view it on any device that reads PDFs, and print the pages you need for the shop. Whether you are working on a single truck or maintaining a fleet of M44A3 Series vehicles, having the manual on hand in digital format means you can search, zoom, and print the exact pages you need, when you need them. This is the same technical manual used by military maintenance personnel, and it is now available to you as a convenient PDF download.