GENERAL MOTORS DEFENSE LSSV MILITARY TRUCKS COMMAND SUBURBAN PARTS MANUAL

Transcription

1 GENERAL MOTORS DEFENSE LSSV MILITARY TRUCKS COMMAND SUBURBAN PARTS MANUAL

2 Preface Preface General Motors Defense LSSV Military Trucks Parts Manual This manual provides information on replacement military parts for the 2001/02 GM LSSV Cargo/Troop Carrier (Base Pickup, Crewcab), Extended Cab and Chassis Cab. All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication approval. General Motors reserves the right to make changes at any time without notice. Published by GM DEFENSE MILITARY TRUCKS General Motors Corporation Troy, Michigan GENERAL MOTORS CORPORATION ALL RIGHTS RESERVED The information cutoff date is LITHO IN U.S.A. PART NO. TXO 17816P No part of this manual may be reproduced, stored in any retrieval system, or transmitted in any form or by any means (including but not limited to electronic, mechanical, photocopying, and recording) without the prior written permission of General Motors Corporation. This applies to all text, illustrations and tables.

3 Preface 2 Preface General Motors Defense LSSV Military Trucks Parts Manual This format allows you to compare the parts usage on all LSSV models. Figure numbers in the Table of Contents correspond to the figure numbers in the parts illustrations included within each section. Consult the illustrations when ordering parts so you are sure to get the part required. The following is the table used for each parts illustration. The Item No. column correlates with the item/callout number in the illustration. The Parts Description column describes each of the items called out on the illustration. The Parts No. column is to be used for reference when ordering the particular part. The # of Parts Required column is the number of the parts required for that particular item number on the illustration. Views shown in this manual are for replacement part(s) identification or modification and are not intended to repair the vehicle. For replacement part procedures, refer to the Military Trucks LSSV Service Manual Supplement. TXO numbers listed in the manual are available through GM Defense Military Trucks division. 8 digit numbers are available from an authorized GM dealership. Refer to contact information when ordering parts. General Motors Defense Military Trucks Department Contact Information Phone Number General Information Military Service Parts Assistance Technical/Warranty Assistance Vehicle Sales Mailing Address: GM Defense Military Trucks MC: Technology Drive Troy, MI 48083

4 Preface Preface 3 Reporting Errors and Suggestions If you find an error with this GM parts manual, or if you have a suggestion about this GM parts manual, we want to hear from you. When calling, be prepared with the following information: Your name Your dealership s name/military organization Your dealership s/military organization s phone number The model year and the vehicle line The publication part number (if present) The vehicle identification number of the vehicle being worked on The parts manual section and page number(s) Any applicable electronic information element identification numbers A descriptive explanation of your concern The GM parts manual phone personnel will respond to your concerns in the following ways: By delivering your concern to the manual s author By eliciting a response from the author By supplying you with an answer to your concerns For paper manual users: The GM parts manual phone personnel will also explain how to send in examples or markedup pages. The GM parts manual comment telephone numbers do not provide technical assistance. For technical assistance, contact your regular technical assistance source. United States Owner/Operator Vehicle owners or operators are encouraged to address their comments and concerns to the applicable Customer Assistance Center.

5 Preface /02 PARTS MANUAL COMMENT FORM Preface Use this form to advise us of any errors you might find in this manual. We also welcome suggestions for improving this Parts Manual. Parts Manual(s) that have the error Page number(s) that have the error Graphic number(s) that have the error VIN (if available) or model and applicable options Describe in detail, the error found or the suggestion(s). Attach additional pages if necessary. From: Mail To: Dealer/Military Organization Name Dealer Code City/Town State Name of Person Submitting This Comment Form Signature Date GM Defense Military Trucks Mail Code: Technology Drive Troy, MI USA Attention: ILS Manager

6 Table of Contents Table of Contents 1 Table of Contents Section General Information Section Front/Rear Suspension Section Tires and Wheels Section Front Axle Covers Section Vent Filters Section Engine Electrical Section Wiring Systems 24V Section Lighting Systems Section Body Front End Section Body Rear End Section Seat Covers Section Weapons Mount Section Winch

7 General Information Table of Contents 00-1 Owner s Manual Supplement Service Manual Supplement Blackout (B/O) Lighting Switch Label Customer Attention Label Customer Info/Contact Label Section 00 General Information Paint Colors Vehicle Data Plate V Battery Caution Label V Circuit Breaker Labels Underhood Air Compressor

8 00-2 Table of Contents General Information BLANK

9 General Information General Information 00-3 Owner s Manual Supplement 1 Owner s Manual Supplement TXO

10 00-4 General Information General Information Service Manual Supplement 1 Service Manual Supplement TXO Note: Military Replacement Part Only

11 General Information General Information 00-5 Blackout (B/O) Lighting Switch Label 3 Label Blackout (B/O) Switch TXO

12 00-6 General Information General Information Customer Attention Label 1 Customer Attention Label TXO Note: Place label as shown both sides of vehicle.

13 General Information General Information 00-7 Customer Info/Contact Label 1 Dealer Information Label TXO B 1 A Glove Compartment Door

14 00-8 General Information General Information Paint Colors Graphic Not Available Flat Brown (Camo) DAV Flat Black (Camo) DAV Green (Camo) CA 8211 Desert Tan WAOEM 5403 Forest Green CA 8211/ I15086 PPG PR C Desota Replacement Coatings Phone # US:

15 General Information General Information 00-9 Vehicle Data Plate 1 Data Plate TXO Rivet TXO A 3.18 cm (1.25 in) B 8.26 cm (3.25 in) C 6.35 cm (2.50 in) D 6.35 cm (2.50 in) Note: Vehicle Data Plate Not Stamped

16 00-10 General Information General Information 24V Battery Caution Label 1 24V Battery Caution Label TXO

17 General Information General Information V Circuit Breaker Labels 1 24V C/B Label TXO V C/B Label TXO

18 00-12 General Information General Information Underhood Air Compressor Note: For replacement parts contact VMAC 1333 Kipp Road Nanaimo, BC Phone: (250) V9X IR3 Fax: (250) Canada

19 Front/Rear Suspension Table of Contents 01-1 Section 01 Front/Rear Suspension Front Shock Absorbers Rear Shock Absorbers

20 01-2 Table of Contents Front/Rear Suspension BLANK

21 Front/Rear Suspension Front/Rear Suspension 01-3 Front Shock Absorbers 1 Front Shock Absorber BE HO 2 If equipped with heavy duty shock absorbers

22 01-4 Front/Rear Suspension Front/Rear Suspension Rear Shock Absorbers 1 Rear Shock Absorber BE H1 2 If equipped with heavy duty shock absorbers

23 Tires and Wheels Table of Contents 02-1 Spare Tire Lock Spare Tire Spacer Section 02 Tires and Wheels Wheel Assembly

24 02-2 Table of Contents Tires and Wheels BLANK

25 Tires and Wheels Tires and Wheels 02-3 Spare Tire Lock 1 Retainer Retainer

26 02-4 Tires and Wheels Tires and Wheels Spare Tire Spacer 1 Nut M8 x 1.25 TXO Spacer Tire TXO Bolt M8 x 1.25 x 19.0 TXO A B C D 55.9 cm (22.0 in) cm (11.0 in) Vehicle Center Line Hole diameter 10.0 mm (0.39 in)

27 Tires and Wheels Tires and Wheels 02-5 Wheel Assembly 1 Wheel Tire LT 265/75R16C (Procure Locally) N/A 5 Item 1 paint to match.

28 Front Axle Covers Table of Contents 03-1 Section 03 Front Axle Covers Front Axle Boot Cover

29 03-2 Table of Contents Front Axle Covers BLANK

30 Driveline/Axle Front Axle Covers 03-3 Front Axle Boot Cover 1 Driveline Axle Boot Cover

31 Vent Filters Table of Contents 04-1 Front Axle Vent Filter Rear Axle Vent Filter Section 04 Vent Filters Transmission/Transfer Case Vent Filter

32 04-2 Table of Contents Vent Filters BLANK

33 Vent Filters Vent Filters 04-3 Front Axle Vent Filter 1 Hose Clamp Filter

34 04-4 Vent Filters Vent Filters Rear Axle Vent Filter 1 Filter Clamp

35 Vent Filters Vent Filters 04-5 Transmission/Transfer Case Vent Filter 1 Clamp Filter A To transmission/transfer case

36 Engine Electrical Table of Contents V Battery V Battery Cables Section 05 Engine Electrical 12V Battery Tray A/C Generator

37 05-2 Table of Contents Engine Electrical BLANK

38 Engine Electrical Engine Electrical V Battery 1 Battery Insulator CCA Battery Bolt M8 x 1.25 x Battery Hold Down Retainer A B C D Dash Panel Battery Tray Weld Nut Battery Tray Battery Tray Support

39 05-4 Engine Electrical Engine Electrical 12V Battery Cables 1 Strap Conduit V Battery Cable Negative Bolt Self Tapping Screw M8 x 1.25 x V Battery Cable Positive TXO A Passenger Side Frame Rail

40 Engine Electrical Engine Electrical V Battery Tray 1 Nut M8 x 1.25 mm Right Tray Assembly Bolt M6 x 1.0 x A B C D Dash Panel Bracket Weld Nut Weld Stud

41 05-6 Engine Electrical Engine Electrical A/C Generator Note: For replacement parts contact: Aura Systems Phone: (800) 909-AURA (2872)

42 Wiring Systems 24V Table of Contents 06-1 Circuit Breaker Bracket Template Circuit Breakers and Mounting Volt Circuit Breaker Harness Voltmeter NATO Jump Start Connector NATO Jump Start Wiring Section 06 Wiring Systems 24V NATO Jump Start Cables Equalizer/Regulator Wiring Regulator Wiring Equalizer Wiring Contactor Wiring Contactor Mounting

43 06-2 Table of Contents Wiring Systems 24V BLANK

44 Wiring Systems 24V Wiring Systems 24V 06-3 Circuit Breaker Bracket Template 1 Template TXO A Hole diameter in

45 06-4 Wiring Systems 24V Wiring Systems 24V Circuit Breakers and Mounting 1 Bolt x Nut Amp Circuit Breaker (24V) TXO Screw TXO Amp Circuit Breaker (12V) TXO C/B Bracket TXO A Part of 12V Circuit Breaker

46 Wiring Systems 24V Wiring Systems 24V Volt Circuit Breaker Harness 1 Wiring Harness TXO V 120 Amp Circuit Breaker TXO

47 06-6 Wiring Systems 24V Wiring Systems 24V 24 Voltmeter 1 Panel I/P TXO V Gage Assembly C Part of Volt Gage Note: Panel to be installed after harnesses are routed

48 Wiring Systems 24V Wiring Systems 24V 06-7 NATO Jump Start Connector 1 Blackout (B/O) Headlamp Assembly Bolt M12 x 1.75 x 35.0 TXO Bolt NATO Connector Assembly Brace Assembly TXO Nut A Part of Lamp Assembly

49 06-8 Wiring Systems 24V Wiring Systems 24V NATO Jump Start Wiring 1 24V Battery Caution Label TXO Clamp Connector Assembly Cable Assembly (Ground) Bolt M TXO Cable Assembly (Battery to NATO) TXO A Hole diameter 6.0 mm (0.24 in)

50 Wiring Systems 24V Wiring Systems 24V 06-9 NATO Jump Start Cables 1 Jump Start Cables (Procure Locally) N/A 1

51 06-10 Wiring Systems 24V Wiring Systems 24V Equalizer/Regulator Wiring 1 Cover TXO Support RH TXO Support LH TXO Regulator TXO Bolt Nut Bracket TXO Rivnut TXO Equalizer TXO 175QZ 1

52 Wiring Systems 24V Wiring Systems 24V Regulator Wiring 1 Voltmeter Relay Harness TXO Contactor Wiring Harness TXO Equalizer/Regulator Jumper Harness TXO Voltmeter Harness TXO Regulator TXO A B C D 12V Terminal 24V Terminal Ignition Terminal Ground

53 06-12 Wiring Systems 24V Wiring Systems 24V Equalizer Wiring 1 Regulator Harness TXO Equalizer/Regulator Jumper Harness TXO Battery Equalizer TXO

54 Wiring Systems 24V Wiring Systems 24V Contactor Wiring 1 Regulator/Contactor Wiring Harness TXO Equalizer Wiring Harness TXO Washer # Nut Jumper Harness TXO Nut Washer Boot Contactor TXO

55 06-14 Wiring Systems 24V Wiring Systems 24V Contactor Mounting 1 Bolt x Contactor TXO Mount TXO Nut

56 Lighting Systems Table of Contents 07-1 Blackout (B/O) Lighting Switches Front Blackout (B/O) Marker Light Blackout (B/O) Headlamp Relay Block Bracket Underhood Wiring Harness Relay Block Harness Interrupt Wiring Harness Section 07 Lighting Systems Front Blackout (B/O) Lamp Harness I/P Blackout (B/O) Wiring Harness Rear Extension Lamp Harness Rear Blackout (B/O) Lighting Harness Relays and Connectors

57 07-2 Table of Contents Lighting Systems BLANK

58 Lighting Systems Lighting Systems 07-3 Blackout (B/O) Lighting Switches 1 Panel I/P TXO V Volt Gage Assembly Label Blackout (B/O) Switch TXO Switch Blackout (B/O) Control Switch Blackout (B/O) Drive Lamp A B C D Hole Diameter 3.2 cm (1.26 in) Spacing 2.5 cm (0.98 in) Included with Volt Gage Included with Switch

59 07-4 Lighting Systems Lighting Systems Front Blackout (B/O) Marker Light 1 Lamp Assembly Bolt x 0.62 TXO Bracket Nut 8 32 TXO Nut Ty-Wrap A B Front Grille Rear Extension Harness

60 Lighting Systems Lighting Systems 07-5 Blackout (B/O) Headlamp 1 Blackout (B/O) Headlamp Assembly Bolt M12 x 1.75 x 35.0 TXO Bolt NATO Connector Assembly Brace Assembly TXO Nut A Part of Lamp Assembly

61 07-6 Lighting Systems Lighting Systems Relay Block Bracket 1 Relay Block Bracket TXO Rivet TXO A Drill Holes using 3 16 Drill Bit B Use Letter 1 Drill Bit

62 Lighting Systems Lighting Systems 07-7 Underhood Wiring Harness 1 Front Blackout (B/O) Harness Assembly Rear Extension Lamp Harness Assembly TXO I/P Harness Assembly TXO Equalizer/Regulator Harness Assembly TXO Interrupt Relay Block Harness Assembly TXO

63 07-8 Lighting Systems Lighting Systems Relay Block Harness 1 Relay Block Harness TXO A Existing Harness

64 Lighting Systems Lighting Systems 07-9 Interrupt Wiring Harness 1 I/P Harness Assembly TXO E 1

65 07-10 Lighting Systems Lighting Systems Front Blackout (B/O) Lamp Harness 1 Front Blackout (B/O) Harness A Ty-Wrap where necessary

66 Lighting Systems Lighting Systems I/P Blackout (B/O) Wiring Harness 1 Blackout (B/O) Wiring Harness TXO E 1 2 Self Tapping Screw TXO I/P Panel TXO

67 07-12 Lighting Systems Lighting Systems Rear Extension Lamp Harness 1 Rear Extension Lamp Harness TXO Strap

68 Lighting Systems Lighting Systems Rear Blackout (B/O) Lighting Harness 1 Clamp Rear Lighting Harness TXO

69 07-14 Lighting Systems Lighting Systems Relays and Connectors 1 Turn Signal Relay Black Out Control Relay Relay Connector Interrupt Wiring Harness TXO E 1 5 Relay Block Harness TXO Relay Block Base Relay Block Module Relay Relay Block Cover

70 Front End End Table of Contents 08-1 Grille Center Bar Grille Front Bumper Modification (Multi-mount Winch) Front Bumper Bar Front Bumper Assembly Section 08 Body Front End Front Bumper Grille Guard Assembly Radiator Baffle Modification Front Clevis/Tie Downs Front Clevis Mounts Front Clevis Mounts (w/o Winch) Front Frame Drilling Template

71 08-2 Table of Contents Body Front End BLANK

72 Body Front End Body Front End 08-3 Grille Center Bar 1 Grille Center Bar TXO A Before Chrome Remove chrome bar from existing grille and install paintable bar. Reuse existing hardware.

73 08-4 Body Front End Body Front End Grille 1 Bolt Grille cut out template TXO Nut Grille A Hole diameter 6.0 B Blackout (B/O) cut out both sides C Hole diameter 3.25 Existing grille (chrome) to be replaced with grille shown rework grille using template.

74 Body Front End Body Front End 08-5 Front Bumper Modification (Multi-mount Winch) A Vehicle Center Line B Trim out these areas C 76.0 mm (2.99 in) D 70.0 mm (2.76 in) E 70.0 mm (2.76 in) F 4.5 mm (0.18 in) G 35.0 mm (1.38 in) H 64.0 mm (2.52 in) I mm (4.17 in) Note: Bumper modification for vehicles with winch only.

75 08-6 Body Front End Body Front End Front Bumper Bar 1 Front Bar A Use existing parts Note: Paint as required.

76 Body Front End Body Front End 08-7 Front Bumper Assembly 1 Front Bumper Assembly A Brace Note: Paint as required.

77 08-8 Body Front End Body Front End Front Bumper Grille Guard Assembly 1 Bolt M10 x 1.5 x 25.0 TXO Support TXO Bolt M10 x 1.50 x 30.0 TXO Strut TXO Grille Guard TXO Lamp Assembly Brace Assembly TXO Plate Assembly TXO Spacer TXO Bolt M12 x 1.75 x 85.0 TXO Connector Assembly Bolt M12 x 1.75 x 35.0 TXO Nut M10 x 1.50 TXO A 2.7 cm (1.06 in) Hole saw diameter through bumper 1.2 cm (0.47 in) both sides

78 Body Front End Body Front End 08-9 Radiator Baffle Modification A B C Hole diameter 8.5 cm (3.35 in) Existing Part Holes A to correspond with Bolts

79 08-10 Body Front End Body Front End Front Clevis/Tie Downs 1 Nut 1.0 x 12 mm TXO Clevis Bolt 1.0 x 12mm x mm TXO

80 Body Front End Body Front End Front Clevis Mounts 1 Right Clevis Support TXO Left Clevis Support TXO A Existing Hardware

81 08-12 Body Front End Body Front End Front Clevis Mounts (w/o Winch) 1 Bolt M12 x 1.75 x 18.0 TXO Front Extension Support TXO A Existing Hardware

82 Body Front End Body Front End Front Frame Drilling Template 1 Template TXO A B After mounting template hole must pass a 1.4 cm (0.55 in) bolt through both right and left frame must be drilled Drill hole to diameter 1.6 cm (0.63 in)

83 Body Rear End Table of Contents 09-1 Rear Bumper Rear Bumper Components Factory Rear Hitch Receiver Military Rear Hitch Receiver Rear Clevis Tie Down Rear Clevis Mounts Section 09 Body Rear End Pintle Hitch Trailer Light Adapter License Plate Bracket License Plate Lamp Wiring Modification

84 09-2 Table of Contents Body Rear End BLANK

85 Body Rear End Body Rear End 09-3 Rear Bumper 1 Bumper TXO

86 09-4 Body Rear End Body Rear End Rear Bumper Components 1 Nut TXO Nut Lamp Asm Retainer Retainer Nut Bumper TXO Bolt Door Assembly Harness Asm Bolt TXO Bracket A (SPO) requires modification B Existing Part

87 Body Rear End Body Rear End 09-5 Factory Rear Hitch Receiver 1 Nut M14 x Hitch Assembly, Rear TXO Bolt M14 x Bolt Flange Head TXO Bolt M14 x 200 x TXO Extension Rear Tie Down TXO Nut 12 x 1.75 TXO

88 09-6 Body Rear End Body Rear End Military Rear Hitch Receiver 1 Nut M Bolt M Bolt M Hitch Assembly (Short Box) TXO Hitch Assembly (Long Box) TXO Tie Down TXO Nut 1 x 12 TXO Clevis Bolt 1 x 12 x 100 TXO Bolt M14 x 200 x

89 Body Rear End Body Rear End 09-7 Rear Clevis Tie Down 1 Bolt 1.0 x 12 TXO Clevis Nut TXO Bolt M14 x 2.00 mm

90 09-8 Body Rear End Body Rear End Rear Clevis Mounts 1 Flange Nut M12 TXO Right Plate TXO Bolt M14 x 20 x Nut 1 x 12 TXO Clevis Bolt 1 x 12 x TXO Rear Clevis Extensions TXO Bolt M12 x 1.75 x Bolt M12 x 1.75 x Left Plate TXO A Hole diameter 14.0 mm 2 holes in line use item 2 as template

91 Body Rear End Body Rear End 09-9 Pintle Hitch 1 Pin and Spring Clip TXO Pintle Hook TXO

92 09-10 Body Rear End Body Rear End Trailer Light Adapter 1 12 to 8 Pin Adapter (12 V) TXO Note: Converts factory 8 pin to MIL style 12 pin connector.

93 Body Rear End Body Rear End License Plate Bracket 1 Bracket TXO Bolt Nut A B C D E F 8.9 cm (3.50 in) 1.0 cm (0.39 in) 4.45 cm (1.75 in) Hole diameter 19.0 mm (0.75 in) Hole diameter 6.0 mm (0.24 in) 1.5 cm (0.59 in)

94 09-12 Body Rear End Body Rear End License Plate Lamp Wiring Modification 1 Rear Bumper TXO A B To Ground Connect to harness TXO using supplied connector and terminal

95 Seat Covers Table of Contents 10-1 Section 10 Seat Covers Seat Covers

96 10-2 Table of Contents Seat Covers BLANK

97 Seat Covers Seat Covers 10-3 Seat Covers 1 Passenger Side, Front (Green) TXO P 1 1 Passenger Side, Front (Tan) TXO P 1 2 Center, Front (Green) TXO Center, Front (Tan) TXO Drive Side, Front (Green) TXO D 1 3 Drive Side, Front (Tan) TXO D 1 4 Passenger Side, Rear (Green) TXO P 1 4 Passenger Side, Rear (Tan) TXO P 1 5 Driver Side, Rear (Green) TXO D 1 5 Driver Side, Rear (Tan) TXO D 1

98 Weapons Mount Table of Contents 11-1 Section 11 Weapons Mount Weapons Mount

99 11-2 Table of Contents Weapons Mount BLANK

100 Weapons Mount Weapons Mount 11-3 Weapons Mount 1 Bracket Assembly TXO Strap TXO Bolt 8M x 1.25 x Mount - Lower Bolt 8 M TXO Rivnut TXO Nut 8M x 1.25 TXO A Hole diameter 11.09/11.38 mm (0.44/0.45 in)

101 Winch Table of Contents ,000 lb Front Winch Receiver (9,000 lb) Front Receiver Assembly (9,000 lb) Winch Assembly (9,000 lb) Section 12 Winch Front Winch Components (9,000 lb) Rear Winch Wiring (9,000 lb) Rear Winch Power Lead

102 12-2 Table of Contents Winch BLANK

103 Winch Winch 12-3 Front Winch Receiver (9,000 lb) 1 Receiver Kit TXO A Right End Plate B Receiver C Left End Plate D Bolt 7 16 x 1 1 4

104 12-4 Winch Winch Front Receiver Assembly (9,000 lb) 1 Receiver Kit TXO A Warn Winch Part Number 60268

105 Winch Winch 12-5 Winch Assembly (9,000 lb) 1 Winch Kit TXO Remote Control N/A 1 3 Connector Cover N/A 1 Kit includes all parts shown Note: For items 1-3 contact Warn Industries at

106 12-6 Winch Winch Front Winch Components (9,000 lb) 1 Bolt M6 x 1.0 x Bracket TXO Tapping Screw Washer M Nut M Winch Kit TXO A Hole diameter 5.2 mm (0.20 in) B 11.0 cm (4.33 in) Note: For Winch repair parts contact Warn Industries at

107 Winch Winch 12-7 Rear Winch Wiring (9,000 lb) 1A Bolt M6 x 1.0 x B Washer C Nut M Bracket TXO Self Tapping Screw Strap A Rear power lead to be Ty-wrapped to existing rear blackout (B/O) and trailer harness

108 12-8 Winch Winch Rear Winch Power Lead 1 20 ft Power Lead TXO ft Power Lead TXO Total length including connectors