Willys Ford GPW Technical Manual Download | Manualshive

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Summary of Contents for Ford GPW

Page 1: ...WAR DEPARTMENT TECHNICAL MANUAL TM 9 18034 ORDNANCE MAINTENANCE Engine and Engine Accessories For l d Ton 4x4 Truck Willys Overland Model MB and Ford Model GPW WAR DEPARTMENT 24 FEBRUARY 1944 ...

Page 2: ...A G 300 7 9 Ckt43 O O M 461 Rar Ar s 2 25 44 BYORDEROFTHE SECRETARYOF AR Chief of StatX OFFICIAL J A ULIO The Adjutant General DISTRIBUTION 4 ...

Page 3: ... 5 III Disassembly of engine into sub assemblies 6 7 IV Disassembly cleaning inspection repair and assembly of sub assemblies _ _ 8 17 V Assembly of engine 18 19 VI Installation of engine _ 20 2 1 VII Fits and tolerances _ _ 22 24 CHAPTER 3 CLUTCH ASSEMBLY _ _ ___ 25 28 REFERENCES INDEX 4 7 8 64 8 8 14 14 2 1 2 143 43 57 57 61 62 64 65 7 1 72 74 ...

Page 4: ... 9 803 contains information and guidance for the using arms and first and second echelons TM 9 1803B contains information for removal inspection re pair rebuild assembly and installation of the power train and chassis e TM 9 1825B contains information for the maintenance of the Auto Lite electrical equipment used on this vehicle f TM 9 1826A contains information for the maintenance of the Carter c...

Page 5: ...INTRODUCTION Figure 1 Front View of Engine 2 MWO AND MAJOR UNIT ASSEMBLY REPLACEMENT RECORD a Description b Instructions for Use ...

Page 6: ...TM OR0lNANCE MAINTENANCE ENGINE AND ENGINE ACCESSORIES FOR 14 TON 41x4 TRUCK WILLYS OVERLAND MODEL MB AND FORD MODEL GPW 9 1803A 2 Figure 2 left Side View of Engine Figure 3 Right Side View of Engine ...

Page 7: ...TM 9 1803A 2 INTRODUCTION Early Modifications ...

Page 8: ......

Page 9: ...Figure 4 Underside View of Engine Installed in Vehicle 4 ...

Page 10: ...Ollt Figure 5 Right Side View of Engine installed in Vehicle ...

Page 11: ... _ _ _ ...

Page 12: ...ACCESSORIES FOR 14 TON 4x4 TRUCK WILLYS OVERLAND MODEL MB AND FORD MODEL GPW b Remove Battery c Remove Radiator d Disconnect Oil and Water Temperature Gages Remove Air Cieaner Hose f Disconnect Eiectrical Wires and Bond Straps Remove Cranking Motor 12 ...

Page 13: ...TM 9 1803A ...

Page 14: ...LLYS OVERLAND MODEL MB AND FORD MODEL GPW k Remove Stay Cable and Clutch Housing Bolts 1 Remove Engiue From Vehicle Section III Paragraph _ _ _ _ 6 PRELIMINARY OPERATIONS a General b b Remove Carburetor Remove Fuel Pump fig 6 d Remove Distributor fig 5 Remove Oil Filter fig 5 i4 ...

Page 15: ...d II RA PD ...

Page 16: ...L Figure Three quarter Stripped ...

Page 17: ...TM 8 1803A 6 7 1 r RA PD 28667 Locks ...

Page 18: ...I ...

Page 19: ...s which are open become closed and remove the rest of the valve spring retainer locks Remove the valves and place them in a valve carry ing board so that they can be identified as to cylinders from which they were removed Compress the valve spring with the valve lifter on each valve tappet thatis in the closed position and pull the spring off the valve guide Turn the crankshaft until the tappets a...

Page 20: ... Rod and Assembly Removal ...

Page 21: ...Remove Piston and Connecting Rod Assemblies Remove Crankshaft DISASSEMBLY CLEANING INSPECTION REPAIR AND ASSEMBLY OF SUBASSEMBLIES Paragraph 8 8 CYLINDER BLOCK HEAD AND OIL PAN a Cleaning b Inspection and Repair 21 ...

Page 22: ... f RUR MAIN BEARING ap ...

Page 23: ...TM 9 1803A a ENGINE Figure 14 Driving Camshaft Bearing from Cylinder Block 2 HEAE fig be ...

Page 24: ...004 inch oversize and 0 004 inch oversize valve tappets must be installed when assembling engine If valve tappet bore will not clean up at 0 004 inch oversize the cylinder block must be replaced 4 REPLACE STUDS Remove all damaged studs with a standard stud puller To remove a broken stud indent the end of the broken stud exactly in the center with a center punch Drill approximately two thirds throu...

Page 25: ...5 Line ream the cam shaft bearing to 2 3145 inches 6 REPLACEVALVE GUIDES Remove the guides with a suitable valve guide remover When installing valve guides drive all intake and exhaust valve guides into the block with a valve guide replacer leaving a distance of 1 inch from the top of the guide to the top of the cylinder block for exhaust valve guides and a distance of lyre inches for the intake g...

Page 26: ... t RA PD 28802 ...

Page 27: ...d shaft assembly b Cleaning Clean all parts thoroughly in dry cleaning solvent c Inspection and Repair 1 WATER PUMP BODY fig 17 A cracked or damaged water pump body must be replaced 2 WATER PUMP IMPELLER fig 17 A water pump impeller that is cracked or that has a broken fin must be replaced 3 WATER PUMP PULLEY fig 17 A distorted or damaged water pump pulley must be replaced 27 ...

Page 28: ...pump bear ing and shaft assembly into the water pump pulley Press the water pump pulley and ujater pump bearing and shaft assembly into the front end of the water pump body until the groove on the bearing is in line with the small slot in the water pump body Dip a new water pump seal assembly and water pump seal washer in hydraulic brake fluid and install them in the water pump impeller Place the ...

Page 29: ...stons with cracks scores or damage of any kind must be replaced Determine the wear on the skirt of each piston at the bottom at right angles to the piston pin If the wear is 0 010 inch less than the original size or if the piston is out of round more than 0 005 inch the piston must be replaced Check the width of the ring grooves with new rings and a feeler gage fig 20 If the piston ring groove wea...

Page 30: ...M 9 1803A 10 ORDNANCE MAINTENANCE ENGINE AND ENGINE ACCESSORIES FOR 4 TON 4x4 TRUCK WILLYS OVERi AND MODEL MB AND FORD MODEL GPW Figure 21 Fitting Piston in Cylinder Bore Using Scale w fee err 4 1 s 498 ...

Page 31: ......

Page 32: ...ENGINE AND ENGINE ACCESSORIES FOR l 4 TON 4x4 TRUCK WILLYS OVERLAND MODE MB AND FORD MODEL GPW 28662 Figure 23 Measuring Piston Ring End Gap with Feeler Gage Assemble Piston Piston Pin and Connecting Rod f f Fit and Install Piston Rings ...

Page 33: ...s the top 11 CAMSHAFT ASSEMBLY a Cleaning Clean the camshaft camshaft sprocket camshaft thrust washer and camshaft thrust spring and plunger in dry cleaning solvent b Inspection and Repair A camshaft with excessively scored or damaged cams or with worn corroded scored or discolored journals must be replaced Inspect the camshaft oil pump drive gear If the teeth are worn broken or chipped the camsha...

Page 34: ...x PD 28659 ...

Page 35: ......

Page 36: ...lunger spring must be replaced 12 VALVE AND VALVE SPRINGS a Cleaning Scrape the carbon off the valve heads and stems Clean the valves and valve springs thoroughly in dry cleaning solvent b Inspection and Repair Valves with bent or scored stems must be replaced Measure the outside diameter of each valve stem fig 26 If measurement is less than 0 3685 inch for the exhaust valve or inch for the intake...

Page 37: ...TM 9 1803A ...

Page 38: ... OIL RA PD 28638 Figure 28 Oil Pump Disassembled ...

Page 39: ...TM 9 1803A Figure 29 Checking Oil Pump Relief Valve Spring Tension Using Tester 4 1 T 1600 ...

Page 40: ...RDNANCE MAINTENANCE ENGINE AND ENGINE ACCESSORIES FOR h TON 4x4 TRUCK WILLYS OVERLAND MODEL MB AND FORD MODEL GPW 15 CRANKSHAFT ASSEMBLY a Cleaning b Inspection and Repair Remove Crankshaft Sprocket fig 30 40 ...

Page 41: ...T RIVF PI II I FV YE 5 RA PD 28640 9 z 5 B ...

Page 42: ...ear with broken chipped or excessively worn teeth must be replaced subpars c and d below Measure the inside diameter of the main drive gear pilot bushing If more than 0 632 inch it must be replaced subpars c and d below If a new crankshaft or flywheel is being used it must be fitted as outlined in subparagraph e below c Disassembly Drive the main drive gear pilot bushing out of the flywheel Heat t...

Page 43: ...Fit Crankshaft to Flywheel When Either Part Is New 17 INTAKE AND EXHAUST MANIFOLDS a Disassembly b Cleaning Inspection and Repair b d Assembly __ _ 18 ASSEMBLY a Install Valves ...

Page 44: ... valve is in a closed position and the tappet is on the heel of the cam Hold the valve tappet with one wrench and turn the valve tappet adjusting screw with another wrench fig 33 clockwise or counterclockwise until O OlCinch clearance is established between the valve and the valve tappet adjusting screw Repeat the same procedure on each valve c Install Crankshaft If a new crankshaft or flywheel is...

Page 45: ...RA PD 28489 ...

Page 46: ...03A 18 ORDNANCE MAINTENANCE ENGINE AND ENGINE ACCESSORIES FOR 4 TON 4x4 TRUCK WILLIS OVERLAND MODEL MB AND FORD MODEL GPW RA PD 28695 34 Measuring Crankshaft End f Install Connecting Rod and Piston Assemblies ...

Page 47: ...PD 28692 puii ...

Page 48: ...in paragraph 16 e Fasten the engine rear plate temporarily to the engine with two bolts Turn the crankshaft until the No 1 and No 4 pistons are at top center Place the flywheel on the crankshaft flange so that the letters TC on the flywheel are lined up with the index mark at the center of the timing hole fig 38 in the engine rear plate and the index mark on the crankshaft flange and on the flywhe...

Page 49: ...t tool in the flywheel and the disk Hold the pressure plate on the flywheel and install but do not tighten six lock washers and cap screws fig 39 Tighten the six cap screws evenly to prevent bending the pressure plate frame Re move the clutch pilot Place a gasket and the engine front plate on the engine and install the three cap screws Turn the crank shaft until No 1 piston is at top center fig 38...

Page 50: ...ket from the camshaft being careful not to move the camshaft Place the camshaft thrust washer on the camshaft Place the camshaft drive chain on the crankshaft sprocket and cam shaft sprocket and install the camshaft sprocket on the camshaft with four lock washers and cap screws Tighten the four cap screws and bend the lock washer tabs down on the cap screws j Install Front Engine Cover Place the c...

Page 51: ...on Flywheel k ...

Page 52: ...18 ORDNANCE MAINTENANCE ENGINE AND ENGINE ACCESSORIES FOR l 4 TON 4x4 TRUCK WILLYS OVERLAND MODEL MB AND FORD MODEL GPW I RA PD 28631 40 n Install Oil Pump 52 ...

Page 53: ... r ...

Page 54: ...ORIES FOR l 4 TON 4x4 TRUCK WIiLYS OVERLAND MODEL MB AND FORD MODEL GPW RA CD 28792 Figure 42 IGN Timing Marks on Flywheel Install Water Outlet Elbow and Thermostat 19 INSTALLATION OF ACCESSORIES a Install Water Pump b Install Carburetor Install VII r liter fig 43 ...

Page 55: ...clamp Loosen the bolt in the dis tributor hold down clamp and turn the distributor until the points are just breaking Tighten the bolt in the distributor hold down clamp f Install Ignition Coil Install the ignition coil on the engine making sure the bond strap is in place behind the ignition coil bracket fig 43 Connect the primary wire to the coil and distributor g Install Fan Hold the fan in plac...

Page 56: ...9 1 ...

Page 57: ...TM 9 1803A 19 20 ENGINE 5 Install Accelerator Linkage k Install Engine Front Supports Section VI INSTALLATION OF ENGINE 20 INSTALLATION a General b b b Place Engine in Vehicle ...

Page 58: ...IES FOR 14 TON 4x4 TRUCK WILLYS OVERLAND MODEL MB AND FORD MODEL GPW Install Clutch Control Lever and Cable d Install Cranking Motor Connect Oil Pressure and Water Temperature Gages f Connect Electrical Wires and Bond Straps Connect Choke and Throttle Controls on ...

Page 59: ...I RA PD 20794 h Install Air Cleaner Hose Connect Exhaust Pipe Install Radiator ...

Page 60: ...ock nut Turn the clutch control lever cable counterclockwise to decrease the pedal free travel and clockwise to increase the pedal free travel When a G inch free pedal travel is obtained tighten the clutch control lever cable adjusting yoke lock nut b Set Timing With Neon Light 1 PRELIMINARYWORK Loosen the screw in the timing hole cover and move the cover to one side Make certain the ignition swit...

Page 61: ...arm If the correct timing cannot be obtained by turning the distributor set the timing as out lined in paragraph 19 e but do not remove the distributor c Adjust Carburetor Start the engine and allow it to run until it reaches normal operating temperature Turn the idle fuel adjust ment screw fig 1 clockwise or counterclockwise until all indica tions of vibration and roll are eliminated from the eng...

Page 62: ...ANCE MAINTENANCE ENGINE AND ENGINE ACCESSORIES FOR 4mTON 4x4 TRUCK WIl LYS OVERLAND MODEL MB AND FORD MODEL GPW Section VII _ _ __ _ _ _ _ _ DEFINITION OF FITS a General b Ring Fit Slip Fit d d a Running Fit A ...

Page 63: ...Press Fit f Shrink Fit Effect of Expansion on Fits 23 FITS AND TOLERANCES CYLINDER BLOCK Fit Location Manufacturers Name Fit Tolerance Fit Wear limit 0 005 of Fit 0 003 ...

Page 64: ...ove clear ance all rings Piston ring gap all rings 0 0205 in to 0 0225 in 0 0005 in to 0 0015 in 0 008 in to 0 013 in 0 003 in 0 013 in VALVES AND VALVE SPRINGS Intake valve stem diameter 0 373 in Valve seat angle 45 degree Exhaust valve stem diam 0 3725 in eter Valve seat angle 45 degree Spring tension at 2 7 64 50 pounds inches all springs Spring tension at 13 4 116 pounds inches all springs OIL...

Page 65: ...25 26 CHAPTER 3 CLUTCH ASSEMBLY paragraph _ 25 DESCRIPTION AND DATA a Description b Data 26 PRESSURE PLATE DISASSEMBLY a Remove Clutch Adjusting Screw fig 47 ...

Page 66: ...TM 9 1803A 26 ORDlNANCE MAINTENANCE ENGINE AND ENGINE ACCESSORIES FOR d TON 41x4 TRUCK WILLYS OVERLAND MODEL MB AND FORD MODEL GPW RA PD Figure 46 Clutch Disk and Pressure Plate RA PD 28800 ...

Page 67: ...rn springs from the clutch pressure plate bracket 27 CLEANING INSPECTION AND REPAIR a Cleaning Clean all parts thoroughly in dry cleaning solvent b Inspection and Repair 1 CLUTCHPRESSURE PLATE fig 47 A ridged scored radial cracked or burned pressure plate must be replaced 2 PRESSUREPLATE BRACKET fig 47 A distorted pressure plate bracket or a pressure plate bracket with worn clutch fingers must be ...

Page 68: ...ORIES FOR l 4 TON 4x4 TRUCK WILLYS OVERLAND MODEL MB AND FORD MODEL GPW Figure 49 Removing Clutch Pressure Spring Cups and Clutch Pressure Springs 28 a Install Clutch Pressure Spring Cups and Springs h Install Pressure Plate on Pressure Plate Bracket 68 ...

Page 69: ...28 CLUTCH ASSEMBLY RA PD Figure 50 Testing Spring Tension of Clutch Pressure Spring Using Tester 4 I T 1600 c Adjust Pressure Plate h ...

Page 70: ...AINTENANCE ENGINE AND ENGINE ACCESSORIES FOR TON 4x4 TRUCK WILLYS OVERLAND MODEL MB AND FORD MODEL GPW L RA Pb 28799 Figure 51 Installing Clutch Pressure Spring Cups and Pressure Springs in Pressure Plate Bracket 70 ...

Page 71: ...CLUTCH RA PD 26795 Figure Adjusting Pressure Plate 71 ...

Page 72: ...nterest to ordnance personnel MWO s OPSR BSD S of SR s OSSC s and OFSB s and includes Alphabetical List of Major Items with Publications Pertain ing Thereto _ OFSB l l List of Publications for Training listing MR s MTP s T BA s T A s and FM s TM s and TR s concerning training _ FM 2 l 6 List of Training Films Film Strips and Film Bul letins listing TF s FS s and FB s by serial number and subject _...

Page 73: ...AR 850 15 Motor vehicle inspections and preventive mainte nance service _ _ _ TM 9 2810 Precautions in handling gasoline AR 850 20 Standard Military Motor Vehicles TM 9 2800 The internal combustion engine TM lo 570 Maintenance and Repair Cleaning preserving lubricating and welding ma terials and similar items issued by the Ordnance Department _ _ __ _ TM 9 850 Cold weather lubrication and service ...

Page 74: ...ieL Camouflage _ _ _ FM S 20 Chemical decontamination materials and equip ment __ _ _ _ _ TM 3 220 Decontamination of armored force vehicles _ FM 17 59 Defense against chemical attack _ FM 21 40 Explosives and demolitions FM 5 25 Storage and Shipment Ordnance storage and shipment chart group G Major items _ OSSC G Registration of motor vehicles _ AR 850 10 Rules governing the loading of mechanized...

Page 75: ...B C 75 ...

Page 76: ...TM 9 1803A ORDNANCE MAINTENANCE ENGINE AND ENGINE ACCESSORIES FOR h TON 4x4 TRUCK WILLYS OVERLAND MODEL MB AND FORD MODEL GPW c Cont d Pages a E a 59 F G Gages I M Seealso 76 ...

Page 77: ...T ...

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