TM P ARMY TM P AIR FORCE TO 36A12-1A MARINE CORPS TM P/5

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1 TM P ARMY TM P AIR FORCE TO 36A12-1A MARINE CORPS TM P/5 TECHNICAL MANUAL DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LISTS (INCLUDING DEPOT MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LISTS) FOR TRUCK, CARGO, TACTICAL, 1-1/4 TON, 4X4, M1008 ( ) TRUCK, CARGO, TACTICAL, 1-1/4 TON, 4X4, M1008A1 ( ) TRUCK, UTILITY, TACTICAL, 3/4 TON, 4X4, M1009 ( ) TRUCK, AMBULANCE, TACTICAL, 1-1/4 TON, 4X4, M101O ( ) TRUCK, SHELTER CARRIER, TACTICAL, 1-1/4 TON, 4X4, M1028 ( ) TRUCK, SHELTER CARRIER W/PTO, TACTICAL, 1-1/4 TON, 4X4, M1028A1 ( ) TRUCK, SHELTER CARRIER W/PTO, TACTICAL, 1-1/4 TON, 4X4, M1028A2 ( ) TRUCK, SHELTER CARRIER, TACTICAL, 1-1/4 TON, 4X4, M1028A3 ( ) TRUCK, CHASSIS, TACTICAL, 1-1/4 TON, 4X4, M1031 ( ) This manual supersedes TM P, 9 February 1990, and all changes. Approved for public release; distribution is unlimited. DEPARTMENTS OF THE ARMY, THE AIR FORCE, AND HEADQUARTERS, MARINE CORPS 01 MAY 1992

2 TECHNICAL MANUAL *TM P DEPARTMENTS OF THE ARMY, THE AIR FORCE, AND HEADQUARTERS, MARINE CORPS Washington, D. C., 1 May 1992 DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LISTS (INCLUDING DEPOT MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LISTS) FOR TRUCK, CARGO, TACTICAL, 1-1 /4 TON, 4X4, M1008 ( ) TRUCK, CARGO, TACTICAL, 1-1/4 TON, 4X4, M1008A1 ( ) TRUCK, UTILITY, TACTICAL, 3/4 TON, 4X4, M1009 ( ) TRUCK, AMBULANCE, TACTICAL, 1-1/4 TON, 4X4, M1010 ( ) TRUCK, SHELTER CARRIER, TACTICAL, 1-1/4 TON, 4X4, M1028 ( ) TRUCK, SHELTER CARRIER W/PTO, TACTICAL, 1-1/4 TON, 4X4, M1028A1 ( ) TRUCK, SHELTER CARRIER W/PTO, TACTICAL, 1-1/4 TON, 4X4, M1028A2 ( ) TRUCK, SHELTER CARRIER, TACTICAL, 1-1/4 TON, 4X4, M1028A3 ( ) TRUCK, CHASSIS, TACTICAL, 1-1/4 TON, 4X4, M1031 ( ) Current as of 7 February 1992 REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this manual. If you find any mistakes or if you know of a way to improve the procedures, please let us know, Mail your letter, DA Form 2028 (Recommended Changes to Publications and Blank Forms), or DA Form , located In the back of this manual, direct to: Commander, U.S. Army Tank-Automotive Command, ATTN: AMSTA-MB, Warren, MI A reply will be furnished to you. Approved for public release; distribution is unlimited. * This manual supersedes TM P, dated 9 February 1990, and all changes.

3 TABLE OF CONTENTS Page Illus Fig SECTION I. SECTION Il. INTRODUCTION REPAIR PARTS LIST GROUP 01 ENGINE ENGINE ASSEMBLY ENGINE ASSEMBLY MOUNTS, LIFTING BRACKETS, AND MOUNTING HARDWARE CRANKCASE, BLOCK, CYLINDER HEAD CYLINDER HEADS, BLOCK PLUGS, AND RELATED PARTS CRANKSHAFT ENGINE CRANKSHAFT AND RELATED PARTS FLYWHEEL ASSEMBLY FLYWHEEL PISTONS AND CONNECTING RODS PISTON AND CONNECTING ROD VALVES, CAMSHAFTS, AND TIMING SYSTEM CYLINDER HEAD AND CRANKCASE COVERS CAMSHAFT VALVES, ROCKER ARMS, AND RELATED PARTS ENGINE LUBRICATION SYSTEM ENGINE OIL PUMP ASSEMBLY FILTER, PAN, AND RELATED PARTS OIL COOLER LINES, SAMPLING VALVE, AND RELATED PARTS CRANKCASE DEPRESSION VALVE AND RELATED PARTS MANIFOLDS INTAKE AND EXHAUST MANIFOLDS GROUP 03 FUEL SYSTEM CARBURETOR, FUEL INJECTOR FUEL INJECTOR AND RELATED PARTS FUEL PUMPS SUPPLY PUMP, lnjector PUMP, AND RELATED PARTS VACUUM VALVE AND HOSES lnjector PUMP COMPONENT PARTS INJECTOR LINES AND RELATED PARTS AIR CLEANER AIR CLEANER TANKS, LINES, FITTlNGS, HEADERS FUEL TANK AND RELATED PARTS (M1009) FUEL TANK AND RELATED PARTS (ALL EXCEPT M1009) REAR FUEL LINES AND RELATED PARTS (M1009) FRONT FUEL LINES AND RELATED PARTS (M1009) FUEL LINES AND RELATED PARTS (ALL EXCEPT M1009) FUEL FILTERS FUEL FILTER AND RELATED PARTS ENGINE STARTING AIDS GLOW PLUGS AND TEMPERATURE SENSOR ACCELERATOR, THROTTLE, OR CHOKE CONTROLS ACCELERATOR LINKAGE AND RELATED PARTS ii

4 TABLE OF CONTENTS (Con t) Page Illus Fig GROUP 04 EXHAUST SYSTEM MUFFLER AND PIPES EXHAUST MUFFLERS AND PIPES (ALL EXCEPT M1009) EXHAUST MUFFLERS AND PIPES (M1009) GROUP 05 COOLING SYSTEM RADIATOR, EVAPORATIVE COOLER, OR HEAT EXCHANGER RADIATOR, COOLANT RECOVERY RESERVOIR, AND RELATED PARTS COWLING, DEFLECTORS, AIR DUCTS, SHROUDS, ETC RADIATOR SHROUD WATER MANIFOLD, HEADERS, THERMOSTATS, AND HOUSING GASKET ENGINE THERMOSTAT AND HOSES WATER PUMP WATER PUMP FAN ASSEMBLY ENGINE FAN ASSEMBLY GROUP 06 ELECTRICAL SYSTEM GENERATOR, ALTERNATOR ALTERNATOR AND MOUNTING HARDWARE, LEFT SIDE (ALL EXCEPT M1010) ALTERNATOR AND MOUNTING HARDWARE, RIGHT SIDE (ALL EXCEPT M1010) ALTERNATOR AND MOUNTING HARDWARE (M1010) ALTERNATOR COMPONENT PARTS (ALL EXCEPT M1010) ALTERNATOR COMPONENT PARTS (M1010) GENERATOR REGULATOR VOLTAGE REGULATOR AND RELAY (M1010) STARTING MOTOR STARTER MOTOR AND RELAY STARTER MOTOR COMPONENT PARTS INSTRUMENT OR ENGINE CONTROL PANEL INSTRUMENT PANEL WIRING HARNESS INSTRUMENT CLUSTER ASSEMBLY DOOR AJAR AND GLOW PLUG INDICATOR, VOLTMETER, GAS-PARTICULATE FILTER UNIT, AND FLOODLIGHT SWITCH MISCELLANEOUS ITEMS ACCESSORY WIRING TERMINAL BOARD AND COMPONENTS POWER JUNCTION BOX AND CABLE RADIO FEED HARNESS (M1009) BATTERY BOOSTER RESISTOR GLOW PLUG RELAY HEADLAMP BLACKOUT LAMP AND TAlLLAMP SWITCHES AND FUSES LIGHTS BLACKOUT HEADLAMP AND HEADLAMP ILLUMINATING COMPONENTS REAR BLACKOUT LAMPS AND TAlLLAMPS ILLUMINATING COMPONENTS (ALL EXCEPT M1010 AND M1031) REAR FENDER SIDE MARKERS M1028A2 AND M1082A3) REAR BLACKOUT LAMPS AND TAlLLAMP ILLUMINATING COMPONENTS (M1010 AND M1031) iii

5 TABLE OF CONTENTS (Con t) SENDING UNITS AND WARNING SWITCHES ENGINE OIL PRESSURE AND WATER TEMPERATURE SENDING UNITS HORN, SIREN TRUCK HORN AND RELATED PARTS BATTERIES, STORAGE BATTERIES, BATTERY TRAYS, AND RELATED PARTS CABLES AND SLAVE CONNECTOR HULL OR CHASSIS WIRING HARNESS FRONT WIRING HARNESS BODY AND FUEL SENDING WIRING HARNESSES (ALL EXCEPT M1009) BODY AND FUEL SENDING WIRING HARNESSES (M1009) BLACKOUT AND TAlLLAMP WIRING HARNESS (ALL EXCEPT M1010 AND M1031) AND TRAILER WIRING HARNESS (ALL EXCEPT M1010) REAR FENDER WIRING HARNESS (M1028A2 AND M1028A3) BLACKOUT AND TAlLLAMP WIRING HARNESSES (M1010 AND M1031) INSTRUMENT PANEL EXTENSION WIRING HARNESS (M1010) ENGINE WIRING HARNESS (ALL EXCEPT M1010) ENGINE WIRING HARNESS (M1010) GLOW PLUG WIRING HARNESS HEATER CONTROL, DIAGNOSTIC, AND DOOR ALARM WIRING HARNESSES.. Page Illus Fig GROUP 07 TRANSMISSION TRANSMISSION SHIFTING COMPONENTS SHIFTING LINKAGE VACUUM MODULATOR VALVE TRANSMISSION ASSEMBLY AND ASSOCIATED PARTS TRANSMISSION ASSEMBLY AND MOUNTS TORQUE CONVERTER, OIL PAN, AND FILLER TUBE FORWARD AND DIRECT CLUTCH ASSEMBLIES CENTER SUPPORT REACTION CARRIER, AND OUTPUT CARRIER ASSEMBLIES TRANSMISSION CASE PARKING LOCK SERVO UNIT CONTROL VALVE ASSEMBLY GOVERNOR ASSEMBLY, AND SERVO VALVE UNIT CONTROL VALVE COMPONENT PARTS COOLERS, PUMPS, MOTORS OIL PUMP ASSEMBLY AND TRANSMISSION FILTER TRANSMISSION OIL COOLER LINES GROUP 08 TRANSFER, FINAL DRIVE, PLANETARY AND DROP GEARBOX ASSEMBLIES POWER TRANSFER, FINAL DRIVE, PLANETARY OR DROP GEARBOX ASSEMBLIES TRANSFER CASE ASSEMBLY AND ADAPTER (MODEL 208) TRANSFER CASE ASSEMBLY AND ADAPTER (MODEL 205) TRANSFER CASE COMPONENT PARTS (MODEL 208) TRANSFER CASE COMPONENT PARTS (MODEL 205) TRANSFER CASE HOUSING (MODEL 205) CASE VENT COMPONENT PARTS GEARSHIFT, VACUUM BOOSTER, AND CONTROLS GEARSHIFT LEVER AND LINKAGE (MODEL 208) GEARSHIFT LEVER AND LINKAGE (MODEL 205) iv

6 TABLE OF CONTENTS (Con t) Page Illus Fig GROUP 09 PROPELLER, PROPELLER SHAFTS, UNIVERSAL JOINTS, COUPLER, AND CLAMP ASSEMBLY PROPELLER SHAFTS FRONT PROPELLER SHAFT ASSEMBLY (ALL EXCEPT M1009, FIRST DESIGN)... FRONT PROPELLER SHAFT ASSEMBLY (ALL EXCEPT M1009, SECOND DESIGN) FRONT PROPELLER SHAFT ASSEMBLY (M1008, FIRST DESIGN) FRONT PROPELLER SHAFT ASSEMBLY (M1009, SECOND DESIGN) REAR PROPELLER SHAFT ASSEMBLY GROUP 10 FRONT AXLE FRONT AXLE ASSEMBLY FRONT AXLE FRONT AXLE BREATHER FRONT AXLE COMPONENT PARTS AND SPINDLE ASSEMBLIES (ALL EXCEPT M1009) FRONT AXLE COMPONENT PARTS AND SPINDLE ASSEMBLIES (M1009) DIFFERENTIAL DIFFERENTIAL ASSEMBLY RING, PINION, AND RELATED PARTS (ALL EXCEPT M1009) DIFFERENTIAL COMPONENTS (M1009) RING AND PINION (M1009) STEERING AND LEANING WHEEL MECHANISM STEERING KNUCKLE ASSEMBLY (ALL EXCEPT M1009) STEERING KNUCKLE ASSEMBLY (M1009) GROUP 11 REAR AXLE REAR AXLE ASSEMBLY REAR AXLE REAR AXLE BREATHER (ALL EXCEPT M1009) REAR AXLE BREATHER (M1009) AXLE SHAFTS (ALL EXCEPT M1009) REAR AXLE SHAFTS (M1009) HOUSING, BEAM, HOUSING COVERS, PLUGS, SEALS, ETC REAR AXLE HOUSING (ALL EXCEPT M1009) REAR AXLE HOUSING (M1009) DIFFERENTIAL DIFFERENTIAL LOCK ASSEMBLY, RING, PINION, AND RELATED PARTS (ALL EXCEPT M1009, M1028A2, AND M1028A3) DIFFERENTIAL LOCK ASSEMBLY RING, PINION, AND RELATED PARTS (M1028A2 AND M1028A3) DIFFERENTIAL LOCK ASSEMBLY RING, PINION, AND RELATED PARTS (M1009) DIFFERENTIAL LOCK ASSEMBLY COMPONENT PARTS (M1009) GROUP 12 BRAKES HANDBRAKES PARKING BRAKE PEDAL AND RELEASE MECHANISM SERVICE BRAKES REAR BRAKESHOE ASSEMBLY COMPONENTS, FRONT BRAKE PADS, AND RELATED PARTS (ALL EXCEPT M1009) REAR BRAKESHOE ASSEMBLY COMPONENTS, FRONT BRAKE PADS, AND RELATED PARTS (M1009) v

7 TABLE OF CONTENTS (Con t) Page Illus Fig HYDRAULIC BRAKE SYSTEM POWER BOOSTER AND MASTER CYLINDER ASSEMBLIES FRONT BRAKE LINES AND RELATED PARTS REAR BRAKE LINES, WEIGHT PROPORTIONAL VALVE, AND RELATED PARTS... FRONT BRAKE CALIPER ASSEMBLIES (ALL EXCEPT M1009) FRONT BRAKE CALIPER ASSEMBLIES (M1009) REAR BRAKE WHEEL CYLINDER MECHANICAL BRAKE SYSTEM BRAKE PEDAL, MOUNTING BRACKETS, AND RELATED PARTS GROUP 13 WHEELS AND TRACKS WHEEL ASSEMBLY FRONT HUB, ROTOR, REAR HUB, BRAKEDRUM, AND RELATED PARTS (ALL EXCEPT M1009) FRONT HUB, ROTOR, BRAKEDRUM, AND RELATED PARTS (M1009) TIRES, TUBES, TIRE CHAINS TIRES GROUP 14 STEERING MECHANICAL STEERING GEAR ASSEMBLY STEERING WHEEL AND COLUMN PITMAN ARM, ABSORBER, AND RELATED PARTS TIE-ROD ASSEMBLY (ALL EXCEPT M1009) TIE-ROD ASSEMBLY (M1009) POWER STEERING GEAR ASSEMBLY POWER STEERING GEAR AND COMPONENT PARTS HYDRAULIC PUMP OR FLUID MOTOR ASSEMBLY HYDRAULIC PUMP HYDRAULIC PUMP COMPONENT PARTS HOSES, LINES, FlTTINGS HYDRAULIC STEERING LINES GROUP 15 FRAME, TOWING ATTACHMENTS, DRAWBARS, AND ARTICULATION SYSTEMS FRAME ASSEMBLY FRONT BUMPER AND RELATED PARTS REAR BUMPER AND MOUNTING PARTS (ALL EXCEPT M1009 AND M1010)..... REAR BUMPER AND MOUNTING PARTS (M1009) REAR TIE-DOWNS (M1031) FRAME ASSEMBLY COMPONENTS (ALL EXCEPT M1009) FRAME ASSEMBLY RELATED PARTS (ALL EXCEPT M1009) FRAME ASSEMBLY COMPONENTS (M1009) FRAME ASSEMBLY RELATED PARTS (M1009) PINTLES AND TOWING ATTACHMENTS CLEVISES AND SUPPORTS PINTLE ASSEMBLY AND CLEVIS (M1008, M1028, AND M1028A1) PINTLE ASSEMBLY AND CLEVIS (M1009) SPARE WHEEL CARRIER AND TIRE LOCK SPARE WHEEL CARRIER (ALL EXCEPT M1009) SPARE WHEEL CARRIER (M1009) vi

8 TABLE OF CONTENTS (Con't) Page Illus Fig GROUP 16 SPRINGS AND SHOCK ABSORBERS SPRINGS FRONT SPRINGS AND RELATED PARTS (ALL EXCEPT M1009) FRONT SPRINGS AND RELATED PARTS (M1009) REAR SPRINGS AND RELATED PARTS (ALL EXCEPT M1009, M1028, M1028A1, M1028A2, AND M1028A3) REAR SPRINGS AND RELATED PARTS (M1028,M1028A1, M1028A2, AND M1028A3) REAR SPRINGS AND RELATED PARTS (M1009) SHOCK ABSORBER EQUIPMENT FRONT SHOCK ABSORBERS REAR SHOCK ABSORBERS (ALL EXCEPT M1009) REAR SHOCK ABSORBERS (M1009) TORCMJE, RADIUS, AND STABILIZER RODS FRONT STABILIZER BAR REAR STABILIZER BAR (M1028A2 AND M1028A3) GROUP 18 BODY, CAB, HOOD, AND HULL BODY, CAB, HOOD, AND HULL ASSEMBLIES BRUSH GUARD AND GRILLE FRONT MOLDINGS FRONT SUPPORT PANELS COWL TOP VENTILATOR PANEL FRONT HOOD LATCH RELEASE CABLE FRONT HOOD, LATCH, AND HINGES INSTRUMENT PANEL TRIM INSTRUMENT PANEL COMPONENTS SIDE DOORS AND COMPONENTS INSIDE DOOR TRIM PANEL AND RELATED PARTS SIDE DOOR WINDOW REGULATOR SIDE DOOR COMPONENTS SIDE DOOR LOCK ASSEMBLY SIDE DOOR WEATHERSTRIPS BODY CAB MOUNTING (M1009) CARGO BOX AND COMPONENTS (M1008, M1008A1, M1028, M1028A1, M1028A2, AND M1028A3) CARGO BOX MOUNTING (M1008, M1008A1, M1028, M1028A1, M1028A2, AND M1028A3) BODY CARGO AND COMPONENTS (M1009) CARGO ENDGATE AND COMPONENTS (M1008,M1008A1, M1028, M1028A1, M1028A2, AND M1028A3) ENDGATE AND COMPONENTS (M1009) ENDGATE WINDOW HANDLE ASSEMBLY (M1009) ENDGATE HINGES AND RELATED PARTS (M1009) ENDGATE LATCHES AND RELATED PARTS (M1009) ENDGATE TORQUE RODS (M1009) ENDGATE LATCH HANDLE (M1009) ENDGATE WEATHERSTRIPS (M1009) TOP ASSEMBLY AND COMPONENTS (M1009) FRONT TIE-DOWN BRACKETS (M1028, M1028A1, M1028A2, AND M1028A3) vii

9 TABLE OF CONTENTS (Con t) Page Illus Fig BODY, CAB, HOOD, AND HULL ASSEMBLIES [Con t) REAR TIE-DOWN BRACKETS (M1028,M1028A1, M1028A2, AND M1028A3) CARGO TIE-DOWNS (M1008 AND M1008A1) JACK STOWAGE COMPONENTS (ALL EXCEPT M1009) JACK STOWAGE COMPONENTS (M1009) FENDERS, RUNNING BOARDS WITH MOUNTING AND ATTACHING PARTS, OUTRIGGERS, WINDSHIELD, GLASS, ETC WINDSHIELD AND WINDOW GLASS FRONT FENDERS, INNER WHEEL PANELS, AND RELATED PARTS REAR FENDER AND RELATED PARTS (M1028A2 AND M1028A3) FLOORS, SUBFLOORS, AND RELATED COMPONENTS FLOORMATS, INSULATORS, AND RELATED PARTS UPHOLSTERY, SEATS, AND CARPETS SUNVISOR AND INSTRUMENT PANEL PAD SEATBELTS AND MOUNTING PARTS (ALL EXCEPT M1009 AND M1010) BENCH SEAT AND COMPONENT S (ALL EXCEPT M1009 AND M1010) DRIVER S SEATBELT AND MOUNTING PARTS (M1009) PASSENGER S SEATBELT AND MOUNTING PARTS (M1009) DRIVER S SEAT ADJUSTER ASSEMBLY (M1009) PASSENGER S SEAT ADJUSTER ASSEMBLY (M1009) DRIVER S SEAT ASSEMBLY AND COMPONENTS (M1009) PASSENGER S SEAT ASSEMBLY AND COMPONENTS (M1009) REAR BENCH SEAT ASSEMBLY AND COMPONENTS (M1009) SEATBELTS AND MOUNTING PARTS (M1010) SEAT ASSEMBLY, DRIVER S SEAT, ADJUSTER ASSEMBLY AND RELATED PARTS (M1010) SEAT MOUNTING PARTS (M1010) STOWAGE RACKS, BOXES, STRAPS, CARRYING CASES, CABLE REELS, HOSE REELS, ETC COMMUNICATIONS RACK ASSEMBLY AND RELATED PARTS (M1028A1) WEAPONS MOUNT (ALL EXCEPT M1010) BRACKETS AND MOUNTING PARTS SPECIAL PURPOSE BODIES BODY ASSEMBLY (M1010) LEFT SIDE OUTER PANEL COMPONENT PARTS (M1010) RIGHT SIDE OUTER PANEL COMPONENT PARTS (M1010) ROOF PANEL COMPONENT PARTS (M1010) REAR FRAME COMPONENT PARTS (M1010) LEFT REAR DOOR ASSEMBLY (M1010) RIGHT REAR DOOR ASSEMBLY (M1010) REAR BUMPER AND STEP ASSEMBLY (M1010) LEFT SIDE INNER PANEL RELATED PARTS (M1010) RIGHT SIDE INNER PANEL RELATED PARTS (M1010) LEFT SIDE STOWAGE BOX ASSEMBLY AND COMPONENT PARTS (M1010)..... RIGHT SIDE STOWAGE BOX ASSEMBLY AND COMPONENT PARTS (M1010).... RELAY PANEL ASSEMBLY COMPONENTS AND RELATED PARTS (M1010) ATTENDANT S SEAT ASSEMBLY AND COMPONENT PARTS (M1010) UPPER LlTTER ASSEMBLY AND COMPONENT PARTS (M1010) FRONT HALF-PARTITION ASSEMBLY (M1010) INTERIOR FOCUS LIGHT (M1010) FRONT FRAME ASSEMBLY COMPONENTS (M1010) INTERIOR SLIDING DOOR ASSEMBLY AND COMPONENT PARTS (M1010) PULLMAN COLLAR AND RELATED PARTS (M1010) Viii

10 TABLE OF CONTENTS (Con t) Page Illus Fig GROUP 22 BODY, CHASSIS, AND HULL ACCESSORY ITEMS CANVAS, RUBBER, OR PLASTIC ITEMS CARGO COVER ASSEMBLY (M1008 AND M1008A1) COVER FRAME COMPONENTS (M1008 AND M1008A1) CARGO COVER MOUNTING PARTS (M1008 AND M1008A1) ACCESSORY ITEMS WINDSHIELD WIPER MOTOR AND PUMP ASSEMBLY, WIPER ARM LINK ASSEMBLY WIPER BLADE ASSEMBLY AND RELATED PARTS WIPER MOTOR COMPONENT PARTS REARVIEW MIRRORS ANTENNA MOUNTING (ALL EXCEPT M1009 AND M1010) RADIO AND ANTENNA BRACKETS (M1009) RADIO, FIRE EXTINGUISHER, AND ANTENNA BRACKETS (M1010) WINTERIZATION EQUIPMENT HEATER ASSEMBLY, HEATER ASSEMBLY COMPONENTS HEATER BLOWER MOTOR ASSEMBLY AND COMPONENT PARTS HEATER ASSEMBLY AIR DUCTS HEATER CABLE AND CONTROL ASSEMBLY HEATER HOSES PERSONNEL HEATER ASSEMBLY (M1010) WARM AIR HEATER COMPONENT PARTS (M1010) PERSONNEL HEATER CONTROL COMPONENTS (M1010) WARM AIR HEATER VALVE ASSEMBLY COMPONENT PARTS (M1010) WARM AIR HEATER BLOWER ASSEMBLY COMPONENT PARTS (M1010) WARM AIR HEATER BURNER ASSEMBLY COMPONENT PARTS (M1010).. PERSONNEL HEATER FUEL PUMP LINES, AND RELATED PARTS (M1010).... PERSONNEL HEATER FUEL LINES AND RELATED PARTS (M1010) GROUP 33 SPECIAL PURPOSE KITS REUSABLE SHIPPING CONTAINERS ENGINE SHIPPING CONTAINER ASSEMBLY WINTERIZATION KITS TRANSMISSION AND OIL PAN AUXILIARY HEATER FUEL PUMP, LINES, AND RELATED PARTS (M1008) WARM AIR HEATER EXHAUST (ALL EXCEPT M1010) WARM AIR HEATER EXHAUST (M1010) COOLANT HEATER EXHAUST COOLANT HEATER REAR EXHAUST ENGINE OIL COOLER LINES ENGINE COOLANT CROSSOVER HOUSING, HOSES, AND FITTINGS., COOLANT HEATER, FUEL FILTER, FUEL LINE, AND MOUNTING BRACKETS..... ENGINE COOLANT HEATER COMPONENT PARTS WARM AIR HEATER WIRING HARNESS COOLANT HEATER WIRING HARNESS WARM AIR FUEL PUMP EXTENSION HARNESS (M1010) BATTERY BOXES AND CABLES PERSONNEL HEATER WIRING HARNESS DOMELIGHT LAMP AND WIRING HARNESS (M1008 AND M1008A1) HOOD AND RADIATOR INSULATORS ix

11 TABLE OF CONTENTS (Con t) Page Illus Fig WINTERIZATION KITS (Con t) ROOF COVER, INTAKE DEFLECTOR, WINDOW, VENT AND RELATED PARTS (M1008 AND M1008A1) ROOF AND ENDGATE COVERS AND MOUNTING PARTS (M1009) REAR DOOR ASSEMBLY (M1008) REAR PANEL COMPONENTS (M1008) ROOF PANEL COMPONENTS (M1008) FLOOR AND SIDEWALL PANELS (M1008) FLOOR AND SIDEWALL PANELS (M1009) CAB FLOOR INSULATORS SEAT AND SPARE TIRE SPACERS (M1009) BASE HEATER INLET HOSE, PIPE, AND RELATED PARTS BASE HEATER OUTLET HOSE, PIPE, AND RELATED PARTS HEATER CONTROL MOUNTING AND CABLE HEATER CONTROL ASSEMBLY COMPONENT PARTS HEATER AND MOUNTING PARTS HEATER BLOWER AND HOSES BLOWER COMPONENT PARTS INLET HOSE AND EXHAUST PIPE PERSONNEL/CARGO HEATER (M1008) SPECIAL PURPOSE KITS TROOP SEAT ASSEMBLY AND COMPONENT PARTS GROUP 39 SEARCHLIGHT AND ELECTRICAL ILLUMINATING EQUIPMENT SEARCHLIGHT OR ILLUMINATING LIGHT ASSEMBLY SPOTLIGHT ASSEMBLY AND COMPONENT PARTS (M1010) GROUP 47 GAGES (NONELECTRICAL), WEIGHING AND MEASURING DEVICES INSTRUMENTS SPEEDOMETER AND CABLE ASSEMBLY AND RELATED PARTS GROUP 52 REFRIGERATION, AIR CONDITIONER/HEATER, AND AIR CONDITIONING COMPONENTS AIR CONDITIONER/HEATER ASSEMBLY AND GAS COMPRESSOR ASSEMBLY AIR CONDITIONER ASSEMBLY (M1010) AIR OUTLET BOX AND CONTROL PANEL ASSEMBLY COMPONENT PARTS (M1010) MAIN CASE ASSEMBLY AND COMPONENT PARTS (M1010) GAS COMPRESSOR ASSEMBLY AND MOUNTING BRACKETS (M1010)..... GAS COMPRESSOR COMPONENT PARTS (M1010) REFRIGERANT PIPING GAS COMPRESSOR HOSES (M1010) CONDENSER, CONDENSER, COVER ASSEMBLY AND COMPONENT PARTS (M1010) EVAPORATOR EVAPORATOR ASSEMBLY COMPONENT PARTS AND RELATED PARTS (M1010) BLOWER ASSEMBLY BLOWER ASSEMBLY COMPONENT PARTS (M1010) GROUP 94 REPAIR KITS REPAIR KITS REPAIR KITS KITS-1 KITS-1 KITS x

12 TABLE OF CONTENTS (Con t) Page Illus Fig GROUP 95 GENERAL USE STANDARDIZED PARTS BULK MATERIEL BULK MATERIEL BULK-1 BULK-1 BULK SECTION Ill. GROUP 26 SPECIAL TOOLS TOOLS AND TEST EQUIPMENT SPECIAL TOOLS SPECIAL TOOLS SPECIAL TOOLS SPECIAL TOOLS SPECIAL TOOLS SPECIAL TOOLS SECTION IV. CROSS-REFERENCE INDEXES NATIONAL STOCK NUMBER INDEX PART NUMBER INDEX FIGURE AND ITEM NUMBER INDEX l-1 I-54 I-166 xi/(xii Blank)

13 DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LISTS (INCLUDING DEPOT MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LISTS) SECTION I. INTRODUCTION 1. Scope. This RPSTL lists and authorizes spares and repair parts; special tools; special test, measurement, and diagnostic equipment (TMDE); and other special support equipment required for performance of Unit, Direct Support, and General Support Maintenance of the CUCV Series Truck. It authorizes the requisitioning, issue, and disposition of spares, repair parts and special tools as indicated by the source, maintenance and recoverability (SMR) codes. 2. General. In addition to Section I. Introduction, this Repair Parts and Special Tools List is divided into the following sections: a. Section Il. Repair Parts List. A list of spares and repair parts authorized by this RPSTL for use in the performance of maintenance. The list also includes parts which must be removed for replacement of the authorized parts. Parts lists are composed of functional groups in ascending alphanumeric sequence, with the parts in each group listed in ascending figure and item number sequence. Bulk materials are listed in item name sequence, Repair kits are listed separately in their own functional group within Section Ii. Repair parts for reparable special tools are also listed in the section. Items listed are shown on the associated illustration(s)/figure(s). b. Section III. Special Tools List. A list of special tools, special TMDE, and other special support equipment authorized by this RPSTL (as indicated by Basis of Issue (BOI) information in DESCRIPTION AND USABLE ON CODE column) for the performance of maintenance. c. Section IV. Cross-reference Indexes. A list, in National Item Identification Number (NIIN) sequence, of all National stock numbered items appearing in the listing, followed by a list in alphanumeric sequence of all part numbers appearing in the listings, National stock numbers and part numbers are cross-referenced to each illustration/figure and item number appearance. The figure and item number index lists figure and item numbers in alphanumeric sequence and cross-references NSN, CAGE, and part numbers. 3. Explanation of Columns (Sections II and III). a. ITEM NO. (Column (1)). Indicates the number used to identify items called out in the illustration. b. SMR CODE (Column (2)). The Source, Maintenance, and Recoverability (SMR) code is a 5-position code containing supply/requisitioning information, maintenance category authorization criteria, and disposition instructions, as shown in the following breakout: 1st two positions Who can install, replace, or use the item. Source Code How you get an item. Maintenance Code Recoverability Code Who can do complete repair* on the item. Who determines disposition action on an unserviceable item. 5th position Complete Repair: Maintenance capacity, capability, and authority to perform all corrective maintenance tasks of the Repair function in a use/user environment in order to restore serviceability to a failed item. (1) Source Code. The source code tells you how to get an item needed for maintenance, repair, or overhaul of an end item/equipment. Explanations of source codes follows: 1

14 Code PA PB PC** PD PE PF PG KD KF KB MO-(Made at UM/ AVUM Level) MF-(Made at DS/ AVUM Level) MH-(Made at GS Level) ML-(Made at Specialized Repair Activity (SRA)) MD-(Made at Depot) AO-(Assembled by UM/ AVUM Level) AF-(Assembled by DS/AVIM Level) AH-(Assembled by GS Category) AL-(Assembled by SRA) AD-(Assembled by Depot) XA - XB - Aplication/Explanation Stocked Items; use the applicable NSN to request/requisition items with these source codes. They are authorized to the category indicated by the code entered in the 3d position of the SMR code. ** Items coded PC are subject to deterioration. Items with these codes are not to be requested/requisitioned individually. They are part of a kit which is authorized to the maintenance category indicated in the 3d position of the SMR code. The complete kit must be requisitioned and applied. Items with these codes are not to be requested/requisitioned individually. They must be made from bulk material which is identified by the part number In the DESCRIPTION AND USABLE ON CODE (UOC) column and listed in the Bulk Material group of the repair parts list in this RPSTL. If the item is authorized to you by the 3d position code of the SMR code, but the source code indicates it is made at a higher level, order the item from the higher level of maintenance. Items with these codes are not to be requested/requisitioned individually. The parts that make up the assembled item must be requisitioned or fabricated and assembled at the Ievel of maintenance indicted by the source code. If the 3d position code of the SMR code authorizes you to replace the item, but the source code indicates the item is assembled at a higher level, order the item from the higher level of maintenance. Do not requisition an XA -coded item. Order its next higher assembly. (Also refer to the NOTE following.) If an XB item is not available from salvage, order it using the CAGE and part number given. XC - XD - Code Installation drawing, diagram, instruction sheet, field service drawing, that is identified by the manufacturer s part number. Item is not stocked. Order an XD -coded item through normal supply channels using the CAGE and part number given, if no NSN is available. NOTE: Cannibalization or controlled exchange, when authorized, may be used as a source of supply for items with the above source codes, except for those source coded XA or those aircraft support items restricted by requirements of AR (2) Maintenance Code. Maintenance codes tell you the level(s) of maintenance authorized to USE and REPAIR support items. The maintenance codes are entered in the third and fourth positions of the SMR code as follows: (a) The maintenance code entered in the third position tells you the lowest maintenance level authorized to remove, replace, and use an item. The maintenance code entered in the third position will indicate authorization to one of the following levels of maintenance. Code Application/Explanation C- Crew or operator maintenance done within unit maintenance or aviation unit maintenance. O- Unit maintenance or aviation unit category can remove, replace, and use the item. F- Direct support or aviation intermediate level can remove, replace, and use the item. H- General support level can remove, replace, and use the item. L- Specialized repair activity can remove, replace, and use the item. D- Depot level can remove, replace, and use the item. (b) The maintenance code entered in the fourth position tells whether or not the item is to be repaired and identifies the lowest maintenance level with the capability to do complete repair (i.e., perform all authorized repair functions). (NOTE: Some limited repair may be done on the item at a lower level of maintenance, if authorized by the Maintenance Allocation Chart (MAC) and SMR codes.) This position will contain one of the following maintenance codes: Application/E xplanation O- Unit maintenance or aviation unit is the lowest level that can do complete repair of the item. F- Direct support or aviation intermediate is the lowest level than can do complete repair of the item. 2

15 H- General support Is the lowest level that can do complete repair of the item. L- Specialized repair activity is the lowest level that can do complete repair of the item. D- Depot is the lowest level that can do complete repair of the item. Z- Nonreparable. No repair is authorized. B- No repair is authorized, (No parts or special tools are authorized for the maintenance of a B -coded item.) However, the item maybe reconditioned by adjusting, lubricating, etc., at the user level. (3) Recoverability Code. Recoverability codes are assigned to items to indicate the disposition action on unserviceable items. The recoverability code is entered in the fifth position of the SMR code as follows: Code Application/Explanation Z- Nonreparable item. When unserviceable, condemn and dispose of the item at the level of maintenance shown in the 3d position of the SMR code, O- Reparable item. When uneconomically reparable, condemn and dispose of the item at unit maintenance or aviation unit level. F- Reparable item. When uneconomically reparable, condemn and dispose of the item at the direct support or aviation intermediate level. H- Reparable item. When uneconomically reparable, condemn and dispose of the item at the general support level. D- Reparable item. When beyond lower level repair capability, return to depot. Condemnation and disposal of item not authorized below depot level. L- Reparable item. Condemnation and disposal of item not authorized below specialized repair activity (SRA). A- Item requires special handling or condemnation procedures because of specific reasons (e.g., precious metal content, high dollar value, critical material, or hazardous material). Refer to appropriate manuals/directives for specific instructions. C. CAGEC (Column (3)). The Commercial and Government Entity (CAGE) Code (C) is a 5-digit alphanumeric code which is used to identify the manufacturer, distributor, or Government agency, etc., that supplies the item. d. PART NUMBER (Column (4)). Indicates the primary number used by the manufacturer (individual, company, firm, corporation, or Government activity), which controls the design and characteristics of the item by means of its engineering drawings, specifications standards, and inspection requirements to identity an item or range of items. NOTE: When you use an NSN to requisition an item, the item you receive may have a different part number from the part ordered. e. DESCRIPTION AND USABLE ON CODE (UOC) (Column (5)). This column includes the following information: (1) The Federal item name and, when required, a minimum description to identify the item. (2) Physical security classification. Not Applicable. (3) Items that are included in kits and sets are listed below the name of the kit or set on Figure KIT. (4) Spare/repair parts that make up an assembled item are listed immediately following the assembled item line entry. (5) Part numbers for bulk materials are referenced in this column in the line item entry for the item to be manufactured/fabricated. (6) When the item is not used with all serial numbers of the same model, the effective serial numbers are shown on the last line(s) of the description (before UOC). (7) The usable on code, when applicable (see paragraph 5, Special Information). (8) In the Special Tools List section, the basis of issue (BOI) appears as the last line(s) in the entry for each special tool, special TM DE, and other special support equipment. When density of equipments supported exceeds density spread indicated in the basis of issue, the total authorization is increased proportionately. (9) The statement END OF FIGURE appears just below the last item description in Column 5 for a given figure in both Section II and Section Ill. f. (QTY (Column (6)). The QTY (quantity per figure column) indicates the quantity of the item used in the breakout shown on the illustration/figure, which is prepared for a functional group, subfunctional group, or an assembly. A V appearing in this column in lieu of a quantity indicates that the quantity is variable and the quantity may vary from application to application. 4. Explanation of Columns (Section IV). a. NATIONAL STOCK NUMBER (NSN) INDEX. (1) STOCK NUMBER column. This column lists the NSN by National Item Identification Number (NIIN) 3

16 sequence. The NIIN consists of the last nine digits of the NSN (i.e., ). When using this column to locate an item, ignore the first 4 digits of the NSN. However, the complete NSN should be used when ordering items by stock number. (2) FIG. column. This column lists the number of the figure where the item is identified/located. The figures are in numerical order in Section II and Section Ill. (3) ITEM column. The item number identifies the item associated with the figure listed in the adjacent FIG. column. This item is also identified by the NSN listed on the same line. b. PART NUMBER INDEX. Part numbers in this index are listed by part number in ascending alphanumeric sequence (i.e., vertical arrangement of letter and number combination which places the first letter or digit of each group in order A through Z, followed by the numbers O through 9 and each following letter or digit in like order). (1) CAGEC column. The Commercial and Government Entity (CAGE) Code (C) is a 5-digit alphanumeric code used to identify the manufacturer, distributor, or Government agency, etc., that supplies the item. (2) PART NUMBER column. Indicates the primary number used by the manufacturer (individual, firm, corporation, or Government activity), which controls the design and characteristics of the item by means of its engineering drawings, specifications standards, and inspection requirements to identify an item or range of items. (3) STOCK NUMBER column. This column lists the NSN for the associated part number and manufacturer identified in the PART NUMBER and CAGE columns to the left. (4) FIG. column. This column lists the number of the figure where the item is identified/located in Sections II and Ill. (5) ITEM column. The item number is that number assigned to the item as it appears in the figure referenced in the adjacent figure number column. c. FIGURE AND ITEM NUMBER INDEX. (1) FIG. column. This column lists the number of the figure where the item is identified/located in Sections II and Ill. (2) ITEM column. The item number is that number assigned to the item as it appears in the figure referenced in the adjacent figure number column. (3) STOCK NUMBER column. This column lists the NSN for the item. (4) CAGE column. The Commercial and Government Entity (CAGE) is a 5-digit alphanumeric code used to identify the manufacturer, distributor, or Government agency, etc., that supplies the item. (5) PART NUMBER column. Indicates the primary number used by the manufacturer (individual, firm, corporation, or Government activity), which controls the design and characteristics of the item by means of its engineering drawings, specifications standards and inspection requirements to identify an item or range of items. 5. Special Information. a. USABLE ON CODE. The usable on code appears in the lower left corner of the Description column heading. Usable on codes are shown as UOC: in the Description column (justified Ieft) on the first line following applicable item description/nomenclature. Uncoded items are applicable to all models. Identification of the usable on codes used in the RPSTL are: Code Used On 194 M\1008,Type B Cargo, Shelter 208 M1008A1,Type B Cargo, Troop Seat 209 M1009, Type A Utility 210 M1010, Type C Ambulance 230 M 1028, Type E Shelter Carrier 252 M1028A1,Type F Shelter Carrier w/pto 254 M1028A2, Type F Shelter Carrier w/pto 256 M1028A3, Type E Shelter Carrier 231 M1031, Type D Chassis b. FABRICATION INSTRUCTIONS. Bulk materials required to manufacture items are listed in the Bulk Material Functional Group of this RPSTL. Part numbers for bulk materials are also referenced in the Description column of the line item entry for the item to be manufactured/fabricated. Detailed fabrication instructions for items source coded to be manufactured or fabricated are found in TM or TM c. ASSEMBLY INSTRUCTIONS. Detailed assembly instructions for items source coded to be assembled 4