WWII M3A1 Scout Car - Base Shop Data Manual

o Field 8 CAR, SCOUT, M3A1 WITH HERCULES ENGINE = Ato D- B.S.D. No's 1 to 20 VOLUME IT -E to R- B.$.D. No's 21 to 53 = Sto Z- BeS.D. No's 54 to 70 1 Item Accelerator (Pedal Linkage) ‘Mr Gleaner see ee eee sree sees 2 armor Plate &Metal Units ss... e+ +- 3 ‘xde, Rear, Assembly... 5.0 e eee ees 4 dole, Front, Assembly 222 e see F Battery ss ee eee eee eee eees § Bearings, Mains 2. e eee eee eres 7 Botton Pans csc eee ees 8 Breke, Boosters v2 e ees ete tt? Brake, Parking (Lever & Linkage)... +. 10 Brake Pedal & Cluteh Linkege. = +++ +--+ 1 Carmuretors sve cee Sessa Clutch & Flywheel ses ee ee See Connecting Rods & Bearings. - . . - ieee Cowl & Fenders. ++ eee eee eae Crankshaft . 2s see eee eee Cylinder Head | se ee ee Paes Distributor & Shielding Assembly... +. + Duck Top Supports & Canvas Accessories. . . + Re BbOrdnance Field Servi. Shop Data, CAR, SCOUT, M3Al WITH HERCULES ENGINE IST OF CONTENTS VOLUME I-AtoD-B.S.D. Mo's 1 to 20 VOLUME II-E to R- o's 21 to 53 VOLUME III -S to Z~- B.S.D. No's 54 to 70 OLIME I pecrteecteesiiceed as Derateeete % Sates teraie 25 eae teras 26 eset ats 21 Serene icrar iii vee BO tee teat eeere res A Horn Relays ss see eee ee Hydraulic Master Cylinder & Lines... .- + 34 Idler Geer se ee eee ee eee Ignition Coil, Shield & Filter Assem. . « Instrument Panel. . 2 ee ee eee eee es Lampe, Blackout +++ sees eee eee Lamps, Head ee ee Lomps, Tail vce ee es MO Machine Gun Tracks sees eee eee ees Ab Manifolds see eee ee eee ees Motor Starter sso tee ee ees Muffler & Pipe see eee eee ee ee Ah Pintle Hook se eee eee ee ee ee ees AS Piston Rings & Wrist Ping sss .+ ee ee Ab Pump, Fuel. ee eee ee eee eee AF Pump, Oss ee eee Pump, Water ss eee ee ee Radistor . 1. ee fiieretererietteec10: Radio Terminal Box « os ttaaSe Rogulator, Voltage : ae to 58 Roller eee eee iieerererertetterc 192:viiiOrdnance Field Service Base Shop Data CAR, SCOUT, M3A1 WITH HERCULES ENGINE LIST OF CONTENTS: VOLIME I-A toD-B.S.D. Mo's 1 VOLUME II -E toR-B.8.D. No's 21 VOLUME III - § to Z- B.S.D. Ho's 54 to 70 YOLIME IIT Iten Scout Car, Assembly - +. 2s eee es 5h Scout Car, Dismantling... - +--+ + 55 Shafts (Drive & Universals) .- +--+ - 56 Spark Plugs seve ee eee ees 37 Springs (Front & Rear)... + 58 Spring Shackles .. + ---- oe 9 Steering Control & Drag Link. .----++ © Suitches se eee eee ere tee Tenks, Gasoline -- see e rere ees & Trensfer Case sss eee eee es transfer Case & Linkage Controls»... ++ 6% Trensmission se ee eee ett Vacuum Booster Valve ss ee sees se 6a Valve Assembly & Push Rod»... +--+ 67 Wheels & Tires. eee ee ee eee Windshield Wipers & Linkage s+. +--+ 6 70ORDUNGE FIELD SERVICE ‘ASE SHOP DATA (BSD) 1. Scope. - Base Shop Data have been prepared for the purpose of acquainting using personnel with the HIA shop methods of disatling the units described, making the necescary repairs, and reassenbling the componente into a service able unit. 2. General Information. Each BSD, pertaining to 2 particular component or sub-assembly, is into a wit and is provided with a colored front sheet showing # nunber in the lower right hand corner which corresponds to the alphabetically arranged “List of Contents*. b. Plant Lay Out is covered by a separate ESD and includes personnel, shops, ‘tools and equipment required to take care of a predetermined production. Copies of thie BSD can be obtained fron the Office of the Chief af Ordnance, MIPD, Washington, D.C. &. Tool Drawings specified on BSD sheots indicate RIA tool drawings which will be made available on request to the MOPD. 3. Procedure. a. Disassembly. - Digassentle the unit in the sequence described in the BSD and tag the compments, if necessary, to facilitate reassenbly. Thoroughly clean all components. b. Repair. - Repair or replace ali parts which are worn to such an extent that they prevent proper fimctioning of the unit. Smooth all rough spots, re— move all rust, burrs, and sharp comers by means of a smooth file, fine abrasive cloth or an oil stone. g, Reassentiy. — Proceed in the sequence shown in the BSD. Be sure all parts are free from dust or dirt. Cover all steel parts in contact with a light film of lubricating oil prior to assonbly. 4. General Instructions. a. Cotter ping mst be properly apread. Bolts, nuts, and screns must-be tight and should be locked if there is danger of their beconing loose in service. Gap screws, drilled for locking wire, mist be securely wired. Lock washers mst be applied where required. Rivets mist be tight and completely {X11 the rivet holes. Adjustnents mist be securely locked by the locking facilities when pro~ vided. Wow packings and gaskets must be used in Teassemtling. 2b, Lubrication facilities mst function properly, be readily accessible for servicing, and permit uninterrupted passege of the lubricant. Fittings and pas— sages must be free from dirt and possible netal chips prior to assembly and. before ‘the lubricant is applied. Anti-friction bearinga mst be packed at assembly with sufficient wheel bearing grease to fill the space between the balls or rollers. Gear cases shall be filled with the proper lubricant to the proper operating level. Lubrication fittings must be painted red so thet they can be readily located. "De— tailed Lubrication Instructions", wich include the type and grade of the lubricant to be used, are issued as Ordnance Field Service Bulletins, 6 Series (OFSB 6-) and should be followed.BASE SHOP DATA-Issue Or Y/7& i yy | Sua Assewacr ‘SHEET ViSa) |E GaRHA cceiticroe 623) ) Scour Cast ACCESSORIES | PEDALANOLINKAGE ori a 1 Overnaut. FOOT THROTTLE CONTROL: 1y \J_/Btamne Tarorme Covreat Roos ©, @, fi) AND ©). StrarGuren I NECESSARY. EXAMINE ALL Bats AnD SOcKer Join7s@) FOR SPRING TENSION. le Bates Have TooMucn Pay Or Far SP073, REMOVE! BY LOOSENING Nu7@®) To Unscrew Umit AND REX PLace WiTH NEw ONE. IF Busnincs®PARE WORN, Revove With Tao.) By PurtinG BRACKET DN VISE AS SHOWN IN Fic. 2. TAP OLD BUSHINGS OuT AND INSERT New ONE WITH Same TooL.DRILOW HOLES ¢ IN BUSHINGS AT PowrS). Examine HoeDIN fi Le THROTTLE Conraan Lever@, Barr @) Ar RowrD)\¥ * For WEAR. IF Worn, REPLACE Wit NEW PARTS. @ CLEAN AND Olt Alt MOVEABLE PARTS. TENSION ON SpRINGE) SHobxb Be Excucn To RE= TURN Foor THROTTLE To OPiGinal Posiriay Rabioty. IF NECESSARY Cur SoRING TO Gér DE- © SIREO TENSION. EC @) RED LACE ALL AaRTs To Tie Orrcuvat Posir/on, NOTE: Bor @ SHouto BE Scre wen iro ArTacuine BRac- KET @ dusr Enoucn To AlLow THRoTiLe ConrRot LeveR@7O ® 3) ‘Freely. Lock Wita Mor ®. TOOL, OW no sien Dismawnis The Foor THROrTLE ConTRot AT Posirion Shown A1G.2 IN ILLUSTRATION. NOTE: Do Nor REMOVE Baack eT® ANOQUNLESS BADLY GENT. IF They Caw Be SALYAGED, MARK POsiTION ON THE ‘SHAFT WHEN REMOVING. To0Ls REQUIRED (root owe. wo] sueer| omer] DET gos7m_| / | 1 [@4 (msaisc-BH-E3- 7 (1) 52, Me Accelerator (Pedal Linkage)__.. 3Base Suop Dara ~ Issue of Wie? MSAl |B QURHAL] BCIEANER BO| |_| | Scour Car ee0LES Moos inp | MODE. 847s O° ONM orl Can WING NuT@®, TuRNn Ou. Pan@ Free Or Botrs© AND REMOVE. Remove Murs, BOLTS, AND TOOTH TYPE. Lock WasHeRs©) To Remove COML®. BENDOuT TWO OF THE BRACKETS @)AND REMOVE SCREENG), Two FitrER PaDs@) AND SCREEN@.- Wash ALL DARTS /N CLEANING SOLVENT AND DRY WITH AiR. Brush@ Will Be USEFUL IN CLEANING Between Barrie AND Case AT. © To ASSEMBLE, REVERSE SEQUENCE. DIPFILTER PADS @ IN LIGHT OLGA.E9) Sete): BEFORE PUTTING IN PLACE. M3AISC-BH-B6-I (1) BSD. me Air Cleaner... neBASE Sip DATA —/ssue Or asthe VEMICLE UNIT OVERHAUL SUPASSEMBLY SHEET M34 |A “Boor |e, AS | 7 Oras Any Aemoe PLare SECTION Oney WHEN Ber Oe Waerco Suigutiy JF Fi IS IMPAIRED, EEPLACE With New SECTION. Ut The SOFT, Ce Insiwe Suerace 1s Bowen To 8 Convex FokM SHOWN IN FIGURE. STRAGHTEN AS Foujows: PLace Aenoe PLare® Wirn Te SOFT Ano Convex Suemace Down Witn A But Pee Hannee® STRIKE SevERRL BLOWS £161 Towmen OprasiTé DIRECTIONS AS SHOWN, SOTHAT THE SOFT UNDERSIOE WILL STRETCH UNTIL Far: 2 Wp BATTERY PROTECTION Aamoe PLaTEs © Age BENT SLIGHTLY, STRAIGHTEN, OTHERWISE REPLACE WiTH NEW ALATES. Tae Hoop Larcues D) SHOULD BE Hed SécuBeLY By RVETS. If LATOH IS Ear EN, REPLACE Wit NEW. Tat Vision Foer SLines © ShouLn Ween Feely Ue Oe Down, /F 2eoR LEE ARE EBOKEN, REPLACE. See Tiwar AL THE Poneée Cups @)Anp Sriear Loors DAZE SECURELY RUETED REPLACE Any BEOKEN FARTS. See Thar THe Veericat. Loos DAkE WorwKing FareLn RERLACE /E BEYOND REPAIR. Ie WinpsHELD Secrign ®) ESE aKEN, LOOSEN THE Fou CLAMPS ©Q,AND REPLACE COM- PLETE MEW SECTION, INCLUDING GLASS ANd FRAME: Armor Plate & Metal Units__.._. 7BASE SHOP DATA —/ssue OF sfeq/ee ~ aE poe ey oem ar A Maa | A oor ieee AB |e 6 Aumunnrion Boxes @) Toot Bor) ‘Rabio Teeuinat Bar ©) AND THE LARGE Compaerment Box®) SHouto BE iN- “SPECTEC For DEFECTS. SuCH AS BROKEN Hunces, WARPED OR BENT CovERS AND SiDES. MAKE NECESSARY CORRES TIONS. REPLACE IF BEVOND REPAIR. 9) Tue Metax Porrions OF Aue SeATs ©) SHOULD BE EXAMINED For LOGSENED e105, Bent OR. Twisre Back REST MEMBER. STRAIGHTEN To ORIGINAL Post TION. WELD IF NECESSARY. eoio Mas © Shouto Be Examineo For Ben Coz Oe Brox Fook FANE STRAIGHTEN OR Wei As Tue Case May Requiee. See Tar Beackers@)Are SECURELY FASTENED To Boor. IL Inspect Aut Fiooe Phares D Ano Foorweuis @. IF Bent ATTEMPT TOSIRAIGHTEN WITHOUT HEATING. \ @ ‘Crsck. Suive Members © On Dravers SEAT Figure 2 10 Set Tar Tey ARE STRAIGHT. tNseeT CuP GREASEAT®) ToFaciutare Easy Seat ADJUSTMENT.BASE SHOP DATA — Issue Or thifs m7 1 Suede M4 / ° 4 QUERHAUL. | emret Pare 3 sta | ScourCae | & Mera UNITS A or 3 | == TF ANY Cross MEMBER ON THe Insioe Ok On THe NS ae gee UNDERSIDE OF Tite Boor ts Bent OR BROKEN. DISMANTLE AND STRAIGHTEN Oe Wea. /F Bevan Repwe, RepLace Wira kb Ik TicetTen AuwNrs ANo Prowetie Cups @). RIVETS Ow Aux Strap loars @) Seouo Be PEENED To Mace SuRE THEY ARE SECURELY FASTENED. 5 Ceci To See lr Te Winoswie.o Armor. SHIELD © Can BE EASiLy LOWER AND RAISED ALSO Cxec« To See le Te Vision Port Sues D)ARe Ware Ing FREELY UP AND Down. IF Lockie THUMB SCREWS Are Brox En REGLACE, Sek Tuar Tue Taree Props © COLLAPSE WITH EASE. STRAIGHTEN IF BENT. REPLACE Jt BevonD REPAIR. i 6 Sreaicuien Rear Bumper) FG | Ano Beaciers @). Weto IF CRACKED Ok BROKEN MAKE SURE Tua Tie Tio GeiP HANDLES @) ARE RVETED SECURELY. CHECK Aus Poweer CLiPsD To See nar THEY ARE HELD SECURELY, REPLACE, BEYOND REPAIR. [MB41SC-Bh-AS- 33)toBASE SHOP DATA-/ssue OF (0-1-4 4 Vewicte | UN OVERHALL ‘Sus ASSEMBLY SHEET EE —| AXLE, REAR. LEA D ‘POWER TRAIN | Assémely D4) f fe REMOVAL OF AXLE SHAFTS NOTE: NUMBERS In CIRCLES DENOTE OPERATIONS. FOLLOW Iti ORDER. Douwr The REAR AXLE ASSEMBLY @) ONA SUITABLE STAND(EL DRAIN THE GREASE AT PLUG. eae EiguT Nuts @©,four Fiat Lock Washers ©),ANp Foue JAPEPED Liner DowELS © Feom STuDs@,. Simuttaneousty Screw In The Two He Ser Sceews@), Wack Age In PLace On Each AXLE FLANGE, UNTIL AXLE (5 FREE. \WITHOPAW AXLE Q)AND SPRING(®) Fbom HOUSING. Qane ON OTHER SIDE /s PEMOVEDIN THE SAME MANNER AS ABOVE. (RASCBADF-TGD sD me Axle, Rear, Assembly... BeBASE SHOP DATA-. ud OF 10-24-43 f, VEHICLE UNIT -OVEPHAL_| jue ASSETIBLY. E , [SHEET ARLE, PEAR } LA D POWER TRAIN | ASSEMBLY ba 2 poe EHO OOO O00 FIG. REMOVAL OF BRAKE DRUM AND WHEEL HUB (4) srenren EDGE OF Lock WasHeR@)By Benoa, REMOVE ar Nut @WitH Too. ©Ano Sue OFF Lock wasHer @). Use Toot © To Remove AnJusTING NuT®@, SLiP OFF Spacee ©) Ano: Quree GeAene®). JRELEASE BOTH BRAKE SHOE ADUUSTMENT NuTs@ANo@®), Iw Back OF Beare Deu, Wn DikEcTION SHOWN By ‘AeeoWws IN fi6.2, UNTIL Brake Deurt Q) REVOLVES FREELY. Penove Beare Deu @ Ano WHEEL Hie® AS ONE Uni DQ IN THE Saree MANNER , REMOVE OTHER. [MBA/5C-H-D4-2 07)BASE SHOP DATA-Issut OF [92872 SHEET 3 oF 37 der -ASsewaLr fi CHL] wie pa POWER TRAIN | ASSEMBLY WoAl REMOVAL OF BRAKE SHOES 6) To Disuanrié Bran Swors @, Use Tue Fo.Lomne Procepunt Ov ALL Four BRAKE SnoES. Pav OFF Four U SHaréo Locns @ Ano Four Washers ©). (/0) Frou Tne Ancoor Pins ©), Par Orr Two LARGE U SnareD Locas © Ano Two fiat wasners ©. WiTH A PINCH BAR UNDER THE Brane SHOE AS Snows, PRY OFF One OF THe BRAKE Sw0ks, UNHOOK The Sprins @ Ano Remove THE OTHER BRAKE SHOE. Remove Four Sree. Waster @ Frou Aut Four 6vioe Pins Q) Ano Two Sprwes @® FRO The UPPER Gung Pins. Pry OFF Two CuP Wasuers © Ano Two FeT WASHERS @ Frow Ancuor Pins ©) in Fig: 2. To Remove Wuee. Crumoer ), Unscren Two CAP ScREWS AND Loc Wasners ©. [M3AISC-BH-D4- 3 (37)|Se 1X, fis) |95 OVERALL F Eee BASE SHOP DATA-bssu€.OF /0-20-24 P YA! D PONER TRAIN | AS. Y eid VAL_OF PINION GEAR AND “? 906764 RING GEAR ASSEM! Prace The Rear AXLE Housina In A VeeTicat Position, WITH THE RicHT HAND Housiva@) On Wooo Btocks, Ano SécueE To Stan ©. REMOVE Six Cap Sceews AND Lock Waswees ©. Licntiy Tap FLanae Q) WiTn A BRASS MALLET UNTIL PINION GEAR ASSEUBLY © Gan be Wirhoeann, Sceew Toa © To LET Hann Axce Housina @, Sueoer Housiva WITH CHAIN Horst @ And Gemove ELEVEN NUTD, Loce WASHERS AND Cap ScoewaQD. Raise UrpER HALF OF Housina@ AND REMOVE DIFFERENTAL Assemeey @. [MBAI SCBH-D4- $(37}BASE SHOP DATAZ/ssue OF jotta 4 VEMICLE UNIT Sus- ASsEmaLy SHEET or 37 AXLE, EAD YSAl \D ponee Toa ee? Dd DISMANTLING OF PINION GEAQ IPL Y~ Revove CorteR Pin @Ano NuT ®. In AnsoR Press, PeESS OFF FLANGE © Feom Dawe PINiON GEAR SHAFT OD. Poy Our THe Ker ©. Remove Cover ® Ano On ¥X@. 78) Remove Loox WasHeRs @ By Benows Ences. REMove Jad Nut @, Two Lock WASHERS @,ADsUSTING NUT@, And WasHEr ©. @) Sup OFF BEAzine Housine @ WrTH Foewaro BEARING @ Frou PINION GEAR SHAFT ©). (220 Wash Au Paers In Pereoteum NapaTua, Ano Dor WITH COMPRESSED AiR. USAISCBH D4- 5 (37)|BASE SHOP DATA- Issue OF 10-28-45 VEHICLE 5 OVERHA l I ERED D4 SHEL 6 ASSEMBLY POWER TRAIN OVERHAUL _OF PINION _GEAR ASSEMBLY INSPECT Born Bearus Races © Ww Beane Case ®. Ir They ARE Pir TED OR Scored, Remove By TAPPING WiTH A Brass DRIFT AND REPLACE WITH NEW. @ Remove O1o Core Gasket © AND CLEAN OuT Groowe ©. wnspecr Bearinc © Ano © On Pinion Gear SHAFT @ For Wear By Revowvins EACH ROLLER SEPARATELY. IF Rotter On EITHER BEARING Is PITTED OR Scored, REPLACE With New BEARING. fee To Remove Bears © From SHAFT, Cuamp Too. @ Berween Bearins AND Teo. Dive. THE GEAR Ano Press OFF BEARING IN AN " Nog08785 ARBOR PRESS. Revowve The ORWE Pion GEAR SHAFT BETWEEN CENTERS IW A LATHE, Usinc A TEST InbICATOR On SuRFace QD. RePLAce With New Pion Up SHAFT Is Sprune More THan .002" AT ©. (26) Inspect Dave Pion GEAR TEETH FoR WEAR AND SCORES. ALSO CHECK For CRACKS. IF DEFECTS ARE Found, REPLACE WiTH New DRIVE Pinion GEAR AnD ITS MATING RING GEAR. JF SueevE Busnns @ Is Worn Op Pirro, Remove As Fo.tows: WiTH A ScREW DRIVER Pry Tae Lock Rvs ©. Holy Busnws @ On AN Anil ANo STRIKE IT WiTH A BALL PEEN HAMMER UnTu. STRETCHED Enoucn To Come OFF. Do.NoT Mae Tit Gear Win Raoius OR RounveD inner Ebee OF Bushing ® Towaro Pron Gear @, Press New Busnine ONTO PLOT SHAFT @. Ista. Lock Ring © AND SQUEEZE INTO GROOVE WiTH PLIERS.BASE SHOP DATA-Issue OF 10°H-¥¥4 vewete | Our OVERHAUL_| 32 Assenouy eet DA owe tea | Aken = DA) | REMOVAL OF AXLE SHAFTS. NOTE: NUMBERS IN CIRCLES DENOTE OPERATIONS. FoLLow IN ORDER. Dour THE BEAR AXLE ASSEMBLY @) ONA SUIABLE STAND @).DeAIN THE GEEASE AT PLUG ©. Qyeenove Eigur Nuts @,foue FLAT Lock WashERs(©)ANb four APERED Liner DOWELS © Flom STuDS@. SIMULTANEOUSLY SCEEW IN THE Two 6 SET SceEWS@), WHicH ABE IN Puace ON EACH AXLE FLANGE, UNTIL AXLE IS FREE. WITHDBAW AXLE DANO SPRING® Flom HOUSING. Qane ON OTHER SIDE /s REMOvEDIN THE SAME MANNER As ABOVE MGAISCBH D4 =) 31) asa Me, Axle, Rear, Assembly... "BASE SHOP ‘DATA-Issue OF 10-29-82, POWER TRAIN VEHICLE ‘UNIT: ‘Sus-ALSEBLK ‘SHEET ee our Ge oF 37 REMOVAL OF BRAKE DRUM AND WHEEL HUB. STRAIGHTEN EDGE OF Lock WasHER@ByBrwone REMOVE wan Nut @wit Toot. ©Ano Sue OFF Lock WASHER @). Use Too.© To Renove ApsusTiING Nur @. SLIP Ore Spacee®) Ano Quree Bearinc®. RELEASE BOTH BRAKE SHOE ADJUSTMENT ‘Nuts @ANO®), In Bac: OF Beare Deun®, Wn DiRECTION SHOWN By ‘AgeOWS IN FiG.2, UNTIL BRAKE Deurt Q) REVOLVES FREELY. Pemove Beare Deurs@ Ano WHEE. He® AS ONE UNIT DM IN THE Same MANNER , REMOVE OTHER Beaxé Der. [MBAISC-BH-D4-2 ONie O% — _OVERHAUL LENE | AXLE, REA D POWER TRAIN eae BASE SHOP. DATA -lsste OF 10-24-44 SUBASSEPELY 1 mr l oar NoTE: Use New COTTER PINS AND NEW OIL SEALS IN ASSENBLING. LUBRICATE ALL PARTS WAH LIGHT Ot, BEFORE ASSEMBLING. ASSEMBLING OF PINION GEAR ASSEMBLY 2) assovsce DRIVE Pinion GEAR ASSEMBLY, PROCEED AS FOLLOWS: LUBRICATE BoTH ROLLER BEARINGS @)AND @) Wir Cup GREASE. PRESS REAR BEARING @) WiTH Ics LARGER. END NEAREST PINION GEAR. ONTO DRIVE PRON Gea SHAFT ©). SLIP ON BEARING HousinG ©), FRONT BEARING @, HEAVY Wasuer © Anp AnsusTine Nut ©. a ADJUSTING Nur © SoTHATBEARING Housing ©) Witt. TURN ON BEARINGS WiTH A SLIGHT DRAG AND Wirt No LOOSENESS OR ENO PLAY. WasHers @)AND A JAM Nur @). Tis ADJUSTMENT IS LocKED WiTH Two Lock IF Housin (D) is Tiattr AND Does NoT TURN Wirt A SuGHT DRAG, READAST Nut @UNTIL RENEDID. Dow One EDGE OF The Two Lock WASHERS @OeR A FLAT OW OveR A Ae /BEND Gdmoon ®, Ano Pry Up Opposite EDGE PLACE NEW Cork GASKET Q)INTO GRoovE On Housine ©).BASE SHOP DATA-Issvt OF 10-24-24 Tar 1B ASSEMBLY SHEET OER ater DA D|_Povéa Tew ASSEMBLY ee DISMANTLING OF DIFFERENTIAL AND RING GEAR ASSEMBLY @3) CLIP SAFETY WIRE AND REMOVE EigT CAP SCREWS AND LOCK WASHERS @. Taxe Orr Gear Case ®, AsO Thrust WASHER ©). REMOVE INTERMEDIATE GEAR ©), FOUR Wasners ©, Four SPIDER GEARS), AND SPIER ©. LFT OUT INTERMEDIATE GEAR(@) AND TRUST WASHER FROM OTHER HALF OF GEAR CASE®. Cov ALL PARTS IN PETROLEUM ICAL UT CAR ethan (eye 4 cout Ae ER TRAIN | ASSEMBLY. co IN AR 6h) Secure RiguT Hano Housing @) To Stan ® WA verticat Position, ON Wooo Biocs. @) Pur Several. TeeTn OF RING GEAR © Wir Reo LEAD OR PRUSSIAN Bue Ww ORDER To Tae AN IMPRESSION OF Toor Contact. 8 Into Housing @) Inset Tite DIFFERENTIAL Assematy (0) Wirt THe RING Gear Teen ©) FaciIns Downwaro. picts, 4D LO © -® Race NEW PAPER Gasket © Iw Posirion Usine Tine SEA’ OR EQUAL, AND FASTEN Test Cover @) Winn Irs Cur AWAY OPENING Near Pinion GEAR G) Wn THREE CAP ‘screws @), Lock WasnieRs D, AN NuTS @ b tousie @. iwscer Pawon Gear Assemecy © Ino [oUsINé ‘Ano tasten Wie Sux CaP SCREWS @ Ano Lock Wasner @- MGA TSC BHD4- 14037) 26BASE SHOP DATA>hsue OF 1o-24.424 VEHICLE Gear Ow ERI HA UL Sue Assemaur ‘SHEET AXLE , REAR LIGA D POWER TRAIN |ASSEMBLY. D4) os a7 INSTALLA\ IDJUSTMENT OF _PIN/ AND _RIN The HEELS, Tuce Enos OF Pion Gear © Ano Rins Gear @ utd BE Flush. To DETERMINE, Loon TuroucH Openine In Test Gover © AT ®© Ano Estimate The Amount OF Cor- RECTION NECESSARY To BRING HEELS Fu IF Het, OF Pinion GEAR Is In Too Far, Remove PINON GEAR ASSEM- ely © Br Removns Cap Screws ©. PLACE THE Necessary Sacer © OF ESTIMATED THICKNESS BETWEEN AxLE Housins @ Ano BEARING Gace QD. RE-INSTALL PINION GEAR ASSEMBLY AND RE-CHECK. (GZ) JF The Heel OF Te Pion GEAR @) is Away From Hee OF Rins Gear @), WiTHoRaw Paton Gear Assemey © From Housinc @ By Removine CaP screws ©, Rerer To DismAnTLns OF Pwion Gear Assemety ©, lv ORoER To Marine Surrace ® OF Bearing Case ©, SHOWN In a Wn A LaTHE, Remove The EstimareD AmounT OF STOCK From Surrace © On Beans Case ©, So That THE Pinion GEAR Assemety © Witt ENTER FurTHER INTO HousiNG @. REASSEMBLE Axo REINSTALL PINION GEAR ASSEMBLY Gy ®© To Housine, AND InsPECT AGAIN [W3ASCBHD4 — ISP| 7BASF SHOP DATA Issué OF 10-2t-t 4 VEHICLE ur OVERHAUL RE RE SHEET ae XLE REAP LAL D POWERTRAIN | ASSEMBLY D4 (Oa INSTALLING AND ADUUSTIN PINION AND Ri EAR 70>) ROTATE. ‘Pwion GEAR SHAFT @) By HAND UNTIL RinG GEAR @) MAKES SEVERAL COMPLETE REVOLUTIONS,S0 THAT AWN IMPRESSION Wiee BE MADE OF TOOTH CONTACT BETWEEN PINON GEAR AND RING GEAR. To CHeck THE AMOUNT OF BACKLASH, Twat Is, How MucH SIE PLAY THERES BETWEEN The MESHED TEETH OF THE PON ANDRING GEAR,CLAMP AN INDI caTor © To House). MounT Maser WED Too ©) ONFLAT SURFACE OF RING GEAR ®) 50 It TOuHES InorcaTor ©. SLOWLY Move DIFFERENTIAL ASSEMBLY®)BACK ANDFORTH , BUT Nor Enouse To REvowvE PINION GEAR SHAFT @). THE DIFFERENCE BETWEEN THE TWOREADINGS OF THE INDICATOR WiLL DETERMINE THE AMOUNT OF BACKLASH BETWEEN PINION AND RING GEAR. NOTE: ALLOW BETWEEN 010" To .012"BACKLASH, 238BASE SHOP DATA- /ssur_Or soars b VEHICLE UNIT OVERHAUL SUB-ASSEMBLY SHEET [wa [D GERME HER Da [77 oe CAR INSTALLING ¢ ADJUSTING OF PINION. & RING GEAR @® Remove Nurs, Lock WasHeRs Ano Cap Screws @, Ano Lirr Orr Test Comr®. (7A) wnena Dereon Assemey © From Housinc ©). Too. Dwe. No. 308786 NOTE: The Toon imppession OR ConTacr Murs On RIN Gear © sSHouto Cover Two THIRDS OF ‘Face OF Toor Wire No “HEEL” OR “Tok” BEARING, AS SHown IN FIG. 2. Gre ‘MBAISC-BH04-17 (37) 24BASE SHOP DATA Issue OF jo-2t- MAG emer 426. | @ har Tat Forward AND REAR BRAKE SHOES ome @Ano ® Ovro AncoR Pus © Ano OVER Ont Two Gube Pus ©). g low Eact Or Tne Four Guwe Pus D) Mount Ove Srrtz Waster ©) ‘Ano One SrrapoLe Steet Lock ©. Ow Eacn OF Tae Two “Ancor Pins ©Mouwr One Srece, wasticr @)Ano Srravore Loc @. Use New Sreaoove Locks IF Tie Old ONES ARE UNSERVICEABLE. NOTE: Tne BraKe Soe War Tne LoNcER LINING Us Tne FoRwaRD Shoe. TeRCFORE INSTALL IT IN Tht forward Postman, Trar IS, Towaro Tht FRONT Enb Or The Venice. Q@eoe Tne Eos OF StaADOLE Locks ToseTHER A TrirLe Wan PLucRs. Tnew FLATTEN THe BucieD SresooLe Locks ©) By Placing HoLLow Toot @D Over Guive Pins © Ano String THe Too. Wit A HAMMER. Hove OF One Brant Stiot, AND STRETCH Tne Orme ENO Wirt SPRING PLIERS OR A Screw DRIvCA,AS SHOWN IN Fi6.2, Um The Eno OF Spring Enrers MOLE Ow orner Bran: Ste. (BASCBHDE26ET| 38BASE SitoP Dara OF to-2t-da Ab VEHICLE Ur =, OVERHAUL. (Sus- ASSEMBLY SHEET (iy [O ReBe eee a [7 INSTAL, ENTRALIZING OF BRAKE SHOES @® @ remo sx013 Saar avo FASTEN AXLE Housins @)ON 70.A SUITABLE Stan ©. (ODversiee THE INSIDE DIAMETER OF BRAKE DRUM ©) As Stown, In Fic.2, Witt ‘AU'BRAKE DOKTER OR EQUIVALENT BRAKE DRUM MICROMETER ©)- (Bre merce Tht DRuw’s INSIDE DIAMETER FROM Tht MICROMETER ©) TO THE “Braxe DOKTER' GRINDING UN ©)OR EQUIVALENT, BY PLACING THE MICROMETER ONTO The Ganon UNIT AS AT Fig.3. ADJUST GRINDING Disc © To Touch THe END OF MICROMETER © AND Lock Th GRINDING Disc IN THiS POSITION.. ess SHOP DATA Issue OF /0-28-¥2. MaA/\D Sapna) acenewn, DA| 26 POWER TRAIN | “45 SBI. SCOUT Can TALLING ANZ IN (os Meer Avo Secure THe GRINDING UNIT @® ow Axte SuarT Housing ©. Sue Tue MoTor iw OR OuT UNTHL GRINDING Disc © Compre ery Covers The WioTH or Lining ©. @) Loosen Nut ©) Sown /W 16.2 Ano Aosust HEEL” Of Brake Sues AT®), Avo Ansust Toe AT ©, Unmu. Lining Q) Licurty Toucnes THe Grivoer Disc ©. CENTRALIZE THE BRAKE SHOES AS NEAR As PassiBié BEFORE GRINDING. Fig! a Lock The Heet’ AbwusTMENT @), By TisHTENING NUT ©. Ce gy @ Srant THe Motor Ano GRIND EACH aN Beake Suoe Lining @. IF 90% vy SuReAcE Ls NOT OBTAINED In RST GRIND~ fs 6, AbuusT “Toe” ONLY OF EACH SHOE =| = AT ©, To Agour .0/0" FURTHER AND \ Sy REPEAT GRINDING. (eB Renove GainoeR Unit @. RELEASE ONLY THE TOE” ADJUST - menT © So THAT THE BRAKE DRUM CAN FiG.2 BE MOUNTED. [MBAISC-BH-D4-28 (37) 40BASE SHOP DATA issue OF '#ae% 6 VEACLE | UNIT OVERHAUL | SuB-ASSEMELY SHEET MoAl |O “rome rein |itsenatt” OF] 29, WERHAUL OF BRAKE DRUM AND WHEEL HUB. @ Wirt A Brass DRIFT, Tap Our THe WHEEL HUB INNER BEARING @Ano Grease EAL®, DISCARD GREASE SeAL, Ano RepLace Wit New. ie) 1 BRace Deum © On Ween Hus ©) ArE BENT OR CRACKER RePLace Wir NEW. Wasn Tie Bearine In NAPHTHA AnD Ofy WITH COMPRESSED AIR. [1)) A Lancer fetLen Gause © Taw O'S Can Be iserreo In THe Worv Gap © Or Brake ORuM ©) AND STRAIGHT EDGE ©) AS SHOW Iv AiG. 2, THEN REPLACE Wire New Brake Deum. V8 IF Brawé Drum Is SATISFACTORY, INSPECT BOTH Bearino Races @ Ano D) For SCORED OR PITTED BEARING SURFACE. By Taprinc Wirn A Brass DRIFT BEHIND THE BEARING, itv NOTCHES Provibed for, ASAT ®, REMOVE Tle DEFECTIVE BEARING RACE Avo REpLace With New. 119) "Remove Inner Beaninc Race D tae Race Towaras THe Brake DRUM. The Bearine Race @) Is TppED Our I Tie Opeosite DIRECTION. [M3A4/5C-BH-D4-29(37) 4BASE SHOP DATA Issue OF jo-3t-t24 Yee, [OT OVERHAUL | 28 Serer SHEET. : QMATAL lay E REAR LEM D__Powch Te |ASseisec 04 ASSEMBLY OA AE RRONT POWER TRAIN | ASSEMBLY D5 SHEFF {Scart ‘cae @) Rotate Anion Gear SHart @ By HAno UnmTiL PNG GEAR @) MAKES SEVERN. COMPLETE Revowutions, So THAT An IMPRESSION Wil BE MADE OF Teor CONTACT BETWEEN Pinion GEAR ANO RING GEAR. To CHeck The Avount OF BACKLASH, THAT "1s, How MucH SIDE PLAY THERE IS BETWEEN Mesneo TEETH OF Poy AND PING GEAR, ae CLame Aw InoicaTor © Jo ‘On ©. joa79r Mount Macnerizeo Too ©) Ow Far © 2081 Surracé OF Ring GEAR 8) So Ir Toucnes InoicaToR ©. BACKLASH fie2 CD) Seowty Move Dirrerenniat Aissematy © Bar Ano fort, But Nor Enoucn To REvotvE PINON GEAR Swart @) Te Dirtenence BETWEEN THE Two READINGS OF The inoicATOR Wits DETERMINE THE AMOUNT OF Baceiasi BETWEEN Pinta AND Ring GEAR. NOTE: Auow Berweew .010" To 612” BacKwase. MBASCBH- D5-/8 (51), 6sBASE SHOP DATA-Issve Or _te-avtah [ence TH OVERHAUL Sue ASEmeLY SHEET. oD TOA VALE FRONT vad D_Powee reas ASSEMBLY Dd rss | Remove Nurs @ Looe WasHees G)AND CAP Screws Ano Lirt Orr Est Cone ©). WrTHDeAW Tie Derewennias Assempuy © bom Housing ©). Nore THE TROTH IMPRESSION Op CanTaCT Maries ON THE Rina Geno @ Warcn Stauo Cover Tro Teco OF Face OF Teor WITH No ‘BeeL" Od Tee" Benen. As SHOWN IN Fis. 2 _fig.2 oe (W3AISC-BH-D5-19 61)BASE SHOP DATA Issue OF 028A VEHICLE UNE OVERHAUL ‘Su- ASSEMBLY SHEET CURT] AXLE FRONT MAL L)__Fawee reat ASSEMBLY DS ors INSTALLING AND ADJUSTING OF PINONAND PING GEAR 86 We FeopeR Toot CONTACTAS: Be ee nee VAeY PIMON OR FANG GEAR Fosirin As Pee Cnaer, HEN REINSTALL DIFFERENTIAL ASSEMBLY INTO AXLE HOUSING Ano Bepear TAKING IMPeESSION OF Toor Un. PeoPER Toor Conracr 15 OBTAINED THEN ‘Copeecr BAOKLASH By MOVING RING GEAR TOWARD Oe AWAY FEOM PINiON GEAR. “HOVE PINION GEAP IN THIS ‘HOVE FNON GEAR INTHE | | | DIRECTION TOCORRECT | YTION Ai DIRECTION TOC’ ee CIWG TIONS) AL W NOTE: FIST CORRECT THE TOOTH CONTACT, THEN COREECT THE BACKLASH Mave Coepecr Toot Contact Ow Tie ENG GEAR. Heavr Conracr OwHee. Or Toor. ToCoReeCT Tus Move ANG GEAR |-epy “4f Away FEOM PINION GEAR. THEN CORRECT BACKLASH. im wy Conract ON Ibe Or Toor, To Correct Tus, Move PNG GEAP Away FeOM PINONGEAR. ENCOPPECT THE BACKLASH. Heavy CONTACT QNFIANK OF TooTH. ToCORBECT THis Move PINION GRE juny oom Pine CéAe UNI. CONTACT COMES TO FULL WOPKING DEPTHOFT Geae ToT, WiuouT BREAKING CONTACT OF FLANGE THEN QORRECT BACKLASH. face |e wy Contact ON Face Or Toot, To Copeecr This Move Pivion GEAR WARD RING GEAR, UNTILCONTACT COVERS FLANK OF TooTH WITHOUT BREAKING CONTACT AT Face. THEN CORPECT BACKLASH. (WBASCBDS-206)) [MOVE PING INTHS VEECTION TOCOPEECT JON SHOW ATBASE SHOP DATA-Issut OF unto VERICLE UNIT ‘Sue- ASSEMBLY ‘SHEET Al [5 Se eer 0577, | POWER TRAIN ASSEMBLY IF IIs Necessany To Move Rin Gear @) ETHER TOWARD OP Away FRoM Pivion GAR ©) iv ORDER To CORRECT TOOTH CONTACT OP To CORRECT THE BACKLASH, TH EnTIRE DIFFERENTIAL Assemocy (©) WITH BEARING Races (©) AnD ©), 1s SurTED TO Sur, BY AnoING Srusts Ore DECREASING THE THcKNESS OF ROLLER Beanie Races (©) Or ©. iF Runs Gear @ Has To Be Moveb Coser To Pinion Gean ©), Esvimare Hus Distance. DISMANTLE TesT Cover (E) Ano WiTorAW DIFFERENTIAL, ©); Few Remove Besrine Race ©) From Ric Hano Housins G) Writ Tox @. 89) Gino OFF The ESTIMATED AMOUNT OF Stock From THE Suarace D Or Beanie Race (0) Qh A SURFACE GRINDER. Ga) Paws Besans Race © Ino RicHr How Aue Housine ©. Remove OLD IMPRESSION FROM TEETH ON PINION AND RING GEAR AND REPAINT SEVERAL FING GEAR TEETH. Toot Owe. No. REINSTALL DIFFERENTIAL AssEmBLY ©) Ano Fasten TEST 433045. Cover © ToHousinc ©._We He Beanie Axe © Downwaro ONTO Rower Besrine (©). REPEAT THE Toor CoNACT Test ANO BACKLASH TEST. peers <4) Bexrane Race. (©) From Leer Hino Housine © Ado Sams B Equat Amount OF Stock Taxtw From BEARING RACE ©). insta ©, Lave Ue Housine @) On Housins © Avo IieHTEN Fleven CaP Screws ®), Lock Wasers ©), Avo Nurs (2) FFIEST s Satisractony, WH Puen @ Remove OnHeR @ > 63) REVERSE PRoceDuré IF The Rin Gear @).MusT Be MovED FAoM PINION Gear ©). NOTE: To DECREASE BACKLASH, MOVE RING GEAR CLOSER To PINION GEAR. © To increase Excess, Move RIN FROM PINION GEAR. 13ASC-BH-DS=14 (51) 1BASE SHOP DATA-Issue OF _10 andad UNIT Sue ASSEMBLY SHEET D URHAUL 516 FONT DS| 22 POWER TRAIN “ASSEMBLY Was OVERHAUL OF BRAKE BACKING PLATE AND STEERING KNUCKLE | (94) Mawr Tre STEERING Anuonie ® Aone Berween- ConTER OF FixTURE® IN Fic. 2. Pace IoicaToR® To SuRrAce®) Ano Revowve SrecrING Kauckié Stoney By Hano. F Ruv Our Is More Twaw.005;" Repace WH New STEERWG KNUCKLE SPINDLE. fig! Secure Tue Beane Bacnine PLATE®) To The SeRviceAeLE STEERING Kuucxe@) Wote Taree Bons Ano Nurs) Ano Mouvr Tae Asseneur Berween Cenrers OF FixTure@, Sew THE Beare Backinc Prare® Avo Osserve Tee AuounT OF Run Our. IF Ir Is BENT, REPLACE WITH A New BRAKE BACKING PLATE. Ca Te SreeRnc Kavonue @ Is Servcensir, Per Ore THe Ot Crease ReTANER@ ‘Ano Waser @. Mount A New CREASE RETANER@® ON WASHER @. THEN WSTALL Ir Gro SrecrnG KnucxLe @ ATO Wha THE Waswer@ On Tie OUTER SDE. Inspect Tue Ouree Beaninc® For Prrrep Or ScoreD ROLLERS By Revowvine EACH ROLLER SEPARATELY. IF IT 1S Derective REPLACE WOTH New ROLLER BEARING. IF Busine © Is Scored OR Too Loose When STEER Kyscre@ IS PLACED On SPINDLE SHAFT OF Umversa. Jon @, Remove Wie A Brass Drier & © Ano Repiace WiTH New BusHiNc. (8y, Tue Banke BackIne PLATE ©) IS SERVICEABLE, ‘DiSWanTLe I From Tue SreeRinc Kner. @. Tuen Cuean AnD Paint THe Wnsioe Surface OF Tue BRAKE Backing PLare@) WiTH Beack Paw Ano Awow To Dar. Gu THe Orne Boake Backing PLATE AND STEERING KRUCKLE SPINDLE In THE Same MANNER.BASE SHOP tala OF N-so-ne 6 VERICLE UNIT OWLRHA IL I“ASSEMALY WAL (0 See euig DS SCOUT CAR, ASSEMBLY RELINING BRAKE SHOES JF Oto Brae Linine @ 's Worn, REPLACE WiTH New. To REMOYE OLD Linine From Beane Suoes ©), Daive Out The OLD Rivers WiTH A HAND PUNCH. 23 OF 51 BurF THe BRAKE Linine SurFace ©) OF Te BRAKE SHOES In ORDER To Remove At TRace OF Rusr: CLEAN BALANCE OF THE BRAKE SHOES, THEN Apply PAINT ALL OveR AND ALLOW To DRY. NOTE: ‘Tite Foewseo BRAKE SHOE HAs A LONGER BRAKE LINING THAN THE REAR BRAKE SHOE. PLACE THE New Beane Liine @) IN Position On Brae Suoe ®) So Tur END AweT Hotes ARE EQUALLY SpaceD Feo EACH END OF BRAKE LINING. Secure Tt BRAKE LINING To THE BRAKE SHOE WiTH Two 'C” CLamps (0) AND Dre Two RveT Hotes (©) AT One END Iv Boare LINING, FOR LOCATING PURPOSE, WITH A 4." Drit. ©) AS SHOWN. (WABCERDS-23G7) 3BASE_SHOP DATA-issut OF Jo2¢ 4s 4 a SHEET | VEHICLE oer OWEPHAUL NE FRONT DS 34 M3 U POWER TRAIN |” asceMBLY ae RELINING OF BRAKE SHOES @ CounTERGore THe Two DRILLED [SB HALES Dn Ling @ To A 26" Orvrt Tow WA “Srar Brake ReLinins ANO RIVETING MACHINE," OR EQuivaLENT, By PUSHING Brae Soe © On COUNTERBORE AND DRILL ©). USE A 28° Diame TER COUNTERBORE Wit A 46" 2 REMOVABLE DRILL. ©) @ Inserr Rivet © INTO Hove So Head OF RweT Is Wn BraKé Lining ©). VET The LininG To THE SHoe © In Riverine MacHine ©). @ LocATE THE BALANCE OF RIVET HOLES IN LINING By DRILLING WITH THE ate DRILL. COUNTEREORE ALL HOLES TO 4" DEPTH. CONTINUE RIVETING The Linine From ONE END, ANO WORK TOWARD THE OTHER. (W3AISC-BA-D5- 246 1)| +BASE SHOP DATA-issut OF frig “a4 VEHICLE ‘UNI OVERHA. UL ‘Su6- ASSEMBLY (| SHEET ) sowie TAN | LE RONT Maa J D POWER TRAIN |" AcSeMBLY D5 ot INSTALLING AND CENTRALIZING OF BRAKE SHOES Moun THe BRAKE BACKING PLATE @ OwTo Fixture @) ANDFASTEN Wit Four Nuts ©. Qs, THe Wee CYLINDER) TO THE BRAKE BACKING PLATE @)Wimt Two CAP SCREWS @)AND LOCK WASHERS © THroucH Hoes Q. PLACE ONE SPRING @ ONE ACH ONE OF Tit Tyo ToP Guine Pus @). SLIP A STEEL WASHER ® OW Each ONE OF THE Four Gue Ps D. @ CLEAN The Two OLD FELT WASHERS IW PETROLEUM NAPHTHA AND DRY WiTH COMPRESSED AR. REPLACE WITH NEW IF FELT /5 STRETCHED OR WORN. PLACE One Fett Waster © Ano One Cup WASHER @ ON EACH ONE OF THE Tid ANCHOR Pins @. 15BASE SwHOP DATA-Wssut OF 10-29-45 VEHICLE UNIT OVERHAUL a ‘Su8-ASSEMBLY | SHEET, AXLE FRONT SCOUT CAR D POWER TRAN | ASSEMBLY Dd é OFS INSTALLING AND CET LIZING OF BPs SHOES CO nsrase The Forwaen ano Dear Boake EES @ Ano ® OwTo AncHae Ps © AND Over Two Guor ANS). MOTE: Te Boake SH0e Wirt The Lavaee LininG [5 THE Fo@WARD SHOE, THERE FORE INSTALL ITN THE FopwaRD PosiTION, THAT IS, Towaro Te Font Eno OF THE VEHICLE. Oy Enc OF Te Four Guo Ans ©) founT One STEEL Wave ©)Ano One Stoanae S7eeL Lock(h).ON Fac OF The To AncHoe PINS ©) Moun One Staooue Lock ©. Ube New Steen Locns IF Oto CES \@ Qose THe Ewos OF THE STRADDLE Locks eee cTHen A Towue WiTH Puegs, Taek Fiarren \ The Eucened Sreapo1e Locks ©), By PLACNG Heuiow Toot OVER Guine Pins Q) AND STRIKING THE Too. WrrH A HaMMED. @® Hor One END OF Spaina @) IN Toe Fove OF ONE Bopxé SH0c,ANp Putt THE Ome@ EN With Seana Pies Oe A SooEW Dower 65 Juoww I fig.2 Unie The ENO OF Speing ENTERS HOLE ®) INOTHER EioaKE Soe. MIAISCEA-D5-2661)| 1%BASE SHOP DATA-lssut OF 12-29 45 My 4 4/ D QUERHAUL UE FONT. DS © SHEET POWER TRAIN |" AscEMBLY os! INSTALL, 1D CENTRALIZING OF BRAKE SHOES: To MEASURE THE INSIDE DIAMETER OF BRAKE DRUM @ Use Too. © As SHOWN IN FiG.1, AND LOCK IT AT SET Screw©. @ PLACE THE'BRAKE DOKTER™ MicromeTer ©)OR EQuat, To Surraces ® Ano® OF Toor.® To OBTAIN THE SizE Or THE BRAKE DRUM. TRANSFER THE DRUMS INSIDE DIAMETER From THE MicromeTeR ©) To Te "BRAKE DoKTER™ GRINDING Uni © OR EQUIVALENT, BY PLACING THE MICROMETER ONTO THE GRINDING UNIT AS AT FiG.2. ADJUST GRINDING Disc @ To ToucH THE END OF MICROMETER @ Ano Lock THE GRINDING Disc IN Tats POSITION, DE-27(5/)BASE_SHOP DATA-lssvt OF 1021-724 PERICLE UNIT OVERHA UL ‘Sub ASSEMBLY ‘SHEET eee ay \AXLLRONT ei Ab POWER TRAIN ASSEMBLY DS | 2 om l @ MouNT AND SECURE THE GRINDING ‘tr @ Onto Seryote OF Fixture @). Suibe THE Moor © In OF Our UNTIL THE. Grinois Disc ©) COMPLETELY B., Tae Wore OF Linns ©. Loosen Nurs © Locate ON THE Back OF THE BRAKE Backing Pare @ SHOWN ON Fig 2, AND AbuUsT THE “HEEL” OF Brake Suoes At @), Ano Absust THE "Toe" At Nuts @) UNTIL Linine® LicHney Toucnes THE Ganoing Disc ©). CENTRALIZE Tue BRAKE SHOE AS NEAR As Posie Berore Trueins Up OR RINDING THE LINING. @ Lock Tae "HEEL" Apsustment @ By Tistrenne Nut ©. Start Motor Ano Grino EACH BRAKE Snot LINING. IF 90% SURFACE Is Nor OBTAINED IN FIRST GRINDING, ADJUST THE "TOE" Onty OF EacH SHoe AT QD) To ABour .010" FurtHeR AnD REPEAT GRINDING. @ ) Reuove Grinoine Unt @. RELEASE Qnty Tie “Toe” AdsusTMENT Q) So THAT THe Brake DRUM D BE MOUNTED. DismaniLe THE BRAKE Backing Plate © Frou 23 Fixture ®. INSTALL AND CENTRALIZE THE BRAKE. Shoes ON THE Orne R Sibe OF Font Ade In Tht Same MANNER. MIAISCBH-DS- 286 ))| ardBASE SHOP DATA-Issut OF 10:24 fab UMT ‘Sua-ASSEMBLY SHEET WERHAUL D Power tein ME FEONT DS He DISMANTLING OF WHEEL CYLINDER @ TO DISMANTLE THe Two FRONT WHEEL Cr noeRs @ PROCEED AS FOLLOWS: Pu Our Tie Two Eno Rops @), Remove Two Boors © Ano WirHoRAWw THe Two Pistons © Two Rusaer Cus© Ano Srrinc ©, BLEEDER VALVE WITH ITS CAP SCREW AND LOCK WAsHER,®). WasH FiTTING@), BLEEOER VALVE®), Foo ®, Avo SerwG © Iv PETROLEUM NAPHTHA AND DRY WITH COMPRESSED AIR. Att OTHER FARTS SHOULD BE WASHED THOROUGHLY WITH ALCOHOL. [M3MISC-BA D529) 1”BASE SHOP DATA-Issut OF 10-29. 4x6 HICLE UNE OVERHA UL ‘Sus~ ASSEMBLY SHEET YM WAL LD “bows ean ALE FRONT D5 30, OVERHAUL OF WHEEL CYLINDER. ~® ® @, Tue Bore OF CyLINDER @ /s MARRED = AND SCRATCHED, REPLACE WITH NEW. If SATISFACTORY, REMOVE CORROSION From Watts IN BoRE By HONING WITH fig 1 A Very FINE GRIT STANDARD Hone ©) UNTIL HIGH POLISH Is OBTAINED. CLEAN THE CYLINDER IN ALCOHOL. OUTSIDE DIAMETER SurFAcE ©) ON BorH ALumnum Pistons © WiTH i Crocus CLOTH, AND CLEAN IN G) ALCOHOL. fis2 @ Powis THE Flat SURFACE © AND. © fy P I @ /F RugBER Boots © OR RuBBER Cups © Are CRACKED, OR Too SOFT, Replace WITH NEW. FiG.3 MaHISC-BH-D5-306))| 90BASE_SHOP DATA Issue OF fo-25 #44 ACLE UNIT OVERHAUL ‘Sue Assemeny 7 WAL ower rea PEON DS | St S ASSEMBLING. TESTING OF cL CYLI @ Sup THE Comper Washer @ Onto Firrinc @) Ano isTaLe INTO HOLE © Iv Cuinoer ©. Insenr A Core ©) Into Firrine ©. Ino HoLe ) INSTALL BLEEDER VALIE © Ano Gose Wire Coo Screw CH) AnD Loc Wastr D. Pair Te OUTER SURFACE OF Crumoer (©) Wit THe Ouve Deas LusTERLESS ENAMEL AND AoW To Drv. INSTALL The SPRING @ INTO CrLINDER (©) SHOWN WN FiG.1. AND Dip THe Two Rueser Cups ©, Tv BRAKE FLUID AND INSERT INTO CYLINDER, WiTH ITS CUPPED Sunface Toward SPRING (to. ‘Atso DP The Two Asrons @) nro Brané Fut ANDINSERT ONE PISTON INTO EACH END OF Crunpen, Wine [15 FLAT SURFACE AGAINST THE RueBER Cup (L).THEN Fiz, les Comer Bom Enos OF CwLinoer Wit RuBBeR BOors (W). a @) <> Wit A Roo ®) Shown In FiG.2, SMALL EnouGH To FASS THROUGH SY Fe tte in te pussie Boor @ OF Aston ©,Comertss THe ASTON Ano Quecxiy WiTHORAW Roo (®). IF PisToN Does Not CoME Back Iivro Oricinal Posirion AT ONCE, REPLACE WITH NEW WHEEL CYLINDER. REPEAT THiS Test ON THe OTHER END OF CyLinDER ALSO. InsTalt. One Ron ©) into Hote OF LAcn Boor W). [MBAISC-BA-D5-31(51) stBASE SHOP DATA-Issut OF 10-29.¢.4 VEHICLE UNIT ORHAUL ‘Sue ASSEmaLY SHEET MBAL |D eawee roan PE RONT DS | 32, DISMANTLING OF AXLE SHAFT AND UNIVERSAL JOINT ASSEMBLY CO seare THE UNIVERSAL JOINT ASSEMBLY @ Iw A COPPER Jaw VISE. ® @eur Toe SAFETY Wiké, AND REMOVE a) ThREE FLusTER Heap Screws (@) Tat Hoo THe Loctins Rins ©. Brrroea Ante SHartT @) Wire THe Lockins Rive ©) From The Universac Jor Assemay ®. Turn THe Lockine Fine ©) THe Wore OF ONE SPLINE, Wich Wie Auow IT To Sup OFF THE AXLE SHAFT@). Brn Ain ASSEMELY WnicH Consists OF Prot ®, PLunoer @), Spring’), AND Burrer Sprine @, Wat Suir Our Br Turiwé The ENTIRE UNIVERSAL JoinT Assemsty @.on BASE SHOP DATA-Issue OF I1-a4-43.5 CLE TNT OVERHAUL | Si8-ASeneur SHEET, “Bowe Toa |ALESROVT MAI D POWER TRAIN ASSEMBLY. DS 33, ; DISMANTLING OF AXLE SHAFT ASS Push DOWN ONE Siok OF Cage &) WiTH Thum, UnTi. Bearine Bare) On THe Oprosire SDE IS RarsED Ue Ano ExroséD. REMOVE @ Te Bearine Bax. REPEAT THIS PROCEDURE LWTIL THE BALANCE OF BEARING BALLS ARE REMOVED. To Remove Puor Pin Cace ©, Revouve The Case @ Wire inner Race ©) InsiDE OF SockeT (©) UNTIL THE SPHERICAL PLOT PIN CAGE Is RASED To THe ToP Ano EXPOSE a. MANIPULATE THe CAGE @) AND Inne Pace © By Revowne, Unrit Bey ARE INA VeRTICAL Position To THe SockeT Ar @) Avo QD ALLOWING THE CAGE AND INNER RACE 1 Be Weipa From Socner © (SHOWN In FG. 3). ISATA RiGHT ANGLE To THE BEARING CASE @ Avo Prong © OF The inner Race © ProTRUOING THROUGH THe LARGE StoT ©) IN CAGE. THEN Remove Te Race © From Case @ As Shown In FiG.4, MBAISCBH-D5~ 33651) Turw Te inner Race ©) So M5 PositionBASE SHOP DATA-ssue OF _/e 29-454 F THT ONERHAUL |e Ben, MBAl Cee LEONE D5 CUERHALIL_OF UNIVERSAL JONT ‘ASSEMBIY SHEET, oa ‘St Ber The Inne icp Race @Ar Sureace @) Ano At suprace © OF UNIVERSAL ont SocreT ©) for EXCESSIVE WeAR MARKS OR Grooves Mant Br The Bate Bearines (D. Ir Dertcrive. , REPLACE wo ANew UNIVERSAL JoIT SockeT Oo. inace Ract @ Ano New BEARING Bus. ir No Derects ARE OBSERVED, MAGNAFLUX Tac Inner Race @, BEARING CAGE © ‘Ano Pot Pin CAGE ©. IF CRACK fs OBSERVED, Repuace Wim New PART. Me Spring @, BUFFER SPRING @, Puuncer @, OF Por Pn © Is BROKEN, REPLACE wan New PART. Cue The UNIVERSAL JOINT socner ©) BETWEEN CENTERS OF FUTURE @ win mnocarr (D, Conracr Sunrace @\Revawe Tt ‘Socrer ©) Suomty By Hana. IF IN- DeaTor RecisteRs More THAN 005" \ariarion, Reptace With New SPINDLE. SHAFT. owen Tne Ace Srarr Q Berwecn CENTERS Or forure @io See Ben. WITH IN- Dicator @) Beanie ON “Suptact. REVOLVE Tht ALE SuarT Stow, IF INDCATOR READING waies More Tran .005", REPLACE War NEw ALE SHAFT. Tae OMER MLE Start AND UNIVERSAL JOINT ASSEMBLY 15 CHECKED IN THE SAME MANNER. (BAS BHDS- 340)BASE SHOP DATA-Issue OF j0-25-4s 8 VEMICLE Omir O VER] Hy i Wa WM Ee ONT ‘SHEET HOA D _Fowee TRA ASSEMBLY DS ors Bi} IF IF Or Place THe Prone @ OF Inner Race @) INTO THE LARGER StoT © AS SHOWN IN Fic. /. Tus Wie Aicow The Inner Race @ To Ewer Tite BEARine CacE ©. CLAMP THE SPINDLE SHAFT OF ThE UnvERSAL JowT SocnEeT © in A CorrER JaWwED Vist. REVOLVE THE INNER RACE ®@ wence D wri irLnes Ue Wir THE ace. Hon Case Q w Position As Suown In © Fis. 2, So Thar Tie Two Lancer Hotes © Ano @ Fig. 2 Wit Attow THE Case Jo Sup Into SocKET ©. AtLow THe Sioe OF Inner Race @) That Has No Hotes, To BE On Tor, THEN InsTalL PiLoT Pin. CAGE @ RESTS ON THE BOTTOM OF SockeT © AS Suown In Fie. 3. Pust Down ONE SIDE OF BEARING cage ©, As Shown In Fie. 4, UNTIL THe OPENING @ ON OPPOSITE SIDE Wie PECEWE BEARING Bar ®. ASSEMBLE THE Batawce OF BEARING BAUS By REPEATING THE ABOVE PROCEDURE. Fig. + [MBAS C-BHDS-35(D 85BASE_SHOP DATA-Issve OF 1024-428 VERRIE THT OVERHAUL Sue ASSEMBLY SHEET AYLE, FRONT Me Al jo mower TRaw \efiOY = ADIN SEI ASSEMBLY _OF AYLE SHAFT AND UNIVERSAL JOINT ASSEMBLY. @ Wir Tie Burrer Sprine @ /nsioe OF ‘SpRING®, AND PLunceR © HeLD ON THE Evo By SPRING ®), INSTALL THIS ASSEMBLY ‘Ano THe Por PI © Ino SocHeT ©), THE Lone Eno OF Por Pin © ToucHine Pruncer ©: Sup Tie Loctane Ring © ON SPLINE OF AXLE SHAFT ©- Inset THe Axe SHAFT © INTO SPLINE OF INNER RACE @ WiTH CARE, SO THAT Te Pitot Pin © FALLS INTO THE PiLOT. SocueT D INTHE AXLE SHAFT. Turn Tue Locrins Rive © In THe Scor® So THe THREE HOLES IN LOCKING RING Ling UP WITH THE THREE HoLes IN THE INNER RACE @. SECURE THE LOCKING ine In PLace Wir THREE Screws ©. ATTACH SAFETY Wine To THE THREE SCREWS. ASSEMBLE THE OTHER AXLE SHAFT AND UniversaL Jot ASSemecy IN THE SAME MANNER. a WSAISC-BH OS 3605)BASE SHOP DATA-Issue Of 10-36-4248 ra NIT OVERHA SUBASSEMBLY (SHEET. TOAL | YER leon 5) 37 SCOUT CAR ors) OVERHAUL OF STEERING KNUCKLE FLANGE ASSEMBLY EXAMINE BOTH ROLLER BEARINGS @ AND ®)FORPITTED OR SCORED ‘FOLLERS.IF DEFECTIVE, REPLACE MITH NEW ROLLER BEARINGS. IF Tue Bearing RxE ©)0R OS ManRED OR SCORED ON THE INSIDE SURFACE, ‘REPLACE WITH NEW BEARING PACE. Prepare THe uowine Or Bur Tine Surraces © OF The STEERNE HMICKLE FLANGE ©,CaPs @ Ano @By Renovine Any Det ORBuRAS WITH A FLAT FILE.CLEAN IN PETROLEUM NapHT44 ANDDRY WITH COMPRESSED AIR. (fi) Green Ano OreReaun THE OTHER STEERNG KNUCKLE FLANGE ASSENELY IN The SAME MANNER. [7ASAISC-BH DS~ 31(5 0 a7BASE SHOP DATA-Issut OF. 10-29-4204 VEAKLE CRT OWE RHAUL ‘Sue-ASEMALY SHEET 7 M jAl D “power rea EAEOY DS 38. 7 SSEMBLING AND ADUSTING STEEAING KAUCKLE. FLANGE ASSEMBLY — O————-3 G Press Tue Rower Bearines @ AND @ °— Down Ovr0 Truwon Pins (©) AND Ogee x6 In Av AnBor PRESS. MAKE SURE THE LARGEST DiamereR OF BEARINGS ARE NEAREST Tole Tuan socxeT ©. © ras ) ack Rowen Beanies @) Ano ©) Wire Crassis GREASE, Na #00 BELow 32°F), ‘Now| (ABove 32°F). @) @ SECURE THE STEERING KNUCKLE FLANGES © @® Ano © reoetHen In Posirion, WiTH (2h Tae Bars (D0 eee es AS qn: Nor TiGHTEN. GeO ° NOTE: ENo FLANGES ARE STAMPED *L peer Hano OR 'R" RiGHT Hav To FaciLiTaTe IN ASSEMBLING. Mount Beanies Races © Ano ©, ne OF Exc ower Beans @ Ano ©. @ Peace THe UbPER Beanins CAP ©) BAT HAS THE GREASE FITTING, Wns ITS respecte Sum @ OVER Studs © And On BEAnina Race (&) AND FASTEN Win Four NuTs AND LocnwAsHErs©). @ Inv THe SAME Manner, THE LOWER BEARING CAP ® no is Reseece Sum © Is PLACED ONTO LONER BEARING RACE ©, ANd FASTENED WITH FOUR LOCK WASHERS Ann CaP Scans D. Figs Fe face Nurs @ Ano THE Beane CaP NuTs @ Avo CAP ScREWS TM SAISC-BH-DS 386) 88GF at SHOP DAT sie OF 024 eee OERHA LL -ASSEMOLY SHEET. AXLE, FRON: WAL Powe Teal |Wschay © DS oo ASSEMBLING f ADJUSTING STEERING FLANGE ASSEMBLY. ‘Aawustmtnt OF TRunmion Bearines @)Ano 6) 4S ACCOMPUSHED By INCREASING OR DECREASING ane ©) Locarco Unocr Tac Beane Cars @) The Bearins Are Abwustto UNI InERE IS ‘No © ‘END Play In The Kuwente Assemety, Bur ir OscutaTe FREELY. To Reaove Eno Play Remove Bearing CAPS ©An®, Ano Reouce THe Sum Pe 005” Unoer Each Being CAP Anb REINSTALL BEARING Caps. ArTER Tis |s Done, THERE Snouto BE A. SMALL AMOUNT OF DRAG Whew Romrive Tne STEERING NNUCKLE FLANGE Asscamety (G), Bur StHouLd Nor Bino. © ‘DISMANTLE The SrécRne “flanee Assemey By Remoune Upecr Bearing Cap © Ano irs Sum, Then Separate Trt Two Fiances @> D QD. KecP The Stes Ted To THER RESPECTWE BEARING CAPS. ‘Sup Tht New Grease Retawer @ Over Trunwion Bearing (B) Win Cane Nor Jo STRETCH Ir, Place New Expanoer @) in Sor @ Of THe fiance). Instat GREASE Retainer Ow Top OF GANDER. Luewcare Tie Teunmon SockeT Dy Wire List Ot, AND REASSEMBLE ThE STECRING KNUCKLE FLANGE ASSEMBLY. Tne. Secrine Kaucre fanet On The Omitr Eno OF Axue Housing 15 ASSEMBLED AND ADJUSTED IN The. SaME MANNER. [M3AISC-BH-D5- 386i) 84SHEET, Mes CAR 404 | INSTALLING OF AXLE SHAFT AND UNIVERSAL_ JOINT ASSEFBLY Bone The UnwersaL Jon SocKeT Br HaNo AT Openins @) Wirt 1 POUND OF CHASSIS GREASE No.0 (BELOW 32F), Na¥t (ABOVE 327). JoinT AsseriLy © INTO THE Guus THe AXLE SHAFT@)AND UNIVERSAL Axe Housne@®. Tuen THE UNIVERSAL JOINT Assere.y UNTIL SPLINE INSIDE OF AXLE HOUSING. OCAXLE SwAcT EnTeRS ITS PUTING SPLINE Use Precaution Nor % Dariace GREASE RETAINER IN HOUSING , wH END BASE SHOP DATA-Issve OF 102% 424 VEHICLE UNIT OVERHAUL “Sus- ASSEMBLY POWER TRAIN ALE FRONT D5 OF AxLe SHAFT. NOTE: The Lert HAND SIE OF AXLE Housine RECEIVES THE LONGER ONTO UNIVERSAL AXLE SHAFT. © BEARING ©OW w, Qn Borrort PosITION. Gh STEERING KNUCKLE “sonore SHArT© AND STuDs @, WITH SLOT 9E ASSEMBLY QIN PLACE ‘JOINT PLACE Beak BACKING PLATE AND Beate Sot CYLINDER© 15 IN UPPERMOST On STups@, MAKING SURE WHEEL To Axe Housinc©- Position, IN RELATION EMENT To Ol. SLINGER@D.IHEN INSTALL IT ONTO @ Away Fron BRAKE Qn Liou GAsKeT CI ‘STus@WitH Cueveo INNER EDGE OF OIL SLINGER: BACKING PLATE®). SECURE ENTIRE ASSEMBLY WITH TWELVE SHAKEPROOF Loce WasHeRS AnD NuTS@ ON STuDs@. IN THe SAME MANNER INSTALL OTHER AXLE SHAET AND UNIVERSAL JOINT. 40BASE SHOP DATA-Issut OF 10-2401 $ POWER TRAIN | ASSEMBLY OUT CAR Ll ors | Venice a “| Sup ASSEMELY SHEET Eat D ORAL | A Foi D5 \ 4/ OVERHAUL OF BRAKE DRUM ANU WHEEL HUB. ARBeME DRun @ OR WuEEL HUB @IS BENT OR CRACKED, REPLACE WITH NEM @ IFAFEELER Gauct @,LARGER THAN .OI5! CAN BE INSERTED IN THE WoRN GaP BETWEEN BRAKE Drun@ And THE STRAIGHT Epat ©, THEN RepLace WitttNew Brake Drum SHON IN Fig.2, (i) inspect BOTH Bearins Races @Ano @FoR Score ORPITTED BEARING SURFACE. By TAPPING, THA. BRASSDRIT Béwinn THE BEARING RACE, IN Narcnes Proveco Far As AT), KEMove The DEFECTIVE BEARING RACE AND REPLACE WITH NEW. (GA) Toren Tre wer Race @,Dpwe Out Towaros The Braxeé Drum. The OureR BEARING RACE® Is DRIVEN OUT IN THE OPPOSITE DIRECTION. 4BASE SHOP_DATA-Issut OF #2924 VEHICLE TH OVERHAUL [ieee SHEET. , AXLE, FRONT, MA D POWER TRAIN ASSEMBLY. DS 42 OVERHAUL OF BRAKE DRUM AND. WHEEL HUB. To Test BRAKE DRuM For Run Our (THAT Is.How TRUE IT Revotves), Moun THE Braxé Dipum @ AND WHEEL Hus @® BETWEEN CENTERS OF TEST- ING FIXTURE ©). USE TAPERED ROLLER BEARING © ON EACH CENTER. REVOLVE Je BRAKE DRUM SLOWLY BY HAND AND OBSERVE VARIATION OF READING picaror © WHEN PLaceD To Surrace © Ano ©. Ip Exc OF THE Two Surfaces ©Ano® Run Our OR Vary More Tuan .020" REPLACE WITH NEw Brake Dum ONLY. To REMove THE DEFECTIVE Brae DRUM @ From THe WHEEL Hus ®, Remove Nurs @ Awo Press Our Sruos @ In ARBOR PRESS On WiTH A BRASS DRIFT AND HAMMER. Lace THe WHeeL Hue © BETween CENTERS. Fx THE INDICATOR To THE SurFact @ AND REVOLVE THE Wuee. Hue By HAND. IF THe SurFAcE® Varies MORE THAN O10; REPLACE WirH New WHEEL HuB. WAEN THe WeeEL Hue IS DEFECTIVE, ASSEMBLE THE OLD BRAKE Drum @ ONTOANEW WHEEL HUB AND FASTEN TOGETHER WiTH New srups @ Ano Nuts @, RECHECH THE BRAKE DRUM IN FIXTURE © For Run ‘Our WiTH InpicAToR © To SurFAceEs © ANO ©. /F EITHER READING VARIES More ot 5070 REPLACE WITH NEW BRAKE DRUM. © Toot. Dwe.No. 433044 IG [WASCBDS42E 9)BASE SHOP DATA-Issue OF 10:2¢ 42-6 SCOUT CAR nie OVERHALIL | SuB-ASSEMBLY SHEET MAL | D roucnrman |e OS os | -QUERHAU. OF BRAKEDRUM AND WHEEL HUB WuEN Assemetinc THE Braxé ORum ® 7o THe WHEEL Hus @®, Ista STups So Tar The FLAT Sine OF HEAD© Witt BEAR AGAINST SHOULDER Iw BRAKE Drum To PREVENT. THE STups From TuRNING. PLACE The BRAKE Drum So THe Head OF STuo © RESTS On OR Acainst Aw Ani. ©, THEW WiTn Toot © OvER THE STuo, STRIKE THE Too. © WiTn A Hammer Unrit Enoucn METAL Oh SHOULDER OF STUD is FiARED, Fitting THE SURROUNDING AREA. This HoLDS THE Drum AND HuB TOGETHER. CuEcn For Run Our OF Drum (w THE TESTING FIXTURE. @ © [M3AISC—BH-D 5-430)BASE SHOP. DATACIse OF pass $ VEHICLE OVERHAUL ‘Sie: ASsiMaLy SHEET DOWER TRAIN aes FRONT M3AL tue D POWER TRAIN \ Asch D5 44 INSTALLING AND ADJUSTING OF BRAKE DRUM ‘AND WHEEL HUB_ASSEMBLY” Que The Rince OR Eb0E NEAREST BraKinG SurFAcE AT INSPECTION Hote @) OF Brant Drum @), Wincn Is Causeo By WEAR, pane Tne Wnetet Bearine © For Pirreo OR Scoréo RoeRS By REVOLVING Ener RoweR Separareéty. I DEFECTIVE, Reptace With New BEARING. Pou Bor Wwee. Bearin6s ©) Ano ©) By Hano With #2 Heavy Duty ABER WHEEL BEARING GREASE. Pera Tue Beare Oru Ano Wee Hue Assemety © Qvro Brae SHoes® Ano StéERING KNucKE@). SuP THe WHEEL Bearins(C) Avo AosuSTING Mut @® Quro SHAFT OF STEERING KNUCKLE®. [MSAISC E+ D5-44G 1WEE ee SHOP DATA Issue OF joatts A Li j~ ASSEMAL) ‘SHEET QURHAUL | 8a | AXLE FRONT: UAL B POWER TRAIN \" ASSEMBLY DS ie, INSTALLING & ADJUSTING OF BRAKE DRUM & WHEEL HUB ASSEMBLY Dew Up Aowstins Nur @ Ticery Win Too.(®), Meawwrute Roane’ Brake Orum © In One Direction, THEN In The Omer, Unni. Bearings Bind Stisnmuy. Bact Of The Aowustine Nut 1/8 OF A Turn. ‘Puce A New Nor Lock ©),-Onro Spout OF STEERING HNucKLe ©), Avo Instaet Tne Look Nut ©, MAKING SuRE To How Tre Aowusrins Nut @)7o PREVENT irs TURNING When Lock Nur © & Tisnreneo Tne Epets OF Tac. Nur Lock (@) Sound Trew Bc Bent Over Born THe Absustins Nur @ ANo THE Lock Nut ©. INSILL A NEW PAPER Gast ©) Ano The Drive PuaTé MAKING SURE IAT Tne Luerication Firtines D)Ano ®) Ow fiance OF Drive PLare @ Line Up Wire Tie: Two Swau. Hotes In Gasket Ano The Two Luericarion Howes ©) Ano @ In Te FLANGE OF The Ware. MuB. this IS VERY IMPORTANT. Jwsracs The Screw Avo Lock Waser P) Trrousn Te Cenrer OF Deve. Plate @luro you OF Tae Unnersa. Jour Ano Tre Enon Lock Wasnices Ano Nuts @ ovr Stun @. IN The SAME Manucr,. INSTALL THE OrneR Braxe Drum. AND Wheel MUB ASSEMBLY. [M3AIS-BH-D5- 45(51) asBASE SHOP DATA issue OF je-ubdn $ WA oe OVERHAUL | $e EP TEEF MAL POWER TRAN | ACSE VBL Y” DS ol INSTALLATION OF TIE ROD _& PINION SHAFT FLANGE IF CROSS TUBE OR Te Roo @ is Bevonn Repair, REPLACE WrTH New. IF SERVICEABLE, Remove Yores @ Avo © From Eacu Ewo OF Te Rov @ By Loosenins Four Clamp Bors © Ano ©, Aso THE Loca Nur ©. @ ‘LuppicaTe Tnreans AT BoT# Enos OF Tie Roo @. Reassemace vores @& © Owro Tuer RESPECTIVE THREADS, In SOMEMERE Near THE Crusis POSITION. WOTE: One Euo OF Tie Roo Has 14 Tartans, The OTHER 12 Per Ice. Mount Axce Assémecy © On Srano @. Wstaue Tie Roo @ To Arce Hovsine, Manus Sure Yore @ Wirn Locrwr © Is Ou Lert, dso OFFSET PoRTION OF Tie Rep CLEARS Housine. musta. Yoré Pw Q AT Exc Eno OF Tie Roo Wire Care Nor 10 Daace THREADS. Auow Hex OF Yone Pu To Burr Asausr Far Stop @ Ar Tap OF Excn Yone dub Draw Ue Yore Pu Wor D) TEMPORARILY ‘wsrat nev Qn Stor OF Puen Gear SHAFT @. SuiP Flawet On SHAFT ®. CYavstur Mor @, Ano Loce with New CorTER Pu ®. D5-4E5i) 6BASE SHOP DATA-lssue OF 10-2544 4 SHEET at ee OT, A/ POWER TRAIN ASSEMBLY RUNNING-IN TEST ON TEST STAND =-Y) /Hoist Tne Front Axte Assemety@) Oro T Beams @®) OF Tesr Srawa@) Ano Covnecr THe Driveswarr @) Ar Flanses ©. Pace LEvEL@®) Ov Pao @. Aosust The Axe Housins Unric Levee. THEN Fasten: ty Securety To Toe Test Stan AT @ Ano@. ‘iu THE Front Ayte-Housive AT) With 9 Pwrs OF SAE. #60 Aicrarr ENGINE OL AND REINSTALL Pius. START Morar OF Test Uni. Enoase The Front AytE AND RUN AT 1000 RP ke * (DRIVE Starr SPEED). WHEN A Louo Carrer Is HEARD, MAKE SURE THe BRAKE Hoes Do Nor Biito Ow The Brake Deum. Reweor Thus By Loosenine THE* Tier Brake SHoe AT Toe Anwustine NuTsQ, Dresr Svano OPeRATOR SHouLD Nore Any Unusual Noses OR EXCESSIVE HeaT IN “The Axte Assematy To DeTERMiNE WaicH Beapine MicHT Be DEFECTIVE: F Noise. Faits To Become QuireR AFTER 50 MINUTES OF CONTINUOUS RUNNING, THE AXLE Assematy Wit Have To Be Torm Down Ano RecnecKen For fautry PARTS. Dosrsse bewe Start @ Ar Flanees ©. M3AISC-BH-DS-#7(5 0} a7BASE SHOP DATA-Issue OF joie 5 _ MOA) |) QERHAUL Vane Fro, D5 SHEET. POWER TRAIN | ASSEMBLY OF SI Scour Can CHECKING AND ADJUSTING THE TOE-iN CD rasren One Toor @ To Eacw Brage Deu AT Stuns @ Wen Nurs ©. @) Revowve Brake Daums ©) Uwri. Eact Toot-@ 1s Iv A LEVEL HORIZONTAL Position Awo Lock IT Iw Tals Position Br TiGHTENING ONLY ONE TOE AnsusTMENT NuT © Ow EACH Brane Opuw So TwaT THe Brace Daum Does Nor REvoLve WHILE CHECKING THE ToE-IN Nore: Tus 's NoT To Be ConstRucb As A Fnac “TOE=In "ADJUSTMENT, @ Biace A Measuring Roo © Iwo Hoes AT THe Ewo OF EacH Too. @ Ano Nore Tue Reaoine On THE MeasurinG Rod. Reuove MeasuanG Roo Ano Ser Exc Too. @: Ow THe OpposiTé Sie OF Tue Brake puss Iw A Levec HorizonTat. Position, — OBTAIN READING On MEASURING Roo BETWEEN TooLs @ tw Tue LATTER Position AND Cacunate Tue Dirrrrewce In READINGS. More: Tue Disenence Swoulo Be 1/8; Peus On Minus IIB; TAT IS, THE Measvawe Roo Susuca Reso /8" Less AT Tue FrowT Or Tue Ance Thaw AT THe REAR. M3AISCBHOS#EGY 9BASE SHOP DATA-Issue OF 1024 12I Umer fj GERHALL VSI FRONT NS| A. D “comen raul eel ON! DS) 49 SCOUT CAR co TING THE TOE-IN ADWUSTMENT OF TOE-IN |S ACCOMPLISHED By TURNING THE Tle Rob Yore @ OR @, OR MaybE BOTH, INCREASING OR DECREASING THE LENGTH OF TiE Fob, DEPENDING ON THE DIRECTION ROTATED, NoTE- BoTH Enos OF IHE Tit Roo Have RienT Hand THREADS. ONE Eno Has 14, THE OTHER Has 12 THREADS PER INCH. B Turn THe Yore @ Orn @, Disconnect The Tie Rov © AT One OR Boru Enos By ReEmovins Nut © Ano YorEPIN ©. AFTER THE NECESSARY CORRECTION 15 MADE, REASSEMBLE THe We Roo To THe Axte. ReinsTau THE Yore Pins © Ano Nurs ©. Recnecr THE ToE-IN WiTH Measuring Rob, IF SATISFACTORY, WSTALL New CorTER Pins © In Born Yore Pins ©. TisHTEw Cuamp Barts © AnD ®, Auso Loc Nur @. la SD 9BASE SHOP DATA-Issue OF 10.21$2 4 my OERMALL Vth FPRONT D POWERT PAIN ASSEMBLY DS ea AQUUSTING OF BRAKE SHOFS Jo Apuust THE Branes: TichTéN NuTS @® One ATA Time, IW THE DirecTion SHown By ARROWS. MEANWHILE Revove BRAKE DRUM UnTi. Brane SHOE Touches THE Brane Drum. Bac OFF Tus ApuusTMENT SusHTiy UNTIL BRAKE ‘Drum Rorares Freety WiTdouT ORM | Venice SHEET, Scour CAR Remove Cap Screw ©, AND Locir wasHeR ©, ALSO INSPECTION Hog Cover Plate © FROM THE BRAKE Drum ®- @ Te Proper Toe Cuesrance 1s .008,” BETWEEN The Bran UMN Ano Brake DRUM, MEASURED with A FEELER GAUGE © Turous Tue Inspection Hole AT @ ABOUT 1” From THe Enp OF Brawe Lining AT THe Top OR Toe. Instat .Six Wieet NUTS-@ To STups QD On Eacn FRONT AXLE BRAKE DRUM. @ Pau The Ewrine FRONT AYLE Assemaly With AN OLIVE DRAB LUSTERLESS ENAMEL, EycerT Tue Expose SURFACE OF THE ‘STecrwe Knucrie BALL JOINT, Wc SHouLD BE OILED AND FREE FROM PAINT. NBAISC-BH-DS- 50 (51) 100BASE- SHOP DATAIssut OF 105 42.6 VEHICLE UNIT OW ME TON r ‘SHEET ‘i LE, A MiAl [Diem eevee DS |S | [a]o]e|om) color noo} ofr] tot [M3AISC-BH-D5-51(51)1oz- it SHop Dara 4 VEHICLE = UNIT OVERHAUL [SuB ASSEMBLY SHEET Fecaneal ~~ ~—=«| BOOSTER foes! E eee SOEs Brake E 5 Or 9 Fig.l @ To Tae OFF Back PLaTe@\Pemove THe Foue NyTs ‘Anp Lock WasHers As@)AND Four Hoons As©, To Remove BoosTeR Eno PLate®), PLAce Sevew Dewer ©) Benno GasxeT(E)AND Tap GenTiy WitH A Hammer AT DIFFERENT LOCATIONS AROUND THE BOOSTER. Fig. 13A/ SC- BHE = 209) totBASE SHOP DaTA-issue Or /0-8-4. & WemeIE Yoni more marr MBAL IE OVERHAUL |S Asseoe CHG Fecuncn | Booster Scour: Cag ACCESSORIES Brake org i From Back Eno OF Eno PLATE, REMOVE THE LOCK e wc Spawe@, RETAINER Wash fo. LEATHER Oi. RETAL © Ano Gasxer @. Fig. 1, To Remove PisTON Rob PLUNGER ASsEM- 8x Geasp PISTON Poo®Ano Put Out WhiLE Movie Up Ano DOWN StigHTty AS Stow IN Fie.2. Fig.2 les:Base SHOP DaTA- issue OF /0-8-42.4 [rsa i" O\ OVERHAUL Sus ASSEMBLY E 5 4 BoosTER Beare. Ptace Piston Ro Ano Puuncee Assemo.y @) In AVise. CAUTION: Use Woopen Buocks Oe SAFETY Jaws IN ViSE WHEN HOLDING PisTON Rod AND PLUNGER ASSEMBLY. Remove Lance Cap(6)Faom Back OF PLun- en Copper. seu O's REMOVED From VaLve ©, Spane®)Ano wasner © Ake THEN REMOVED. FIG.2 e Place ASSEMBLY IN VisE,BETWEEN Woop BLocKs Or Sare- Ty ais. Remove Hex. NuT®, PLATE FeLT Ano THE Spane®), PLaTe®, LEATHER PLuncEe GD Ano NoTCHED Prare®. Remove Spane @)Feon Fer ®. © Att METAL PARTS ARE THEN WASHED OFF IN PETROLEUM ete BAISCBHES-4O) 106BASE SHOP DATA-1s3ut OF 10-3-42 5 VEHICLE [UNiT [Sus ASSEMBLY eee MBALIE OVERHAUL [*? ES 5 {COUT CAR, FeGaNRAL~S«| BOOSTER ACCESSORIES BRaKe or IF Bustin Is hor In Ewo Pcave@), New ONE Is In- ‘STALLED. OLD BuSHiNe SHOULD BE PRESSED Our AND NeW ONE PRESSED INOW A BEARING PRESS, Using Toot)/F Bearing Press Is Nor Avait sce, PLACE Ir In Vise ‘BETWEEN Wood Buocks AS SHOWN IN Fig. 1. Knock Our Oto BusHing, sine Toot © Ano Harner. Vise Mav BE USED To PRESS NEN BEARING IN. ‘Sxoutp ENp PLaTE@) BECOME C2acKe, Replace IT Winn A NEW ONE, Atways Reptace With New LEATHER Olt ReTaweRQ)WHEN OVERHAULING. LUBRICAT LeaTHER ReTAINER© WITH ENGINE Ou. At INSTALL IN E,D PLATE AS SHOWN. _INSTA RETAINED WASHER®,LOCK SpRiNs®)AN: Nore: AFTER BUSHING HAS BEEN REPLACED BURNISH WITH TooL. 9082956.BASE SHOP DATA-Issue Of [o-t-424 VEHICLE [UNIT OV. E | P Hy, lA UL Sua AssemaLy aa ~—SC*| BOOSTER MOA! (Crore ware £5 | O,, | SHEET Fig.t TF Oto Vatve IS Woe, BENT, Oe Fits Too Loose.y IN PISTON Rop, A NEw One Is DepLaceo. IF New VaLve@)Firs Too TicHTiy IN Piston Lop@), Use Vatve GeinoINe CoMpouND On Suaraces@)ANo Lap It Down To Fir, As SHown In Fie.t IT SHouo Run Freety Ano NoT BE Loose. [3)) Aware Use A New FeTO WHEN OverHautine. Enos OF FeLT@Can BE STapLeo Tose THER By A OFFICE STAPLING MACHINE Oe Can Be Fasr- ened By Wine @)As Soown IN Fig.2. Wibe Is PusHep THRouGH AND ENDS Are BENT OVER. SHave Speing®As SHown, WiTH THe “V" Eno ON InsibE AND _PRO- Trung Lip@In NorcH@). SteeTcu Feit@)Over Seaine ©. os,BASE SHOP DATA-Issue Or 10-8 4% 4 VEHICLE |Unir 'SuB AS: (SHEET OVERHAUL eet ial |t meamer—~ |Seosee = £5 | 7, ® New Piston Roo®)Is USED, /F OLD ONE Is Maneeo Oe DamaceD. race Piston Roo@) IN Vise, With Compe Jaws Ano Ticuren Nur @) As Far As IT Witt Go. insTate NOTCHED PLATE) WITH BEVELED nce As Som. ALways INSTALL New LEATHER PLuNGER®). INSTALL PLATEE Over PLuncepO)WirH BEvELED EDGE AS SHOWN. PLACE FELT®)ANo SpRiNGG Over FLANGED ENo OF Plate @, WiTH "V" Or Speine In Line Wir V'OF PLATE. IN STALL As UNIT Over PLATE(®@)ANb Ino LEATHER PLUNGER), TicHTEN Assenacy Wry A Insta, WasHER®@INTO Piston Roo©), INSTA New Speins @D/F Oto One Is DisTorreD. Puaa Vave Rao®)Inro Roo©Anp Fir tr Trmoust WasHER @®, So THAT Valve Eno®) Is Dow In Roo. IF Copper Seat@Is NoT WoRN EXCESS Ly Ob BENT, INSTALL IT INTO Cax@)AND TicHTEN Cap Over Eno OF Pop, OTHERWIS! USE A New Copper SEAL.Bast SHOP DATA issue OF J0-1-4.4 VEHICLE [UNIT Sue ASSEMeL: SHEET M3AI F QEREAUL erasers F518 PECHANICAL BoosTer ACCESSORIES Brake @ Crunoer@IF Score Ok DENTED IS REPLACED Wit New. Pur A LisHT CoaTine OF ENGINE Ou Att Azouno Insibe OF Cuyinoer@, LuB- RICATE LEATHER PLUNGER @ INSIDE AND OuT Wir SAME Olt. INSTALL ONE Eno OF Pluncee@/4"DOWN INTO CrLinDER@). PLACE Screw Dax Down INTO CYLINDER WHERE Eoce OF LEATH- 2 /s BareLy INSIDE, STRAIGHTEN PisTON kov©) As Screw Deier© Is Moven In DigecTion OF Arrows. PUSH PLUNGER DOWN WHEN THE F LEATHER 1S ENTIRELY INSIDEOF CYLINDER. Fi¢.1 | Insta END PLaTE®)AS SHOWN IN FiG.2. -Hosé CONNECT JON® SHOULD BE TOWARD RIGHT SIDE WHEN LooKine AT Tor View. Back END SHOWS RELATIVE PosrTion OF ALus@) @) Ano ConnecTiov@®. Fig.2. Instat. Back PuaTEDAS IS SHOWN IN Fie. Secure WITH Four Lock WasH- es Ano NuTS®. 110BASE SHOP DATA -/ssue OF 10-3428 VEHICLE [Unit OVERHAUL ‘SuB ASSEMBLY oreer, pA! If memes [fee ES |g @ INSTALL New Gasker @ Over END PATE @. PLACE Ate QeAneR® In COER@. INSTALL Cover Ov END PrATe ®, AND SEcuRE WITH Five PouNo HEAD Screws a Loc WasERs As ©. Instaut New Fair Waster © Into Seconn Hump @) OF Dust Boot ® As SHown By Dorreo Lines. IF OLD Boor!s CRACKED Of SpuT, REPLACE Wi NEw Boor. SrretcH Boor@) Over Fiance OF Cover D. Compress BooT@ Towarn Cover@ AND Screw Youe®) Over Piston Ron © Unri_ Piston Roo: EMERGES ABOUT ‘M'Inro FORKED END OF YoLK@. IF NOT CRACKED, STRETCH OLD Dust cap @ Over Piston Rop©,. Turn Lock NuT@ Over Vatve Rao® ABouT 72". TURN VALVE ROD Your @ On70 VALVE Rop® So THAT End OF YOKE@ ALMOST TOUCHES PIN @®, WHEN Pin ® is INSTALLED IN YoRE@. INSTALL Pin @ THROUGH Yor @ AND VALVE Rob YoRE@. SECURE Wa COTTER Pin ©). BACK up Lock NuT @ Fiusi With VALVE Rob Yore @. [MBAISC- BH-E 5-93)ueBASE SHOP DATA — _ Issue Or ¥/e/a.€ VEHICLE Unit OVERHAUL Sup Assemery ‘SHEET [Al POWER TRAIN | PERERA MIE D7, 1 i DISMANTLING Remove Corer Pin@ Ano WasHee®) From ‘Buock (©) Ano Press Buock Our OF Brake Levee©. Unsceew AnwusTine Roo) feo Biock©. @ Remove Correr Pin) Feom Bout ©. Unscrew, Nor @ Ano Remove Bair Feom Beane Lever Q)Suce Our Rarcuer Pate QD. @ Deve Our Pin ® Wine Sorat Punch Ano REMOVE Beare Lever Pusn Burron ©) Feo Past Roo. > Remove Corree Pin @ Feort Pus Rov €D, Ano FiGR2~ Agree Feceme Ir Feom Rarcuet ®), Putt. Pus Rod. ‘Feom Borrom OF Beaxe Lever. Remove Sreine@) From Top OF Beake LEVER. (MBAISCBH DFT BSD. Me. 10 Brake, Parking (Lever & Linkage). 13BASE SHOP DATA ~_ Issue OF Mcp. © VEHICLE UNIT OF HAUL BERING ie Maal |D See Ze POWER Tea | LEVER ANDLINCAGE SCOUT CAR Oo qh Qreceer To See Thar Brave Lever @/s Nor BENT Op Ceacxeo, Or Tuar Hoves Are Our OF Rouno. STRAIGHTEN Ie BENT. REPLACE LEVER IF NECESSARY. °f/ 7 Inspect Pusn Roo @ lo See Tuar Ir Lines Up Coreecriy Wii Brake Lever @. Remove Aut UNNECESSARY KINKS And. BENDS. /ExAMINE RarcHer © To See nar Toorn Firs Snuety Into Rarcuer PLare TeetH ©. le Rarcuer Tore Is Worn Oe Broken, Geiwo OFF Eno OF River ©) AND Dawe Our With Punch. REMOVE RATCHET ©) AND RIVET ‘NEW RATCHET IN PLACE, Inspect RarcHer PLate ©) For Worn Or Broken TeeTH. REPLACE PLATE It NECESSARY REPLACE BLOCK @)IF THREADS ARE STRIPPED OR SHANK IS BADLY WoRN. INSPECT THREADS OF ADJUSTING Roo ©. |e Tapeans Are Strippep, Re- PLACE Rob. Ik Rob Is Bent, STRAIGHTEN, Je Speine @ /3 Broken, OF DAMAGED, REPLACE. MBAISC-BH-DF-2 (2) utBASE SHOP DATA —__|ssue OF W/e/n VEHICLE UNIT OVE) HAL SusAssemey SHEET Fa (5 ee esas O7| O ASSEMBLY Inséer Puss oo @) In The Borrom Eno OF Parxine ‘Beare Lever @As Suown iv Fi.2 AND Sube Roo Inro Lever Tit. END Comes To Rest AGAINST SHOULDER IN- SIDE Tor Eno OF Beaxe Lever. Peace Lower Eno oF koo@® In Vise Ano Twist Beake Levee @)SLIGHTLY- RIGHT AND LEFT Tite Rep Finps ITS War THeoucH Srounnee, Use SmaLt Sceew-cever To Guine Roo Tnkous ToP Hove In Levee. @ Inseer Spens (©) Oree Tar Or Pus Rao @ Avo into Hote In Top OF Beane Levee ®). Pees Posn Burrav On To Eno OF Roo @)- seer Pin© In HALE In Soe OF Pus Burrow Anp Theous# Eno OF Roo. © INSERT Lowee END OF Pus Ron @ In Rarcuer © Ano Lock WiTy Corree Pin @. © Supe Barner Prare®@) Iwro.P_ACE In Beaxe Lever ®). insert Bor Q),Sceew On Nur(®) Ano Lock Wit Correr Pin ©). AiG. InseeT Swank OF Biock®) In Beare Levee ®). PLace WasHee@) On Eno OF SHank, Ano Lock In Pace With Corree Pn). Sceew Eno OF Apiustine SHarT @inro Biocr@) usBASE SHOP DaTA —_fssue OF wefea™ ewer TO OVERHAUL | Se Asseney ea WA), | Boeri powcemeaeD7| Ag DISMANTLING ) © yrewoverowuzne ‘SpRING@FROM Beaxe Suoes BAN © (QDerrsot tock er Ounosereoen Nor®Feom Tie Roo®. REMOVE Corter Pivs @AND®@ AND Press Our Pins D @ Reeasive OveraTinG LeveRO. RELEASE SPRING WAND TWO WAsHERS@ By REMOVING Tie Rop® Fron Brake Arms © Ano ©- [93A/SC-BH-. 16BASE SHOP DATA —_Issue OF wlelaT VeHeLEURT OVERALL [sus eer aes BRAKE, PARKING Seam Cae POWER TRAIN | LEVER AND LINKAGE D7 OF 12 @ Remove Ser Sceews@ Ano ® Feom Suproer Beacrer©,. @ Peess Our Levee Aem Pwvor Ps ® Ano © Pu. Lever Aem Brake SHoe Assemecies@)Ano© OFF Support BeackeT ©. WwBase SHOPDATA —_. Issue Or wisleaC VERICLE Oyer FE RHA ‘Sua AssemMaLy ‘SHEET, 1|D OLE ve panuns D7| 6 ‘Scour Ca POWER TRAIN | LEVER AND LINKAGE OF Remove Cap SCREWS (A) AND ) AND Lock WASHERS © AND ©) FROM RESPECTIVE SHOES ©. @) ‘Remove Brake SHE vor Pn Locks © AND@)« Press BRAKE Suoe Pivor Pins Q)ANO®) Our OF RESPECTIVE BRAKE SHOES@) ANODE), AND BRAKE SHOE ARMS DAVE). MBAISC-BH-D7-6 (2)BASE SHOP Dara - Issue oF 1#/fee€ VEHICLE UNIT T SuBASSEMBLY SHEET Moa) |> GERHAL 07] BRAKE, eine | Seavr Can POWER TRAIN | LEVER AND LINHA 4 OVERHAUL cers @ Inspect BeaKe Sxoe Pivor Prvs @ Ano) for Pirs Ano Wear. ReeLace IF ® Necessary. REMove GeeAse Firrives ©) AwoQ)Feor Pins Ano CLEAN INSIDE OF EACH Pin Witt CLEANING SOLVENT. (a) Inspect Sear ©) OF EACH GREASE FITTING Fib.2 For Wear. REPLACE IF WORN. @ Inspect Bearing Sueraces©,©,@Ano@ foe Ars Ano Wear. Rervace EiTner Oe Born Beaxe Swoes &)Avo® IF Beariés As BAoLy Worn Op Pirreo. @ inspect LEVER Aem Pivot Pins @) Ano @ Ano THEIR RESPECTIVE BEARING SuRFACES ©),@,@ Ano). If Pins Aee Banty Worn Oe Arte, Deve Our Busines @)Ano Peess In New Ones With Areor Press. (HSAISC-BADFTIA neBASE SHOP Dara —- (ssue OF 1/shC VEHICLE ‘UNIT OVERHALI UB ASSEMBLY (SHEET. MAL |D Smee are poms D7 | 8. SCOUT CAR weeHaut OF Parking Beaxe SupporT BeAcKeT a Support Beacker @) For CRACKS. REPLACE BeAcKEr It CRACKED. spect THREADS OF Set SCREWS (G) AND ©) FoR DAMAGED Or STRIPPED THREADS. REPLACE IF NECESSARY. /Pemove ADsustive Stubs ©) AnD ©. Ispecr For Damacen Or SreIPrED THeeAvs. RENEW If NECESSARY. Iwspecr Taeeans Iv Screw Hoes @). ©.@.D, ©. ®, Ano @. tf Bevowo Repair, REPLACE BRACKET. [M3AISC-BHD7-8 (72) \20BASE SHOP DATA _-_Issue OF "fife (~ VEHICLE UNIT (Sue Asse) ‘SHEET, / QUERHALI ar | LOA D POWER TRAN | PEE AB LMA DT OF 12 G6) Remove RWETS With Hamme AND Punce Ano Take OFF Woen Lining ‘Feo Beane Sue @) 1) CLEAN Face OF SHoe®) Wir Wire Beush. G8) Place New Loune ©) Aeamsr Face OF SHOE Wink Counreesune ive OF HOLES In Liming Away Feom FACE OF SHOE. inser EicuT Tusucae RveTs@, 73 In DiameTee Ano £'Lone, Ano ‘RWET LINING TO SHOE. Note: APPLY THE SAME PeoceDurE IN INSTALLING LINING ON OTHER (MGAISC-BA DF 92) ratBASE SHOP DATA — _Issut OF 71 Gp2 7 [Venicre UNIT | OVERHAUL! Sup ASseMaLyY “SHEET BALD Sonenron soeetins OT | 1Q., ASSEMBLY Oars GREASE FiTTINGS@ ANO@®IN BRAKE Soe Prot Pws@/ANo®). See Thar FITTINGS ARE TIGHT. di) PRESS Brake Shoe Pivor Pins ©@ANC® INTO RESPE CINE BRAKE SHOES®AND@), AND Brae SHOE ARMS@)AND@)- InsTalt PrvoT PInLOCKS@ AND @®, AND SECURE WiTH CAP SCREWS @)AND@), ANDLOCK WasHeRS@AND®- (MSAISC-BH Dion 2BASE SHOP DATA = Issue OF sly) VEHICLE UNIT OVERHAUL ‘Sus Assemety SHEET M3AI|D coven ran BRAKE, PARHI) ‘sears POWER TRAN erat D7 J bem ence SHOE ANDARM ASSEMBLIES® AND@/NPLACE ON SuppoRT @4) press Levee sam Drvor Ps |@ AND © INTO PLACE In ARM ASSEMBLES @Ano® Avo Supvorr BRacreT ©. @) Instat SET Screws) AND©® IN SuPPORT BRACKET ©. TIGHTEN Lock NuTs@) AND @). [MSAISC-BHEDFIZABASE SHOP DATA _- __ Issue OF 1/s5/1ac VEHICLE Unit OVERHAUL (SueAssemecy SHEET FOAL \D power raw pomeoenre DT | IK, I) inseer Tie Roo@) In Beaxe Aen @). Suve Opeearing Lever © Inro PLace Gv Eno OF Beare Aem®). Insvau. Pin ©) Ano Lock Wire Corree Pr). ‘Sune Tie Roo@ Inro Operating Levee©. inser PinE)Ano Lock WITH Corrée Pin). Stine Wasnee@), Spee D) Ano WasHER(S) ON Tie Ro® inscer Eno OF Tie Roo @ In Eno OF Beare Aem©, Sceew SPHERICAL A ee Two Incues Onto Eno OF Tie Roo@)Ano Instat. Lock ier Deaw Enos OF Sxoes ©) Ano @ TosemHer Avo Instat. Equatizine SPRING (MBAISC-BH Dried etBASE SHOP DATA-Issue Or 7-v- 444 VEHICLE OnIT O /ERHAUL Ae KE “SHEET LOAN |E “mcm Vabeuen EO] / Ds Diswanrte CluTcn SHAFT. Assemacr @Remove Correr Pw), Casrue Nut ©, Wasner ©),AND Beare Peoa. ©) Fron Te Suarr ®). Unscrew Nur©@ Fron Borr@ AND REMOVE THe Bou Ano Its LOCK Wasuer Feo Te C.urcu Peoar QD. Take THE C.utcH PEDAL AND THE Wooorurr Ker Q)OFF THe SHAFT. CSxry © UNSCREW bare AND THEIR LOCK WASHERS From Inner Cuamp @DAno Outer Cuanp@). Wire A HAMMER AND Puncn Drive Lock Pw) Our OF Lever ®)ANo Camps @) Ano @). Remove YY Uy Inner Cuamp@), Wooorurr Ker @, Lever ®, &% Quer CLame@ANo WooorurF Ker @) In Thar ORDER. InseEcT SuarT ©) Ano Brass Busy ) For Wear AN REepLace wirH NEW ParTs IF NECESSARY. IF Bearins (5) Is To BE Reetacto, Dawe Our OLD BusHiNs WITH A HAMMER ANo Special Too. D. REPLACE New BEARING Wire Same Too. IF THe WoooruFF Keys Have BEEN Damaced REPLACE WITH New Owes. REPLACE At STEEL CASTINGS THAT ARE CRACKED Or Batuy Rusted. TeST The Two Zere Frrmines QAND REPLACE le NECESSARY. WASH ALL PARTS In PETROLEUM Napnina Ano Dee TO ASSEMBLE CLUTCH SHAFT Assemety @), REVERSE DISMANTLING PROCEDURE. [MBAISC-BH-E6 107 BSD. Ma. ——11 Brake Pedal & Clutch Linkage ..... 125WeBASE SHOP DATA-/ssue OF nly. VEHICLE NIT” ‘Sus ASSEMBLY SHEET MEAL |B See Caer BolT | ‘SCOUT CAR HERCULES MODEL.IDL CLEAN THe CamsnuarT ThopougHty In Auy CLEANING SOLVENT AND Dev Wirn COMPRESSED Aik. mf € USE) Ja) a) Sy) TB) | Or The CamsnarT douenars® Foe THeie Liwrrs AD TLeRAnces: In Size Accorons To The Cxaer Bewow, Ie Nor Accceoine To SPECIFICATIONS, THE'Cam SHAFT Wit. HAVE To BE DISCARDED. iT SPECIFICATIONS. DSEXOOE © TF axe 2 ae UL Q Tech ie oe BIZ See Thar Tie Fear Ano Rese Beaemes Run Teue Wire There Cenrees. IF Nor, THe CENTERS StouLD BE Re-Cur in A LATHE BEFORE ATTEMPTING T STRAIGHTEN CAMSHAFT: PLACE Tit Camsuagr BETWEEN BENCH CENTERS, AND USING A STANDARD Dial INDICATOR, QHECK ThE CAMSHAFT FoR CONCENTRICITY, MAX/MUM Error PeemiTTeD 13.005." Geck Au Four Bearncs ®, WF The Camsarr Has Moee Tray O05 Run Our, IT May Be Ste AicHTENeD By USING A LUCAS MACHINE Toot Co. PRESS (CLEVELAND, OHIO) Oe 175 Equa. VBLocrs SHOULD Be USED To SunpoeT CamsHarT WEN STRAIGHTENING. USE EXTREME CAUTION WhEN OPERATING Ths Macuine By APpLvING ONLY SMALL AMOUNTS OF Pressure UNTIL Fawitiae WITH MACHINE. INSPECT The Gears Ano © FOR NICKS OR CHIPPED PLACES ; ie Any, SmoorH Quee THE RouGHNEsS WITH A Swat. Dié Oe Hano Geincer. IF THE Geae TEETH Are Foun 1 Be DavaceD Oe Norn, THe Gear Stroud BE REPLACED. To REMOIE Gear, REwove Nur © Ano Dewve OFF GeEAe WiTH A FiBéR Oe LEAD Hamer. REPLACE The New GEAG BY REVERSING PROCEDURE. ‘POLISH AND CLEAN ALL BEARING AND CONTACTING SURFACES With A Finé Geane OF Russer Srove (600F-/06 Geir) Oe Geocus CLOTH, (3A1SC-BH-B29-1 (0 SD he, Camshaft____.12 127\23BASE SHOP DATA -bsur OF hin C VERICLE wir Sus ASSEMBLY [SHEET MaAl |B Oba CAeeibirce B7| | SCOUT CA Heecues maces sy MODEL ZENITH OF 8 Nuwases Wn CIRCLES DENOTE OPERATIONS, FOLLOW IN ORDER. USE NEW GASKETS, COTTER PAINS AND SpRINGS Oney WHEN NECESSARY. SET Up CaesureTae Ov BescreT @ IN Vise. Remove Pus ®), Gasner©), SrmaneR ©, Strainer Bowl © Ano GasxeT © WITH WRENCH, REPLACE STRainee © WITH NEW, J BROKEN Qe DEFECTIVE. QDeanove Inte AduusTING NEEDLE © AnD SING ®, Qecmore THREE CAP SCREWS @ And Lock WASHERS WiTH WeENCH, MAI SC-BH B7-/(6)| rns Carburetor___.__.13 124BASE_SHOP DATA-/ssue OF : ‘Sue-ASSEMALY. SHEET, A SHER Aisin lok B7 | 2 | MoveL_ZENITE Gre cnet [1 M3Al | scourcae | 6) Tur Boor Asscuexr @ Over. Put Our Furcrum Pin) With FinceRs AND REMOVE Fost ©. Woen Furcrum Pin 1s PEMOVED, TURN Boy ASSEMBLY Back To ORIGINAL POSITION. Lut Our The NEEDLE VALVE) Wit Fincers, Unscrew NEEDLE Vave Seat© Ano Remove CaseeT ©. Quer Orr Boor GaxeT ©. @Qyzeine ACCELERATING PUMP ‘AND Vacuus Pasrow Assemar@) BY HAO. @) pence PONER AND ACCELERATION. Jet @) AND CAKET®), Wire 4 DEEP Sooner Weencu. (MBAISCBH- B72 cy 130BASE SHOP DATA “tore ¢ a oppo -_ VEHICLE UNIT OVERH, iA | PBLBETOR | M3A / PH eee, CARBURE B 7 Oo ERCULES MODEL IX] Monel ZENITH OF 8 With IntaKe AssEMBLy B) Tite MounTéD Ow Bracer ©), Remove SECONDARY VENTURICA) FROM Tit MAIN Booy ®). Remove Primary VenTuRI LOCKSCREW An Lock WasHER©). LUFT Our PRIMARY VewruRIQ) ol HAND. ‘Remove Wet Vewr © Wer WRENCH, : Remove le ur®. ‘Ano GASKET. (C6 remove Cueck Vawve @. vwececw Power JET Valve @ With Specia. Screw Driver @ Ano Lier Our Wit Smat Nose PUERS: [MQAISC BH B73 (6) BhBASE_SHOP DATA -tssuc OF /3/406 ENGINE SCOUT CAR. hercuLes ope. Jo] MODEL ZENITH ora ay Be eee Gat ice By FF © TURN INTAKE ASSEMBLY ® Over Ano Moun On Bracrer ©. eo ©) Remove Drain Pus ©h Remove Main DISCHARGE JET Plus © AND GaskeT. With Screw Drier, UvscREW MAIN DISCHARGE JET ©. TAKE MAIN Bopy OFF BRACKET, AND REMOVE MAIN DISCHARGE JET. @) SOAK ALL METAL PARTS IN CLEANING SOLVENT (Hypro-SeAL OR EQuivaLeNT) For AT LEAST Six Hours: Rise Parts AND CLEAN CARBURETOR Bopy IN Warm WaTeR IF HyDRO-SEAL IS USED. ALONG Smatt BRUSH AND AiR PREssuRE Hose SHOULD BE AVAILABLE. BLOW OuT ALL PASSAGES WITH AiR. WASH PARTS IN ALCOHOL.BASE SHOP DATA -/ssue Or Mfe/e © Venice our OVERHA i eee on B 7 THEE iH CAR Scour cae ences wepte aaj MODEL ZENITH “re 330 owe. Hol 308 607 D ) @ Tor tnrare Asseuscy B) Upsice Down, CHECK THROTTLE Swarr@®) AD Busanes© For Wear, Repcact SHAT AND BUSHINGS IF NECESSARY. To REPLACE BUSHINGS, REMOVE Tneee Screws At ©) Ano Remove Burterriy Vave ©. Remove Screw Ar©) Avo SLIDE OFF LeVER@). REMOVE Correr@. Press Swart Our Oo By Taree AT @. |Mount INTAKE (Borrow Sine Ue) ON BRAKET®. (2A )ncear DRAIN Puc®, Iseer MAIN DISCHARGE Jer). Be Sure Tuar Twelve Air_HOLeES ARE Oren Ano THOROUGHLY CLEAN, As THese Have A Tencency To Leap Suut. Screw Jer Down TicHt. 26 )insert Maw Discnaace Jer Pus Aw Gasxer®). (M3AI SC-BA-EB75(8]BASE SHOP DATA-Issue_ Or 0/:/42 7 [were Tir OY Riga | Se Asenece aaEF UMP! | OF ttt adamaner D7 | Cy @ TURN InTaKe AsseMBLy @ RisHT SIDE UP. Too. One.ta INSERT POWER JET VALVE © WITH ScREW Driver ® oI @) @ : ‘ImsERT CHECK VaLve ©. MaKe Sure VALVE In Boor Moves FREELY. CHECK HORIZONTAL PASSAGE Ar © To Make Sure Ir/s CLEAR. Brass Wine Can Be USED. @) INSERT IDLE JeT @. @ InsenT Weit Vent QD WITH WRENCH. @ INSERT Primary VenTuRI ® By Hand. Secure With Lock Screw @Awo Lock WASHER. INSERT SECONDARY VenTuRI @. BE Sure Stot @ Stibes Over Pw ® AND THaT Pin Prorrupes Far ENOUGH To PREVENT VENTURI TuRNING. IF Pin DoS Nor HOLD Venturi RiGib, Drive Our Pin AND REPLACE WiTH NEW. IM3A/SC-BH-B7-6 @)BASE SHOP DATA -hsve Or fee [ vewere ‘UNIT iSSEMBLY ‘SHEET Wad |B ORB as Biroe B7)"7 MODEL ZENITH @) Wrrn Booy Assemery @ Uesive Dow, INSERT POWER AND ACCELERATION VET @) AND GASKET. USE A DEEP SOCKET WRENCH. INSERT Vacuum Piston ©). See THAT IT WoRKS FReety UP AND Down Iw CruinoeR By Testinc With FINGER AS SHOWN Fic./. _) REPLACE ENTIRE UNIT. INSERT NecDLE Vave ©) Sear © Mo Gaseer®. Examine Por OF S VALVE AND REPLACE IF WORN. Creck Fioar @ For LEAKS, REPAIR OR SuBsTiTUTE Mew FLOAT IF NECESSARY. INSTALL FLOAT AND SéCuRE WiTH FutcRum Pn’ To CHECK CARBURETOR FLOAT (©) Level, PLace Booy AssemaLy Upsine Down Ow Taste. Tor OF Float) Stouo BE %2” BeLow MacHined Surrace OF Cover) Withour Gasket Use %2"Drut Rop As A Gauce AND Move Back Ano ForTH. BEND THE Lip© Ow Fioar AssemBcy 76 Correcr DEWATION.BASE SHOP DATA -Issue OF Mpafta 7 VEHICLE UNIT SuBAssemecy “| SHEET M34) BH ABET B7 |S | TURN Baby ASSEMBLY @ OER AND PLACE ON His D Assemeiy 8) On Boacwet ©. Stet Sow Tate De Screws © Arb Lock WASHERS. INSERT loLe ADwUSTING NezDLE E10 Serine Screw CLeAe To Bortom By Hao, Tats: REVERSE ULL TLRN. Repuxce Gasner@. Wnstate STRAIN Eon 7 Stranee®, Gastet ®, Ab Pe ©. Oy Hh coe Veve™, See —) Far Ir OPENS A VERTICAL HOLT, 4B ho Coss Nonny nA Hoan. KET ‘SPRING, Hato LEVER@) IN CLOSED POSITIGN AND Move Crore Vaeve Ue Avo Down Wri FHNGERS Acanns Aa Lever SPRING, I Sout Woek Fees Ip DEFECTIE, REPAIR Qe REPLACE. fo REepLace Sens) DISMANTLE CHOKE Vauve Assemeny, Remove Corre Pv©) SPQING Retanee® Lever Spec) An Ap Lever ®. Examine Lever Seng) IF Beowen CantarseD, Oe Wear, Reeiace Wine New. Inspect BusHine D Ato REPLACE IF WORN. ‘Sheng By PLACING ONE PeonG In HOLe IN : Bisnine®. Prace Spee Revanee © On Har, CaTcHNs Ornée Peone In Hove Ih Busuins@. Pace Toots REQUIRED Seong Retainer On SHAFT, CATCHING OTHER FONG In Hole In os Des SeeEr fore FE] RETANER, WIND UP 46 TURN AND Skeure Win Corer An ©. pense? Pan CarBureToR BLACK. 908778 3 17 GB) SAI BEBASE SHOP DATA-lssuz Or 10 21-424 iy [64 See ae eT OF? NOTE: NumBers IN CIRCLES DENOTE OpERaTIONS. FOLLOW IN ORDER. USE ONLY New CorreR Pins ANG NEW LINING. Use Toot Assemacy @ To Comeress CLucH So Nurs ® Caw Be Easicy Taxen OFF ANO CLUTCH PRESSURE PLATE REMOVED. SéT CLUTCH ASSEMBLY OVER Gott © Awo SET Tio Woonen BLocKs @ UNDER Pressure PLATE AND THEN ADD PLATE ©. TiGHTEN.NuT ® UNTIL PRESSURE IS RELEASED From NuTs ®. Remove Nuts ANo Remove CLutcH Assemay From Toot. Examine SerInGs © CAREFULLY AND REPLACE Any THAT ARE BROKEN OR Weak. LARGE SPRINGS SHOULD TeST 125 To 130 L8s., WHEN CompresseD To 12%" THE SMALL SpRINGSSHOULD TEST 60 TO 70 LAS. COMPRESSED To Use New Tass ® When Necessary. REMOVE Pins Q) ANO LiFT Our Fingers @. REPLACE PINS WITH NeW IF WORN, WATCH FoR ROLLERS © WHEN REMOVING FinGERS. REPLACE & ROLLERS THAT ARE Worn Op Babty RusTéo WITH NEW. es, ~ CONTACT SURFACE (@ OF PRessuRE PLATE @ MusT BE MACHINED SMOOTH IF MARRED FROM IMPROPER CLUTCH OPERATION, FIG.2. YZ} CLEAN Alt PARTS In PETROLEUM FIG.3, SOLVENT AND Dry With oT" COMPRESSED AIR. BH B2!-1 (7). cca tsa te Clutch & Flywheel_....14 137BASE SHOP DATA-Issue OF /02r42 EET. VEHICLE ‘UNIT WV Su8 ASsEmeLy Sh MAI \BH SRREL Goris Ba) "2 [scour Cae Cluren Linne Must Be REPLaceir Worn OR BuenT. Renove Rivers WiTH ANY COMMERCIAL RIVETING MACHINE. ‘AN ORDINARY PUNCH AND Hammer May Atso Be USED. Rewove Soun Rivets @ Thar How Sprine PATES®) To MAIN PLATE©. REMOVE TUBULAR Rwers © Thar HOLD SPRING PLATES TO UPPER LINING. INSPECT RiveTS@, Bouts) Ano Springs Q. See Thar The Sune ®) Is Nor Broken Or CHippeD, Use A New CLuon PLATE IF Any OF THESE PARTS Are Derective. @EMOvE AvETS() To Dismanmie Lowen Linins ©) Ano Main PraTe©. M3AISCBHE 2I- 2 (7) 136BASE SHOP DATA-Issue OF /0-2/-42F its [Bn SR ca P3 HERCULES Mone. sno| FLYWHEEL 1.1 Duce ANY COMMERCIAL RIVETING MACHINE Op Hawo Too. @) ann @) 70 REPLACE Rivers. KEEP CLUTCH PLATE LEVEL AND See THAT THE LINING DOES NoT Sip OUT OF POSITION WHILE FivETING. HEAD OF FiveT Must Be Wett ForMED. /F Nor, Remove AND REPLACE WiH New River, Fi. 3. USE TUBULAR SOFT STEEL RiveTs IN THE LINING. SEE THAT THE CORRECT HOLES ARE In Line‘AS SHOWN, ALL THE RIVET HEADS IN The Living Are To Be To THE OUTSIDE. /- RIVET SPRING PLATES©® TO UPPER Lininc ©. 2- River LOWER LINING To MAIN: PLaTE ®. 3- USING SOLID SOFT STEEL RIVETS, ATTACH SPRING Plates © To Man Plate ©: AN ORDINARY FLAT Punc ©, With A Sie’Enp May Be USED WITH Too. ® In Tis CASE. MBAISC-BHB2I- 3 (7) 139BASE SHOP DATA-Issue OF 10:21-42F VEHICLE. NIT SuB ASSEMBLY (WBA By eget CLUTCH € Scour C42 encites moos. sto) FLY WHEEL Bal ‘SHEET a ® Pack Rowers @) WITH GREASE ARD ASSEMBLE Fingers @) 1 THe PRESSURE Puate ©. No OTHER LUBRICATION Is NECESSARY For COMPLETE ASSEMBLY. REMOVE ALL SuRPLUS GREASE. SET PRESSURE ‘Pare ONTO Too ASSEMBLY @ FIG ‘App FIBER Tass © AnD SPRINGS G AND @. Be Very Canérun THAT THE SPRING. Tare Tuein CORRECT POSITION To THE PRESSURE Plaré ANO IN THe Housing QD uso SEE THAT ALL TWELVE LARGE SPRINGS @ AND Six SMALL SPRINGS @ ARE UseD. «K PD) Too} Dwe..Ne- D 433047 = D Ao tH 9) © Ticten Down PLATE @ UNTIL Nuts © Can BE READILY ATTACHED. ADJUST FINGERS AT A REASONABLE LEVEL. FURTHER ADJUSTMENT 1S SHOWN O. NEXT SHEET. MBAISC BH-21-4¢ (MBAISC HEIN 40BASE SHOP DATA ~_ ksue or /0-2-42-$ wr, OVERHATL | 8 er SHEET. YBAl GH ats JD eave Bal 3, OF 7 QD ASSEVELE QLUTON ALATE Ano Paessune Phare ASseuaLy To The Fur Wee Oe A for Wee. Kepr For Tits Pureose. Sct Asstueay ON Suerace Plame. Ust Tit TRANSMSSION SET Oh Too. @) Ween Is Senco Ano Is Toe Sue Lance, Gace ®) We Deverwne The CorricT Position OF Tie Fines. 6 OF The Ficers © May Be Ue Or Dow 002" Bar Teer Most Ax Be Ov The Same Pane. Anwist fincers By Ticureune Avo Loosowne NuTs©. Woe PROPER ADWSTMENT Has Been Ostamen, Star€ boce OF Nur Into Stor ©). Remove QUTCH Assemecy From Fiy Whee WiA/SC-BH-B21 5 (7). (4BASE SHOP DATA-tssue Or /f 21-424 venice UNIT 0 ER, VA ‘Sua-AssEmaty SHEET OUR RAUL CLUTCH | Med BF ca MODEL JXDI j Une Bal (Of ©) Examine Betr Housine @) FOR CRACKS. RepAR By Wecoinc Or Use NEW HOUSING. See THAT STARTER Hooinc Stups @ ARE IN G000 SHAPE OR REPLACE WiTH New STUDS. Tap New On RETAINER © IN PLACE WITH THE SAL. © Stawtine Towaro Tite CRANKCASE, Fig.2. FiG.2. SET FLYWHEEL On SuRFACE PLATE AND DISCARD IF SPRUNG. EXAMINE THE GEAR TeETH®, REPLACE THE GE4R OR REPLACE The ENTIRE Flywite”' ip TEETH ARE DAMAGED( TEETH 182, FiG.2.) AS SHOWN By DoTTED LINES ®. THE METHOD OF REPLACING GEAR Is SHOWN ON NEXT SHEET. @ ExaMin€ TRANSMISSION SHAFT BEARING © Ano Arpiace if Dérectve. Toot @ MAY Be Use0 For Thuis Purpose. Examine THE CLurcH Sureace Q) Ano REGRIND IF SCORED, SHSCBH-Bal-6 (7)BASE SHOP DATA- Issue OF /t-21-42 4 VEHICLE UNIT Sus Assemaly | SHEET M3Al |BH CRRRAL\ Cone Boy our Cag Heecuts mooe.sto| FLYWHEEL os Toois REQUIRED loot Du/e.No.| FET | OPER. | DET. 1433047| (| / |B 208789 [3 [4 TF 908790) 5 7 A 908791) 5 ran EJ 9090721 6 7, H ® FLYWHEEL IF THE FLYWHEEL GEAR @) MUST BE REMOVED, QUICKLY HEAT THE GEAR @) With A Brow orc. Tiss Witt MAKE IT EASIER To PRESS FROM THE FLYWHEEL, Take Care Not To Damas THe CLUTCH Contact SURFACE. THE INSIDE DYANETER OF THe GEAR MisT BE 030" SMALLER Than The DiameTER (B) ON THE FLY WHEEL. Hear Tue New GeAR@) To 400°F In Hor Oi. Beveeen Enps© OF Gear Een Musr Be Up. Press ONTO FLYWHEEL AND HoLb IN PLACE For ABOUT Tho MITES. CHECK THE ASSEMBLY OW A SuRFACE PLATE AND To See THAT GEAR ISON STRAIGHT By USING SURFACE INDICATOR, [M3ASC-BHB2/-7_(7)) \43i BASE SHOP DATA-Issve On 1p-t-42.4 VEWCLE NIT HAUL ‘Sub-ASSEMBLY SHEET [GA |B Sagem B24, | ® CLeaw The Connecrine Roo @) Ano Irs Pars In A CLEANING SOLVENT AND DRY WITH CONDRESSED AIR. MAGNARLLK. THE Cowecting Rao @ AND BEARING CAP @ FOR CRACKS. Check THE CONNECTING Roo For BEND Wirt THE FIXTURE SHOWN, FIG.2. Take THE FinsT Reanine AS Stow. THEN CHANGE TRE Two P, fas © Ano © Eno For Eno Sone @ TAKE THE SECOND READING. THE ALLOWANCE Wt Be .00I"For Every IcH, iW HALE THE LencTH BETWEEN THe Two READINGS. IN THE CASE ILLUSTRATED AT@ ThE ALLOWANCE Wit, BE .co1s! ©) meee one wo. 308197 VGAISC-BFBA-T (2) BSD me, 15 Connecting Rods & Bearings... 45,BASE SHOP DATA-Issuc Or /0-6-424 VEHICLE ww OVERHA Lees pees [sveET. LOM |BH saiiten groewnes OC4] 2, Tees. Doe. No © se 9083 G) Mu fis ff PARALLEL Us / i : ae 908188 CHECK THE COMECTING Roo For TwsT As Shown. Te ALLOWANCE Wit Be FicureD The Same As In OreRaTion 2 Attow .00!" Foe Every incu Feom The CenreR OF ‘Roo To Tie Pony Where Reson Was Taxen, SET Paratters ©THE Same Distance Fou CENTER OF Rap. © THE Roos May Genepatty BE SYRAIGHTENED By PLACING The Rap SEcurELy In A Vise, InsceT A Bae INTO THE Piston Pin Hoe At @ ANo Twist THe Roo WeicH Ever Way NECESSARY TO STRAIGHTEN, RECHECK AFTER EACH ATTEMPT TO STRAIGHTEN. TOOLS REQUIRED oak Owes. no. [weer] once | DET. 908770 9oare2 [7 906197 _|_T 908143 | 2 30a 14e afeal-s]e [aBase Snop Dara - Issue Or- 7-424 VENRLE OVERHAUL Ss AST ser MQA/ A BODY Cre Ae | / or Note: Numgers In Ciecues DemoTe OPERATIONS. Fotow In Oe0eR. Check THe Com.@) Ano WeLDED Memeers For Any BuckLes OR CRIMPS. STRAIGHTEN Or WeELg As THE Case Mar Reauie CHECK To SEE IF THe FRESH AIR VENT SHUTTERS @ ARE WorKine ProPERty Examine THE BRACKETS © To 5€6 IF Tey ARE SECURELY FaSTENED. Qe THE Fenoer © Is Bent OR Torn, STRAIGHTEN Or WeLp. SEE THAT BracneTs ©Are Wevnen To The FEND- ER IN ITS CORRECT LOCATION AFTER THE Straicurenine 1s DONE. STRAIGHTEN THe HeapLicaT Guard ©) AND SEE TuaT Iv ls Heto SEcurELY To FENDER. Jp Any Parr Is Berono Remar, REPLACE Wire New. ezIaN BH-AR-/ (7) BSD. He, Cowl & Fenders____._.. 1€ \47148BASE SHOP DATA-Issue OF mfsa VERICLE iNT UB ASSEMBLY EET M3Al BH QUERHAUL ine sever B2B / ‘Scour CAR HERCULES NODELRD oe 2 @ CLEAN THE CRANKSHAFT THOROUGHLY In CLEANING SoLYENT AnD Dey WinH COMPRESSED AIR. 2 Place THe CRANKSHAFT IN BETWEEN BENCH GENTERS, AND Usine A STANDARD DIAL INDICATOR, CHECK THE CRANKSHAFT FoR Run QuT. THE ALLOWANCE FoR UN Our Is .005" OR UNDER. CHECK EACH MAIN BearwG JournaL @ IN This MANNER. Jr THe CRANKSHAFT Has More THAN 005” Fun Our, IT May BE BENT STRAIGHT By USING A LUCAS MACHINE Took. Co. PRESS(CLEVELAND, OHIG)OR ITS EQUAL. \Blocks SHOULD BE PLACED UNDER THE FRONT Avo REAR MAIN. BEARING JOURNALS AND Pressure APPLIED To THE CENTER MAIN BEARING JOURNAL. Use EXTREME CAUTION WHEN OPERATING THis Machine By APPLYING OLY ‘SMALL AMOUNTS OF PRESSURE UNTIL FAMILIAR WITH MACHINE. CHECK THE DIAMETER OFTHE MaIN AND CONNECTING ROD BEARINGS. THEIR LIMITS ‘AND TOLERANCE ARE GIVEN I CHART BELOW. IF Any OF THE JOURNALS ARE ScoréD, UNDERSIZED, OR PITTED, THE CRANK SHAFT SHOULD BE REGROUND .010" Unoersize. Tas Is Don On. Bock” CENTERS AND Oncy By EvPERIENCED MEN. ["3A/SC- BH-B25- / (2) asa me Grankshaft—__.17BASE SHOP DATA-/ssue OF #3407 ENGINE Scour car HERLILES “MODE xe Wad | Bu VERHA SuB-ASSEMBLY CRANK SHAT BB SHEED © Powis Avo CLEAN ALL POLISHED Sureaces OF CRANK SHAFT Wit A Fine Geace OF RUBBER STONE. @® Inspect ThE GeAR@. IF THERE ARE Any Nicrs Oe CHIPPED TEETH, They May BE ToucweD Up With A Sat. Dig Oe Hand GeinDeR. Je The Gear @Is Prep Oe Woe, REMOvE IT Fam CRANKSHAFT Wirw The Geae Per ® Aww Discaep. Repiace Te New Geae By USING AN Aes0R PRESS. Nore: Be Sure T Line Ue THe Kevway In Gear Wire The Kev IN SHAFT Whew RepLAcins GEAR ®. TOOLS. REQUIRED 700 OMG. no [SHEET] OPER] DET. war [2 |7 |e {50 WSHISC BHEZB-2 2]BASE SHOPDATA -ISSUE OF Far-ae $ VEHICLE UNIT OVERHAUL SUE-ASSEMBLY Feeetatatas (ia) [EH «phe B20 o ‘OUT CAR Drenoven L CARBON From CYLINDER HEAD WITH Scraper (ORnaINARY PurTy KniFe)AND WiREBRUSH OR Use Moror DRIVEN WIRE BUFFER. CLEANTHE GASKET Surrace @ OF Cruinoer Hean By CAREFULLY DRAW FILING THIS SURFACE WiTH A 12° OR /4° FILE, (2ND CUT. PARALLEL SIDES). Qpsrecrovumnen HEADFDR LEAKS.ATTACH PLATE AND Gasker @ AND POUR GASOLINE INTO THE WATER CHAMBER. Jp Tite Test Suows A LEAK, USENEW CYLINDER HEAD. INSPECTNEW HEAD IN THE SAME MANNER. WGAECEE: 35D. te Cylinder Head... 1& istBASE SHOP DATA- Issue_Or pws € VEMICLE UNIT OVERHAUL Sus-Assemay MM! | BH GAM wae B2 | 1 Scour Gar, HERCULES-MODELtHO DISMANTLING NoTE: NUMBERS IN CIRCLES DENOTE OPERATIONS. FOLLOW In OROER. SAVE ALL GROMMETS, SPARK PLUG SLEEVES, ET¢., UNLESS THEY ARE BADLY DAMAGED. WASH DISTRIBUTOR AND SHIELDING ASSEMBLY IN PETROLEUM NAPHTHA AND DRY THOROUGHLY. RELEASE Two Sprnc CLamps®, Turn Cover® 2 To The Fsny, Ano Lirr OFF DISTRIBUTOR CAP ASSEMBLY ©. DISCONNECT KWURLED MTQ, Lirt Cover © OFF OF DisTRIBUTOR CaP ASSEMBLY © Ano Pune Oistrieuror Wires Our Or CPO, Gai SEVEN KnurLED Nuts ©,Aey Our Seven Grommets ©, Ano Pott. THe Sixx DistRiBuTOR WiRes AND One Con Wire Out OF Exeow@ Bowe Cerra Thar Each DISTRIBUTOR Wire RETAINS /7S CORRECT NUMBER AS MARKED On Irs Steve @. (BAISC-BRBZ TD asp Me Distributor & Shielding Assembly. 19BASE _ SHOP DATA- Issuc_Or 9-9702 © VEMICLE UNIT Vi PH, ‘SuB-ASSEMBLY MGAl | Bi CUERHAUL lositieti6# ane p> Scour Ax, HEROULES- MonEL:di0 V'guro-LiTE: TeW- #47 é ‘oF 6 SHEET | (S) kero Gromer, Concur @, Grormer©) Exsow.D) Ano Suceve ©) From Eacu DisTReUTOR Wire ©, Wuen Renovine Sueeves\©), Grip SLEEVE AT About Cenrer WiTw A Pur Or Picrs Ano Pau Orr Or Wire. Do Nor Grip Any HARDER Than Necessary So AS Nor To BREAK SLEEVES. CLEAN AND inspecr Each Farr OF Conpurr ASSEMBLY. REALACE ALL DISTRIBUTOR WARES WITH NeW WiRES OF Te SAME LENGTH. Fepuact A Daracto Or Mosins FARTS Wir New PARTS ANo Reassenece Disrmicuror Wires In ConpurTs Whrn Eacn Parr In Fosirion Show. C6 ‘Tx Our Two Screws Arolocn O wasters @aAno Revove Conenser Siew Cover) Taré Orr Nur Avo Lock Wasner Mo fiemore hiec Fron Tenrou. Txt Orr Kurcen Nor DyAno Rersove Concur ‘Avo Vee Asscnety Fron Conncnser AssEreLr ” Tané Our four Screws @) An Fenove Swiecos ©) e Lirt Orr Rotor @) Ano Exarnwe FoR BURNED CONTACTS OR CRACKS. Repcace Wir New RoTor Ir NECESSARY. INSPECT DISTRIBUTOR CAP®@ For BuRNED ELECTRODES OR Cracks. REPLACE Witn NEw DisTRIBUTOR Cap If NECESSARY. H-B2-2 (6) 1s4BASE_SHOP DATA- Issue OF'9-0-08 € (GA! [By URAL lot ww 5 2 SHEET EASINE SHIELDING _ASSY Scourcae | HERCULES: MODEL: sH0] “auTO= Li TESTE W414? ore © Test Conpenser@ Ow Avr Stanono CONDENSER TESTER. TéST FoR SHORTS, CAPACITY, AND LEAKAGE. THE CaraciTy OF THE CONDENSER SHOULD ‘Be Ar Least 22 IMCROFARADS. /F Conoenser Is Derecrive, Take OFF Nur Ano Loce WisieR@); Tae Our CONDENSER AND INSTALL A New One In ITS PLACE, ©) Loosen Nur©)Ano lirt Orr Breancr ARO). Remove Two Screws, Lock WASHERS, AND CLanps@) AND ONE SCREW Ano Lock Wasner®. Turn BREAKER PLATE© ABOUT 3” COUNTER CLocKwise, Avo LarT Our. Examine BREAKER ARM© AND Breaner Pate® For Conorrion Or Conracrs@) Ano Fit Or Arri© On Pin. Arm Must Worn FReeLy Wry. our Too MucH Fay. «REPLACE WiTH New Arr Ip NECESSARY. IF Contacts Are Baoty BURNT, INSTALL NeW ARM AND CONTACT SCREW. CLEAN ConTacTs ON Fine Ott. Stone. Use No On. issBASE SHOP DATA-Issue Or 1-2 € VEHICLE UNIT (SUB-ASSEMBLY ‘SHEET Al BH CRE aia B2| 4 Sesurtne end rooeso SEG ASS os Or Cup Serine @ Ano Too Tension Sernes @. Lier Orr ca ©, Forwecurs © Ano Sercer®, Remove Pw © Ano Dawe THe Suaer © Our OF Pinion @. Use BRASS DRIFT, WASH ALL PARTS THOROUGHLY IN Petroceum NapuTHa Axp Dev Wirt COMPRESSED AR. Jexanne Firwercuts ©) Ano Cam © FoR WORN SporS. Aiso Examine SHarT©, Pwion @,Ano Busunss ArQ Ano ® For WeAR. REPLACE Ali WORN FARTS. Ie Tension SPRING @ Or Cup Spins @ ARE BROKEN, REPLACE, )REASSEMBLE FARTS IN POSITION SHOWN IN FigURE. OL. ALL Movine ParTs WiTH LiGHT Ott. IF FeuT In End OF Can © bs Drv, Masten WiTH A Few Deoes OF LicuT On, iseBASE Shop DATA~ Issue_Or m0 € WERRIE ar a-ASSEMBLY SHEET M3Al \BH OVERHAUL [pitviai'8e ano B2 5 SHIELDING ASS ENOINE Scour Can, HERCULES MODEL: sO FAUTO= ITE: TEWe 4147 ore ASSEMBLING ® Gazer Brcancr Prate@ In DistRiBuToR BASE ® Iv Posirion SHOWN IN FicuRE 2 INSERT AND TIGHTEN Two Screws Ano Locn Wasners ©) Wir CuampsO)AnD ONE ScREW AND Lock wasner ©. Peace Breaner Arr © On Fin© Witx Eno@ OF SPRING INSERTED BETWEEN HEAD OF Screw), FiG./, AND ¢ Square STEEL WASHER®. Be Sure Tua FisgRO/s In Peace. BEHIND SPRING MaKe Sure Twar Conracrs @ Line, Up And THEN TisnrEn Nur ©. Hoon Tension Scat @ On BREAKER ‘Arm Nexr To Contacts @ Ano Test Tewsion OF Sprnc®. Ir Tension Is Less Tran 17 Oz. Or More THan 20 OZ, INSTALL NEW BREAKER ARH. Ou ConTacTs@ Hato OFEN WITH Lope OF Can ®AS In Fic. CHECK Tue Clearance BETWEEN THe CONTACTS With A STANDARD FEELER GAUGE. THE Cuearance Must BE .020°+.00!" for Each OF THE Sx Con7acT OPENINGS IN One RevowuTiovOr THE Cam SHAFT: 1BAISC-BH-B2-5 (6. 1s7BASE SHOP DATA -Issuc Or 9-03 &. (BH a VE A UL | pSe ASS ano B? "B ] MEROULES- MODEL AD ayro-LiTE=TBW-8i47 [wencte 4d 8 ASSEMBLE SiteLDS@ ON Base @) OF 1O) disreeuror In Pasirion Stow. Frace Roror©)On SHarr ©) . INSERT WIRE © Trroucn Quruet ©n Compenser Housine AND Secure On Stuo@ WITH Nur Aw Lock, Waser @. Fur Ov CoverDAnb SECURE With Two Screws Ano Lock wasters ®. Secure Conouir® To CONDENSER HousING With Knurceo Nor @. (O)sreme Tie Seven Wines © Tarouse Exsow® Inserting EACH WiRE TurRouce ITs RESPECTIVE QuTLeT AS NuneereD. — Press GronmeTs© In Ouruers WO SECURE WiTH KNURLED NuTs®. AO) INSERT EACH WIRE In Irs RESPECTIVE Position IN DISTRIBUTOR CAP ©) AND TIGHTEN KwuRLED NurD. Clamp DisTRIguTOR CaP ON Distrieutor BaseQAND SECURE Smiewone Cover @ In Place By Turnine CatcH Pin ATW IN SLOT®. BAISC-BH-B2- 6 (6)BASE SHOP DATA —Issve OF 9-/- 424 VEHICLE UNI Sus-Assemery (SHEET MsA/ \ A QUERHAUL | iit spvcers All 7 SeourCar BODY __| Gaus Accesses ay Nate: Numsers IN Circces DENOTE OPERATIONS. Fa.tow IN ORvER. D ernane The Wareveraore0 Ducx Toe ®, Siac Curranss @, SrRAPS AND Bucxces ©, Trace Pros), Personne Seas @, Camas Cusnons @), Ano Dawver SEAT @, For Wear Ano TeAR. REPAIR MINOR TEARS. REPLACE THOSE PARTS THAT Are Berono REPAIR. Caution A WET Top SHou.o Be Drep In A RAISED Position WHILE LUnoer TEN- ‘Sion, WHEREAS IF Dito Iv ALOWERED OR FOLDED PosiTion /T Witt SHRINK To SucH AN EXTENT Thar Fir IS SERIOUSLY IMPAIRED. Ceck The Taree Meta. Bows @ Ano The Six Tusuar ADAPTERS (D.. IF Twist DOR SPRUNG, STRAIGHTEN. REPLACE IF BEYOND REPAIR. fig2 WAAISC-BH- A/- 7 (| ESD. he. 20 Duck Top Supports & Canvas Accessories 159leoBASE SHOP DATA-Issut OF /0-Zo-4v § Tete r SHEET (aw |Bn] Aone / OUT Cae HERCULES, MODEL JXD. OF 15 ‘MAKE Suee ALL BeArine” Caps W) KEEP Tee Quicinal Posirion. ASSEMBLE THE Into Tee Buocx. Tap On Sunsaces@) Wir Beass Haver AND Pav Wit Pinca Bap IN Te Diection OF Aeeow ©). ArTacH Inorcarae ©) Witt °C "CLAMP AS SHOWN. Taxe The READING Ow The InoicaTOR. Hoxb InpicAToe Fincee Away Feom THE END OF THe CommsH4FT IF TARPING Is NecessAey, Fey Oe TAP THE CRanKsHAtT IN THE OPPOSITE Direction OF The Aeeow Q,Taxé The ReAcnG OF THe InorcaToe. Ti DikFERENCE OF THE Two Pesoweslino CuzAeance) SHouLo BE 006" Fo..ow Peocecure In Fis.3 To Goepecr The END QLEARANCE. [Me Tuop Or Facne New lveRs AT ASSEBLY JATTACH FACING BAR ©) IN ThE SaME MANNER AS WHEN PUTTING THE CRANKSHAFT IN Place. The Tueée Priors ©) Shou BE IN THE FeONT, MIDDLE, AND NO, 5 BEARINGS. ASSEMBLE Wim One OFTHE Two Coutars @)Aww @ Ow Eacn Sine OF THE Most Cowvenienr SMALL Beaeing Between The Feont Axo MiopLe BeARinGs. SET CUTTER IN PLACE. CUTTING EDsE @ Snows Hye A Sucur Lesa Bb The Sueece Tb BE Our, Fie. 2. Th AMOUNT TO Be Our Feom The Beaeine SHou.n BE DMibeD AND HALF TAKEN Feom ExGH Se, Ween Currée Dis ON Tee SIDE SHown, Pu CurTee Just Up 7b Tre BEARins Ano Ser Cur By Backins Nur @)Away. TicxTen Ser Sceew@/o How in Fosiion. ONLY A Feaction OF A Tuan OF Nur @) is Necessaby Because Nor Over 00!" Soup Be Our Aiay ATA TIME. THiS Sait AMOUNT SHOULD BE Saaven AWAY GeabuaLy BY PULLING LigHTlY ON Tne Hanoue As Ir is Tueneo. Cur The Orrée Sine By Ansusrine Nur @) AND SET CUTTER ON THE OPPOSITE SIBE. (GA BFASEENG- 78), Me. Engine, Assembly... ay telBASE SHOP DATA-Issue OF /0-30-4.4 Vel Unar 47 |B ASSEMBLING mes My, i of nerceuese MODEL JKD 2 OFIS g (4) Repwace Mun Beare inserts Ar @) Ano Drop (aes © \F) coun. sue @) Into Pasion Aca, Arract HeE-O) oot @ FER earns Ceank SHAET. c™ A) Repcace Each Man Bésaine inser © AnoCar ©) I Treig RESPECT FasiTions, PLACING Tw0.00! Peeces OF Suma Unoén Lac Exo Or Every Coe (©). © Teerren Down Tae Back May Bearins ©,©, SECURING I Wire Cae ScREWS AND Lock WasieRs. Tua Cane SHAFT. IF CRankSHAETISToo TIGHT, LOOSEN THe Bacx Maw Earn, ADD ONE.OOI" Stun To EACH END Anb Secure BEARING AGAIN. If CRanicSHAFT TURNS FREELY, Looséin THe Back: Man BEARING, REMOVE ONE.OOI"SHim Fron EACH END AND SECURE BEARING Asan. REPEAT THis Proceouré With Each May BeAaing. THe Force Re@urgeD To Tor CRank- SHAET SHOULD Have To BE INCREASED AFTER EACH BEARING HAS BEEN SECURED. LuspcaTe Aut 12 Pus Roos © Avo Reecace, inspect To Scé Taat EACH PUSH Roo Does Nor Sicx OR BIND. 17 Mar Fir BETTER IN A DIFFERENT GUIDE. ~ @ LupsicaTe Eacn beaane (E) AND Fig2. — Bioc. Lave Ue Tie Timins Dots On Gun. Swat Ar QD Ano CownswrT ATO. (WSATSC BA ASSENBINE 215) tozBASE SHOP DATA-Issut OF /t-30-424 VEHICLE Unit WB [Ba] eugene Scour Cag. ERCULES MODEL JO. SHEET. o/s ® APPLY GASKET Cortpouno AND REPLACE GasKeT @ ON THE FLYWHEEL HOUSING @, Pace The Firwneee HOUSING IN PosiTION ANO Secure To THE ENGINE Bac © With Swe Hex-HeA Cap Screws Ano Lock Washers D. © Reetace The Furwueex ©. Live Ue Two OF THe Hotes © wire The Two LocATING Pins InsWe Furwnee. Housine @. Secure THE FLywHEEL WirH Four CasTLe Nurs Ano Gorter Pins ©. 163 (WEATSC-BHASSEMBLING: 35)BASE SHOP DATA-Issut OF 10-30-42 4 Venieie Tir SHEET 7 ASSEMBLING WA OT ea a ca Ornrce The Fiatr Wasnér @) On loue Gear @) Ano Instéue IoLER GEAR. THS GEAR IS NoT StcuRED In Ayy Way Bur Heo N Pace By The Gear Case Cover ny Gasket Compound To The Suntace (D). Loosen Nut ©) And Back Up Apwustins Screws ©. Rerrace Casner © Ano Gear Case Cor ©. SecuRE GtAR CASE Cover Win Eichr Hex-HEAD CaP ScREWS Ano Lock Washers @. Tienrew Ansusrivs Screw ©) Agawst Tne Gears. Then Loosen 8 OF A Turn Ano Lock Wan Nur ©. teeBASE SHOP DATA-Issut OF 18-30-42 4 Ta EH | ASSEMBLNG "Ey @ Puace He Eneme So Thar Irs invA Perrenticuuar Position Restine Ow Trt Flywrcee Pusce Tue Wave Spans @_ Ano The Serine Sear (©) TOGETHER AO REPLACE Teen w Evcine Buoce Ar ©. Repuace THe Vauves (O. Te Head Damerer OF Tie INTAKE VALVES 15 194, THE EXHAUST VALVES ARE 196. ‘Anus Bee lave Spams Compressor ©) Bins Peover GaP ANd Compress THe Wave Sern ©. Reprace THe Vue Liter Pins ©) Avo RELEASE THe SPRING Compressor. REPLACE ALL VALVES In THs MANNER. NOTE: Vauve SPRINGS SHOULD BE INSTALLED When TaePeTS ARE Down OW THE COMPRESSION STROKE. THE SEQUENCE OF FIRING I5 1-5-3-6-2-4 TURN CRanwspArT To ATTAIN SEQUENCE OF VALVE SPRING INSTALLATION. Loosen Te Wu Ar @) Avo ADAST CLEARANCE BETWEEN YaLye AYO Paustian BY Turon The Screw (2). AdwusT \AtvE 10.0067 Tis Wie Have To Be Done AGAWN AFTER ENGINE Has BEEN TESTED Avo IS Sti Wared, — NSAI SC-REFA SFA és,Base SHOP DATA-/ssue OF 30-424 i BY ASSEA MBL ING MBA in SCOUT CAR HERCULES MODEL JD, ons SHEET REPLACE ROD BEARING INSERTS, LUBRICATE INSERTS. AND Instant. THE PisToN AND Rob Assemety Qn Irs Jounal AS SHOWN IN fic.1. PLace Two.00!" Saas BETWEEN CAP Ano Roo At @ Berore Ticureninc. THEN Ticuren Cap To Tie Roo Just As IT Woutb Be DONE In REGULAR ASSEMBLY. @ A Desire Fir For Tie Roos SHoun BE Jo Tuar Tae Force OF GRanry ALONE Witt Stomy Put The Roo Down From Posirion SHOWN In Fic. 1. ADD OR SUBTRACT The NuMeER Or 001" Sums Ar @ In An Arremer To Acquire. The PERFECT FIT. [Gio Gueck Te Pine Cap, Pace ARING In The Grumper As Suown AT @ AND Sauane Rane Up Wirn Cruinoce WhtH A PISTON. CHECK Cap® Wir A FEELER CAUCE. CORRECT RING Cap Suoub BE 015" To .020". REPLACE The Rancs ON THe PISTON AS SHOWN IN Fic. 2. (oyun Roo Has BEEN FITTED To. CRANKSHAFT, Remove Ir AND IsTaLi. PROPERLY, Fic. 2. Use Too. @ To Compress The Rincs WHEN INSTALLING Piston © In CrtinDER®). SEcuRE Tue CONNECTING Rod To CRANKSHAFT IN SAME Manner AS IN Opeparin (8) ANO USinc Tue Same Amounr OF SHIMS, REPEAT THIS Proceoure To ASSEMBLE THE OTHER PISTON ASSEMBLIES. [M3AVSC- BHASSEMBLINGE eI YeeBASE Ste DATA-Issue OF 10-30-414 VEnicie Scour Cag tw ASSEMBLING ENGINE HEROULES SHEET, OFS. MODEL IXD Tua CasnaxsriarT So Thar Tae Two Cenrer Cownectinc Roo Joumnas 3 Ano 4 Ar @) Ane Tumneo Awe Fron THe Ort Pump Posmay. Resace THe Gasner @ Ano THe Ou Pao Assemary ©. Secune Wn Two Hex- HEAD Cap Screws Ano Lock WasHers ©). 2) CC) sony caseer Cowra To Tne Scene © Ano Pace THe Giser Qn Pace. Ree.ace Tne Borrow Pan ©) Ano Secure Ir To THe Encwe BLocn Ww 25 Ce Screws Ano Lock Washers @. Reevace THe REmanine ANE Cap Screws Ano Lock Wasveas D Secvawe Tre Aw 7o Tae Firwee. Housinc. er \M3AlS C-BH-ASSEMBLING- 70eet SHOP DATA-Issue OF 10-30-44 — VeHILE ir “ASSEMBLING WAL |BH| Senne é | ENGINE HERCULES MQDELJXO Ly Scour CAR- @ REPLACE THe FeonT MOTOR MOUNT @. THis UnIT Is NOT SECURED IN Any Way But CAN BE JuST PUSHED On By HAND. @ ReeLace WoopRuFF Key 8. Line Up Key Stor IN PULLEY ©) WITH KEY ®sAno Deve Puey On SHAFT WiTH Toot AND HAMMER. ‘NOTE: The PULLEY May Nor Have To BE DRivEN On Bur May BE Loose ENouGH To REPLACE BY HAND. REPLACE THE STAR WASHER ©) AND CRANK-RATCHET (6). SCREW RATCHET IN PLACE AS SECURELY AS POSSIBLE. PASSEMELINGSO5) 168BAS SHOP DATA-Issue OF /4-30--4~4 SHEET. VeniCLe Unit ASSEMBLING BH ENGINE Scour Can HERCULES MODEL JXD oris REPLACE THE CYLINOER HEAD) AND GASKET © SECURE CruNDER HEAD WITH 26 CAP SCREWS©) TisHTEW CAP SCREWS, STARTING From Tit. CENTER Ano WarKING OUTWARD Toward Born ENDS, AS INDICATED. (2) REPLACE The Maniroo AssEMBLy ©), EXHAUST AND INTAKE, AND ITS GASKET. Secure Manirowo ASSEMBLY With 10 PLAIN FLAT WASHERS Ano Brass NuTs®. 16a MBAIS ‘BiF ASSEMBLING 105)BASE SHOP DATA-Issug OF /0-30-4 2-4 NA? By ASSEMBLING ay MBAl | BY Nene Scour Can HERCULES MODELJXD OF1s @) ‘eetace Tue Fan Asser @) Ano SECURE To Gear CASE @ wit Two CAP Screws Anp_locr Wasners ©. Bae Up AnsusTine Sonéw @) ANo REPLACE THE GASKET ©. Peeiace THE WATER Pune Gear © 1s Property MESHED WiTH CAMSHAFT pure Assemecy ©. BE Sure WATER ‘AND IOLER GEAP Inv GEAR CASE. SECURE WATER ‘Pune ASSEMBLY WITH ONE LONE AnD TWO ‘Suoar Hex-Hean CAP Screws Ano Lock WASHERS ©. Pace GasreT D Ano Brocx Connecrion © On Buocx AND SECURE Wit Four Lock wassers Ano CaP Screws O- @ ToConneer Water Pune Assemacy © ISTALL RugsER HOSE ANo Hose CLAMPS ®. Secure By TiGHTENING HOSE CLAMPS To Buock CONNECTION (MZAISCE S-ASSENELING 10S) \70BASE SHOP DATA-KssuE OF /0-30-294 VEHICLE Unir ‘SHEET By] [Ba] AS9RBLNG i Scour CAR HEROQHES MODEL SXD_ OFS. CD) REPLACE GASKET @) AND WATER CONNECTION @ ON CyuinoeR HEAD. Secure Wirt Two CAP ScREWS Ano Lock Wasners ©. 7) REPLACE THE SPACER). REPLACE THE StarTER ©. SECURE STARTER WITH $B Thee NuTs Ano Lock WasHers ©: “* Fig. I REPLACE THE ENGINE MOUNTING BRACKET @ON THE Fly WHEEL HousINe. SECURE WiTH Four CAP SCREWS ANO ‘lock Wasners ©. s1SC BHASSEMBLING-1/(13)] mBASE SHOP DATA-Ksue OF 10-30-02 = VEWICLE tur i 1 [Aa] ASSEMBLING IE Scour Cag HERCULES: MODEL JXD. SHEET Ges REPLACE THE GASKETS AND SPACER@. REPLACE THE CARBURETOR AND SECURE With TwoNurs AnoLock Wasners ©, REPLACE THE FUEL PUMP Fig. 2 AND GASKET ©). SECURE Fue PUMP WITH THREE SCREWS Ano Lock WASHERS ©. @ REPLACE THE vacuurt LINE®, Wrich CONNECTS THE MANIFOLD AND FUEL PUMP. fs Pom [MSA SC-BrPASSEMBUNG 2BASE Sho? DATA-Isue OF /0-30-44 i [Ba] eee i Scour Caz HEROULES MODEL IXD EET ors Decnsee Te Soar Aucs @ Ado Them CasneTs @. T/6HTEN Laon Sore Puc FiRMLY, CBnavsce Tue Generator An Bracrer, Fic.2. Secure Wr Thee Cap Screws Ano Lock Waswers ©. ArracH The Two Conouirs Ano Wines @. ISAIS C-BHASSEMBLING- (305)Bast SHOP DATA-lssut OF {0-39-44 F veniae > | Oxir a i A MBLIN saEFF aj |BH| A2shanetiNG /4 Scour Cae HEROULE: MODEL JK i orrs_| jus ! = TOINSTALL DISTRIBUTOR SS) \ | B_@, 1! | MS me = o ar ah D L e » £iG.t gy ST) Toe CeaisrarT Uri Ha. PISTON 65 ON THE COMPRESSION STROKE AND AT ToP DEAD CENTER. Ts INDICATED By Tre DC ‘Mork On Fir wnt, MEN Lineo UP In CENTER OF INSPECTION HOLE AT@. CG Roror@)SHouL0 BESET So Tar When DisTRIBUTOR & nsTALLeo IT Wate Por DirecrLy Towaro No. / Cyunpee. This PosiTion SHOULD Place RoToR®) So THAT IT Witt BE APPROACHING NOI CYLINDER TERMINAL INDSTRIBUTOR CAP (Cwirn Conracr PowTs® Just READY TOBREAK. 4D pore osreeurce Tur barrery Frunc©® ©. POINTS To He REAR OF AD PARALLEL To Enane Bock, Fi. (P} Secuee Ar@)Witn Assenezy Sxomn ATG). BraceT @) SHOULD BEPLACED So ScREWC) is UP AGAINST EnD®) OF ‘Suor. IrPosiriowCr Roror@) Hs Been Crawceo Duens — / &) INSTALLATION, IT Nay Be Correcré By LOosENING SCREW Oyo Teewne LisTeiguToR. Ipepuace Bee Disrereuror CAPC)AND SHeLDING ASSEMBLY @D. THe Luc “AM GB Snouohrinirs Provee Scoxer MDsTesuTOR, SECURE CHP Wi THe Tao CuiRs@). SECURE Senet By TicnTénne Sc2ew@) MOUNT Beacres EON CYLINDER HEAD BoLTs Avo COnNECT Spnek Plu WikeS'AS NUMBERED. a 174BASE SHOP DaTA-bsue OF 10-34-81 $ VEHICLE Unit ASSEMBLING one MAL OT) etB sae De Pur CLUTCH PLATE @ ONTO TRANSMISSION SHAFT®) ORAN OLD SHAFT KEPT FOR THIS PURPOSE. INSERT SHAFT INTO PILOT BEARING. ADD PRESSURE PLATE ASSEMBLY © AND FASTEN WITH TWELVE CAP SCREWS ANDLOCK WASHERS ©) TIGHTEN CAP Screws Down Eventy, NOT ONE ATA TIME, REMOVE TRANSMISSION SHAFT. Tooes _Requinen Toor Dw6. NO] SHEET] OPER] DET] 908876, 41x 433051 5 [6 TE goeza9 | @ [20 [6 SORE e | [M3Ar-5C-BHASSE MBLING?S05)\16BASE SHOP DATA-Issue Qe 10->9-4¥% Wey [Ee nmin B22) 1, CASTING INSPECTION ‘NUMBERS IN CIRCLES DENOTE OPERATIONS FOLLOW In ORDER. WASH ASSEMBLY IN CLEANING FLUID AND TEST For LEAKS. a) a Peviove O1 Seour @ PREVENT BeeACGE WHILE HANDLING Bock. Bott Te Bosen® Ow THe GASKET SuReACE T PREMNT AW DAMAGE. LEAVE BLOCK SET I CLEMUNG SDLVENT PeNeTe@. OR Foutt)OveRwiGHT. Rinse Hor WareR AND Dev WiTH Compressen Ar_NevER Use A So.uTion ConTaINING ANY GaUSTICS TO CLEAN TH BLack Foe Tey Wit Dawace THe Cam BEARINGS. CAUTION: COVER CVLINDERS, VALVE SEATS, AND GASKET SURFAGES WITH A Fiat OF HEAW OL 02 GREASE JF THe Buock IS LEFT SITTING Over Taree OR Foue Hours. Wy NapHTHA (Oe Four) Ano Dev Wim Aig. ATTACH GASKET AnD Plate ©) See THAT Buock is Dey Ano Rove NAPHTHA Oe GASOLINE INTO THe WaTeR Cramer AT ©), EXAMINE ALL SURFACES OF The Buocx For Leaks. Do NOT NEGLECT 70 Beawine WHERE THE Pusy ons OPERATE ON Fie O7neR SIDE Ano Insioe Tie Invane Ano Exxaust Camaers ©). Taxe Special Novice OF Tre Gruner Wais© Aro Discato The Exmee B.00r IFA LEAK Is Found. IF A LEAK IS NOTICED AROUND Any OF Te Feeeze Pues), REMOVE AND INSERT NEW PLUG. IN AN EMERGENCY, SwALL Ouroioe. LEAKS OrGeacrs In Tie Btock Mav BE WELDED. REPEAT THE ABovE Test See TAT ALL OL PASSAGES ABE CLEAR Ce Rewene A OF The Paucs @)ANo @NECESSARY Bean Bem (se Freean Sean Coneouno Men RePLinG Tae TERI ALES). [KAGAISC-BH 632-16) a, Engine, Block 2%BASE SHOP DATA-Issue OF I-v?-te4 vewere | Unr OV/EDEAU] [Sue-dssewaur MOAl |B“ anene IROCKENGNE B32 ScourCar. SHEET Qi The DIAMETER OF THE Cyuncers@). Tus READING MUST BE TAKEN Ar The Tee OF Tre Rine Ravet. Avo Crosswist IN Tre Btock,Fic.2. IF CYLINDER DIAMETER 1S LESS THAN 4.004” Remove THe Ringe) Water Was Mage By THE Piston Rings. PROCEDURE FOR OVERHAULING CYLINDERS o— tL DY Aish Worn More THan 4.0047S Given ON SHEET 6. BLOCKS WITH CYLINDERS OvER 4.024” Have fone BEEN, REBORED AND ARE NOT FiT FoR FURTHER @) fant ‘REMO\ VE Rioge Wire Rioce Reaver ©) (Lysue Corp. CLARINOA, lowA Or Fouat), READ rections Thar Come Werk Feamer. BE Carérun NoT To UNpeRCUT THE CYLINDER Wut. Aosusr Screw © U7. CUTTING ASSEMBLY Witt SLip PAST RIDGE Into “YLINDER, THEN AbvUST THiS Screw UnT. ALL OF Tue Rowers ® ARE Swus AGAINST “te CYLINDER Watt. Torn Not ©) Uwrit. CurTER@Is A LITTLE BELOW THE RIOGE. GREW Cour @ Down AcainsT Surrorr QD. Thus Wit SAVE Time ON The Orner YLINOERS. Use A RATCHET OR ‘T” WRENCH To OPERATE REAMER. EXERT A Downwaro RESSURE While Torwinc To Keep SuppoRT FLAT AGAINST GASKET. |M3AISC-BHBS2-2(6)) iBASE SHOP DATA-/ssue Or _1t-00 wr 8 Ma |B er ccrnene B22] ScourCaR ‘Hteeene sMobeL. VALVE GUIDES Or Our Au Vave Cues @ Ano Measure WiTH “CO” AND ‘No Co’ Puc CAcE®. IF “No Co” END ENTERS A VALVE Cue, Tuar Come Must BE REPLACED. (2 Vure Comes @® Mar Be Presseo Our Wr Paar® OF Tie Toot Assemety ©). INSERT NEW Vave Cuwes@) Ww Toas©@An@. RELEASE PRESS AS Soon AS SHowDER®) Covracts Toa®. Jf "Go" END OF Puc Cact @) Wit NoT Co INTO NEW Cue, REAM Wirn A Suan Ye°STRACHT REAMER. [M 3AISC-BH-B32-366) maBASE SHOP DATA-Issue OF 10-27-47 vewece | Uuer OV/ERHAUL Sue Assemacr SHEEF MAL |B “neha gf MOOKENGNE BI] &-® Fuel @ EXAMINE CAMSHAFT BEARINGS. REPLACE BEARINGS [F DAMAGED ScORED, OR Worn ENOUGH THAT THE INSIDE DIAMETER OF THE BEARING Is 004" LARGER THAN THE DIAMETER OF I75 RESPECTIVE JOURNAL ON CAMSHAFT. IF ONE BEARING IS BAD REPLACE THE COMPLETE Ser OF FoursTwo s""Wi0e Ano Tio'%e" WibE. A SCORED BEARING IS GENERALLY Due To A CLOGGED Ou. CHANNEL. SEE THAT ALL OIL fib 2 CHANNELS ARE CLEAN, © Beapines Mar B€ Driven Our Wirw Too. @. Dre Out Two Fron END OF BLOCK. THe Toon ASSEMBLY ®), FoR REPLACING THE BEARINGS, CONTAINS A SHAFT Wit FOUR STEPS. EACH STEP HAS A ParT © FoR HOLDING Ove OF THE CAM BEARINGS. Att Bur THe FART THAT Hows Eno Bearinc © Has A Stop Washer ©. Fic.2 Shows THe MeTHo0 OF ASSEMBLING Toot INTO THE BLocK. CAM BEARINGS ® ARE Paced On © WiTH BALL S10? INTO BEARING Oi HOLE. PARTS © ARE Pur INTO THE Buocr Dinsions @ Faom The Stoe Nearest THe Fron END OF THE MOTOR. SET WITH Baus. Srop @ In The Oi Guanes, CAREFULLY INSEAT SHAFT @THROUGH THE FARTS @. THe Connect 5iZé Waster @ Must BE Pur IN FRonT OF EACH OF Tie Parts © AS THE SHAFT Passes TuRousH. Aoo PLare ©, Nur AND WASHER @), AND TIGHTEN UNTIL BEARINGS ARE PULLED INTO PLACE. MS3AISCBH B32-46)| \e0BASE SHOP DATA-sssue OF /0-27-4-5 VEHICLE ur VERHAUL|Sue-Assemecy SHEET Wey |6 Meee Mnocinene B22] 5, ] FIG. 2 @”) START MOTOR AND START HOLDING TENSION ON COMPENSATING HanoLe ©. Do Nor Press UP OR Down WHILE HOLDING TENSION. This TENSION SHouLD BE HELD To Mar No.! ©) AND HANDLE SHOULD BE LOCKEDIN No.3 POSITION, /IG./. VALVE SEAT GRINDING. DoNor REFACE Vave SEATS @ UNTIL AFTER VALVE GUIDES HAVE BEEN INSPECTED AND DEFECTIVE GuiDES HAVE BEEN REPLACED. Use (HaLt: Or Equat) VALVE SeAT GRINDER. REMOVE GREASE FROM VALvE SEATS IF Any IS PRESENT. SEE THAT STONE |S CLEAN, HAS THE Coprecr ANGLE (45°), AND Is THE Correct STone For THE MATERIAL. Be Sure To UNDERSTAND THE INSTRUCTIONS THAT COME WITH THE GRINDER BEFORE USING. Pur Guibe ® SECURELY IN PLACE. SLIP GRINDER CAREFULLY OVER THE GutbE AND LOWER THE STONE To JusT ALITTLE ABOVE THE VALVE SEAT BEFORE STARTING THE MoTOR. HOLD TENSION AS LONG AS STONE AND SEAT MAKE CONTACT. BRING STONE IN CONTACT WITH VALVE SEAT AND ConTinuE To FeeD (A Lirrie Ar A Time) UNTH THE COMPLETE SURFACE OF THE VALVE SEAT HAS BEEN Ground. “Do Nor REMOovE MORE METAL THAN Is ABSOLUTELY NECESSARY. STONE MUST BE HEPT SMOO~H AND CLEAN (USE DiAMOND STONE FACER FURNISHED WITH THE GRINDER) To Insure An Accurate JoB. Wet [MBAISC-BHB32-5(6)BASE SHOP DATA-Issue Or 14-27-44 4 VENIGLE Tuer OVERHAUL) ueAssenewr eae ENGINE —_| MoAl |B neice, BLOCKENGINE BIZ] ©, HEAD GASKET SunPace EE S 6.2 Gra 2 NOTE: Turn HONE WITH A SLOW TURNING MOTOR. The Moror May Be Hue From A BALANCER (PNEUMATIC, CHICAGO OR Equa) Op Lance Con. Serine To Make THe JOB Easier. A PorTabLe Ap Dri MoToR May Be USED For THis PURPOSE. ® CreinoeRs Nor WoRN To MoRE THAN 4.004°DIAMETER ARE HONED (SUNNEN HONE OR EQuAL) AFTER THE RioGe Is REMOVED AT THe ToP OF THE RING TRAVEL. KEEP HONES LUBRICATED Ww Dieset Oi. WHILE HONING. UNLESS CrLINDERS ® ARE SMOOTH, ExcePT For RING RIDGES,A Coarse HONE SwouD BE USED First. USE A FINE HONE TO SMOOTH THE CYLINDER. PRACTICALLY 40 MaTERIAL SHOULD BE REMOVED IN THiS OPERATION. PLACE A Wood Bock IN - JorToM OF CruNDER To PREVENT Hone FRoM GOING THROUGH OTHER END OF CYLINDER. L Z CxLINDERS THAT ARE SCORED OR WORN OvER.O04" AnD LESS THAN.020"MUST BE REBORED. ‘ore FoR 020 ‘Oversize Pistons AND RinGS. USE THE HoninG Proceouré IN THe Firs PERATIONS To Pouist. IF THE CYLINDERS Have ALREADY BEEN REBORED AND Nor TOA VWAMETER GREATER THAN 4.024 THE CYLINDER MAY BE HONED ASIN OPERATION @. TOOLS REQUIRED NOTE: MARK THe Beock 020 05.) Fic.2, WHEN 7O0L DweNo [SHEET [OPER. | DET] 7 7 ae Feta IT HAS BEEN REBORED. eT 6 [Oo 908786. 518 [MBATSCBIE3e 66) ia3o¢2—1 = 182BASE oe D4T4-bssue OF ufeha O ‘BH DISMANTLING HERCULES — MODEL JXD gen SHEET ser conse Sane’ oto Wasner ©. Ths Mav Be Done By PLACING A SMALL Bae In THE-Hove Ar ©) AND UNSCREWING THE CRANK SLEEVE, REMOVE The Prev © Wine The Purter ©. Secure THe Puree To THe Pusey AT © WITH Two Cae Screws, REMOVE THe WoooeurF Hey @) Put Front Motor Mour® From Honing FLANGE). This May BE Puured Orr By Hanp. REMOVE 12 WASHERS AnD Sceews ® To Remove The Timine Gear Cover©. (SAISC-BH-DISN=1 (i BSD. ta, Engine, Dismantiing...........23 \s3BASE SHOP DATA-Issue OF tyftfare™ wir Wea \EH DISMANTLING HEROUWES = MODEL JXD SHEET. ©, REMOVE WATER Pump ASSEMBiv, FiesT REMOVE THE Four Cap Screws Avo Lock WasueRs@. Then REMOvE THE THREE Cap Sceews Ano Lock Wasvers®. Pure THe WATER Pump ASSEMBLY Bach UNTIL THE GeAp © Is Free. Remove ThE GasxeTO Aro THe GasreT © Ann Discaro, Tie Ware Pump a Does Nor Have To Be FuetHeeR DISMANTLED AT THIS TIME. 184 (aASC BH DISM-20}BASE SHOP DATA-Issue OF 1#ls/aa 7 VEnce wT JANTLIN HERCULES - MODEL JXD Fig. |. Co The Inter GeaR@. THis GEAR Is Nor SECURED IN “An Way AND May Be Puuted Our By HANb. Ohuee ThE GENERATOR, Fic. 2, By REMOVING THE Three CaP Screws AnD Look Wasners®. DISCONNECT ThE TWO ConbulTs AND WiRES At © Ano ©. Surcoer Generator WHEN Removing THe Screws © 70 Prevent Deorrins. gs ASAISCEH DIS 30BASE SHOP DATA-Issve Or soft/an® 7 = EET HERCULES ~ MODEL’ JXD. OH | Remove THe Sraee, Fic. Bv REMOVING The Thece Nurs AND LOCK Wasners@. Remove THe Spacce®). A Soeew Deiver May Have To Be UseD To Pay The Spacer Loose. oC The Warer Hose Convecrian © occ THe Two Nurs AND Lock WASHERS 2 @ Remove Aut Six Sparen Pues©)Avo Theie Copper SEAT GASKETS. DISCARD GasKeTs BuT Not Spark PLues. (SAISC-BDISM-4'BASE SHOP DATA-/ssue On _1s/sls. iia [ex | OSygauaiins 5 HERCULES ~ MODEL JXD GEHL Oyo Tre Capguretoe, Fic.1, BY REMOVING THE Two NuTS AND Lock Wasnees @._ THEn Lier OFF THe. Gasxer ®, Sracer ©, Ano Gasrer ®, Discaro GASKETS. Qyecovecr The Peee UNE CONNECTING THE Fuel Pump AND Cargueeroe AT ©, Boe The Fue Pump, fie. 2, By REMOVING ThE TheEE Sceews AND ——————| Looe Wastes ©, REMovE THE eaatfeecaatt| GaseeT ®© Ano DISCARD. — WEASCBDSM-S0)BASE SHOP DATA-/ssue OF ‘lela C M3 >A ‘BY DKS MAN. TLING =p [Scour Ae HERCULES ~ MODEL JXO C2 roe [2 BOTs AND Lock Wasners ® 16 Remove Peessuee PLATE ASSEMBLY ® Aw cuuten Disc. This Assemany Mav Be Pure OFF BY HAND. Remove Tae Foue CasteLLaTen Nurs Ano Corter Pins®. Use A Hammer AND A Brass Puncy Bo Tap Fiywree. ©Loose Feam Irs MOUNTING Stubs. THE FLVWHEEL May BE REACHED Wit THe Beass Puncy TreouGh Te STARTER Hate © Anb The Tine HOLE IN OTHER Sive OF Bets Housine ©. To Remove The Bett Housinc @ Remove THe ELEVEN Screws AND Lock wasvers ® Ano D. Bet HousinG Wiut THEN Deop Fee. Do Nor Remove The Motor Mount Bracners ®.BASE SHOP DATA-/ssue OF Helo? Weal By DISMANTLING [Scour we _HERCULES ~ MODEL _JxD SHEET l or Owe Boru The Exnaust Ao IntanE MamiFo.os By Removing Te /O Nuts Ano Lock Wasners@. REMOVE THE MawiFop GASKET ©) AND DiScARD. ae The Ware TEmperaTure Le © By UNSCREWING THE FiTTING ©. Remove The Four CAP ScREWS © AND PULL OFF THE Two INSPECTION PLATES @ Ano Tee GASKETS. [M3AISC-BH-DISM - 7 182BASE SHOP DATA~/ssue OF selejx€ iA) | BA DISMANTLING “2 | =RIGINE [Scour cae. HERCULE 3 MODEL_JXD OM @vune The Crunoée Heap By Removine The 28 Cap Screws @. REMOVE Fie HEAD GASKET © Ano DISCARD: 79) g 1 REMOVE VALVES, Use The Seeing Comagessins To. © To Compress THe VaLvE SpRING ©. Remove The Pn ©, RELEASE THE VALE Speinc AGAIN Ano Remove Tot ©, Putt Our THe Vawve ©, le THE VaLve Sticks, Pry tr Our Witn A Screw Deiver ; However, Be CaperuL NoT To BEND The Vatve. REMOVE THE VALVE SPRING AND SPRING SEAT@. Note: Ir Pusu Roos ® AE UB Maninc IT ImeossiBLe Te Remove VALVE SPRING, TURN CRANKSHAFT UNTIL THosé PusH Roos Can Be Pusvep Down. WRASCBHDism BC t90BASE SHOP DATA /ssur OF H/o lon pers [oer DISMANTLING |*"z SAl HERCULES —- MODEL XD 9, Ano Lock Wasners © 10 Remove THE Exene Pan ®), REMOVE These Cap ScREWS Ano Lock WasHEes © AND Put Our On Pump Assemsiy © Ano GasKeT ©. a ALL CaP Screws Ano Lock WasHees ©, % Remove THe SEVEN Main Bearings Ano insters ©, Remove ALL NUTS, Lock WaséRs, Axo Bouts @. 3 Remove THE Sx CONNECTING RoD BEARINGS AND InsceTS GO) AFTER REMOVING TH. Robs, KEE Roos, BEARINGS, AND INSERTS IN OebEe So Tar Tew May Laver Be Placed Back IN Tet RESPECTIVE POSITIONS. THe CRANKSHAFT Is Now Reaby % BE LIFTED OFF ENGINE BLOCK AND Mee OE Te MEN. eSBIOSISC) htBASE SHOP DATA-/ssue OF f/tlen Wir Wa |BH DISMANTLING ~ |" | HERCULES — MODEL. xD OF/) o The SEVEN Main BeAzines @ Back IN THEIR RESPECTIVE PLACES. Wn CASE Any Have 10 BE UstD AGan, THEY ARE ALREADY FITTED Foe Thar Pace, ere The Camswarr ® By Smpey Puntinc Our iv Mav Take CONSIDERABLE MANEUVERING T Te Our This UNIT. Gace The Pusn Roos © By Pusuine Up-On Them Ar ©, Avo PULLING THEM QuT Feom THe INSIDE OF Moro Block As SHowN. (M3ASCBHD/ SM ~10(1) 192,BASE SHOP DATA ~/ssuc OF ofan M134) BY DISMANTLING [scour CAR Heweuies “Mode. ko THe PISTON AND Rob ASSEMBLY @ teow The Moroe Brock, Fic.) IF Tas ASSEMBLY CANNOT Be PUSHED Out By Hano, Use. A LONG Beass PUNCH AND Dene Our Fon Unoeesing OF ENGINE, aa a Da Od o% O a @ : SEPARATE The Ron @ Feom Tie Prston© Bv Removing Te Sceew Ano Wasee ©. THEN Puncx The Piston Pw © Far Enousy Our 70 ReMove The Rob. NOTE: Use A Beass Punch Ap Hammer To Dene Our Piston Pin ©. ©, PLACE ALL THe Roo Bearincs © AND SceEWS © Ano © Back In Tere RESPECTIVE POSITIONS, wusT AS THEY Weee DismANTLED. TOOLS REOURED. TOOL DWE .Wa| SHEET | OPER | DET] O87: ee E (SASCBADISM-HGN) 193,194BASE SHOP DATA— I/ssuz OF /0-1-42.4 Venice war AU Gy |B RE ze BB) _ | WHEN ASSEMBLING. Leone ADMSTMENT SCREWG) AND Bracke T@). ‘REMOVE SAFETY Wines, Cap ScREWS, AND Look WasveRs ©. LIFT OFF Faw BLape ©) AND DiscAed Gasmer ©. Remove Correr Pw AND Nur ®. Use A Brass Hamer To Tap Surr Feo Aurey Bock @ Ano REMOVE BEARING AND Lock Wasners ®. IF BEARING e-——9 QD Ano Revanse Assenety ® Dib Nor Came Qur Wire The Swart, Tap Our Feo The Opposire Sie WITH Sor METAL RoD AND HAMMER. Fig. 2 WEAISCBH-BB-1(3) asa me Fan Assembly—_____. 24 5BAS SHOP DATA —/ssue Qe 10- 8-424 VEHICLE UNIT OVERHAUL SusAssemay BE SHEET Seourtao BH HEBCLLES HOLL HD cTewill za or 3 Q Wao @ WASH Alt PaRTS in CLEANING Sal VENT AND Dey Wire Air. Gece Bearings For Wear Op Rousrness. REPLACE IFDEFECTIVE, Outer Race @ WHICH /s PRESSED INTO Te PULLEY, SHouLD BE REPLACED WhEN A NeW BEARING /8 USED. © "oat [J @ Emuer Face May Be Driven Our From THe os Grrosire Swe WiTH A Lencr OF Brass Roo @) @® Equat) AND A HAMMER. APPLY FORCE ALL AROUND THE RACE WHEN REMouING, NoT JusT IN ONE SPOT Use Too. Uw ARBOR PRESS) To REPLACE THE SMALL Race;AND Toot. © To REPLACE THE LARGE Race. WHEN A Bearing CHiPs,OP Is Damaced, Tie Farmic.es Usuatty DAMAGE THE SHAFT. REPLACE THE SHAFT IF This Occurs. [GASCBH-B8-2 31) 196BASE Sap DATA = Issn O Lobes O 102-44 (SHEET VERICLE wwr Maal |Ba, Care | Siete BE on HERCULES MODE OF a @ ASSENBLE IN THE OedER SHOWN. LUBE New CopK Goease ReTaner @ Ano GasreT @. Press Bearins © Qn Swarr, A SECTION OF Pipe © THE SIZE OF The INNER RACE USED In Peess Wii. SERVE THiS PURPOSE, Most OF The Tine The Beseine Can BE Pur In Place Wine A SECTION OF Pipe AND Hammer. BoTH BEARines SHOULD Have A LIGHT PRESS Oe Pusn Fit: Tre Bearing © Ano REPLACE SHAFT INTO Puwev®. Fir Saace Avouno Sarr WITH BEARING GREASE AND Pack BEARING) WITH GREASE. E> USE The Same Merron 76 REeLACE This Bearing AS USED 70 RepLAce Beseinc@. Replace Lock- oO So Wasver Ano Mir @. SECURE NuT AND SEE THAT PULEV ASSEMBLY OPERATES FREELY. REPLACE CorreR PN@®. REPLACE GASKET ®, FAN D, NO @e ae Worn Four’ Cap Sceews Ano Lock Washers o THE GREASE RETAINER AssemBLY © BY TAPING Irv PLACE Witt A Swart BRAss Oe FiseR HAMMER. Deere THE SEQUENCE OF DISMANTLING THE ADJUSTABLE MOUNTING ASSEMBLY SHEET |, Fig. /. TOOLS REQUIRED [Feet owana| sneer loner | oct 908771 23 7o = /SC-BA-BB-3 (3) soar [2BASE SHOP DATA-Issut OF We-koga 8 VERIEL ONT Mia |b CRRRUL TGrFitee BO] 7 FL DASH PLATE, O THE Oit FILTER ® Is A SEALED CONTAINER AND NEEDS No OVERHAUL. Te Fitter |S DISCONNECTED From Ott LINES AND A NEW FILTER ATTACHED Wit THE INTAKE PagT @) AT THE TOP. IT Is LOCATED Above THE REAR OF THe Morar ON The Das PLaTe. THe Otb Brackets © Wit Have To BE USED AGAIN. IM3AISCBH-BS-1_(1) RSD. Me, Filter, Oil... 25 maBASE Shop DATA —/ssue OF Ys ‘SuBASSEmeLY SHEET M3A/|F QERHAU | ree. 3 SCOUT CAR ACCESSORIES. Nore: NumBer’ In CIRCLES DENOTE OPERATIONS. FOLLOW IN ORDER. TO SEPARATE. RADIO FILTER FROM INSTRUMENT PANEL ASSEMBLY REMOVE END Cover@By Removing THREE SCREWS AND LocK WasHERS ®. Revove NuT ANphaAsHER ©) Fu WiRE @, Orr TERMINAL ©. Remove. KNURLED NuT@) ‘AND Putt Wine (©) Our OF Rania FitTER ASSEMBLX - REMOVE CONDENSER LEAD @ FROM TerminaL ©. CHECK CONDENSER ER LEAKAGE AND CAPACITY WiTH ANY COMMERCIAL CONDENSER TESTER By CONNECTING One TEST CF) PROD ON CONDENSER LEAD@)AND OTHER TEST PROD ON FiireR HousinG@). Qooreensen SHOULD Have A CaPacitY OF From.8 70! MICROFARAD. /F CONDENSER SUD STOR “Og Fey SOLID DAS BONY HY MUA SOY SMMCTTOS Fl NAIM OE 3a 71M Pee] 34) ISITG LOY QD SHOLIONO ISI 4] 2846 ZONSWY TMOG TH, IH Of (Y) FAM ONO Skieed ORY TOL SID FAL OM NISWRISTIC 30 SING) SSI 40 114 NO ATG ASI OTONS IVE] IHL 'SHIOW ISIN, IO HUF NO AWE 3017 SI90H. SGU Yhe NOLOGUSI TY, SACL MI MOH: SH RAINE SHIOTG HO Bee Hl FAP "SIH IAAL) NOL IMO NI 205BASE SHOP DATA-tssut OF wjaqarh WET Venice ONT, OVEPHALL [> Fasemeur MI | Cc Cuassis FRAME C / 4, ‘pie pases atoet ere — gy ----9 __ @ WHEN Feame Is Our OF ALIGNMENT AS INDICATED ON ‘LusTeATION By DOTTED LINES : Remove Pintle Hook Ceoss MEMBERS @). Bae Ciamps® Ano© Are BaweD Over Foame_To TABLE, Plact FOUR ANGLE Frames AT Positions ©) © © Ano @ @inseer Jack @ ANO Ape. y PRESSURE. @®Cueck ALIGNMENT WiTH Squake Ar Position QD. NoTE © BE SuRE THe DISTANCE BETWEEN SPeING Sucre HowweRs © Ano© Ave THe Same ON Bor SES AND AT RIGHT ANGLES TO SIDES OF FRAME . Too.s _REQURED [ica Drre.ne | Sreer [Oren [Der |[Sovoz4] 7] [x 90g798 | 2 [ 6 | c |[9o9ozst Yi 908796 | T D #33038 | 21 616 #3305 © £ goarer | 2 | 6] t_]BASE SHOP DATA tssut OF i6/ya~ jn See ao] VeneEE, UNES or AERCLL Ah. Scour CAR. oF) NOTE: FoR INSTALLATION OF GASOLINE LINES Set Assembty OF Scout Car ‘Remove Paces Nur @) Frow Tritans Ano Unscrew Varve Assemacr ©) From Eooy ©). Examine Pickine Waster @)Ano Repuace The Exre Une If WASHER IS Derective. Treat Wave Asseubir Qin The Sate Manner. Rewowe Luc ©, Cuan 2 FARIS Thofouctiy Iv Cutawine Sowvent Auo Dry Win ComPRESSED AIR. 10 Trst une ©, Close Owe Eno Win A Car ENGINE | |AQIOLTE COUT CAP. HERCULES MODEL IK D |AQTOT TE nace oe INSERT A ROD OR DRIFT THROUGH A Fai ‘Btane To Keep /7 FROM Tuanin. RE- MOVE NUT, LOCK WASHER, AND WASHER@). Use Toa..(®) To REMOVE Fan AND PULLEYASSEM- ds BLY ©. FINGERS) ARE PLACED BETWEEN THE BLADES ON OpposiTE Sioes AnD Powr® Is: Ptacen IN CENTER Hote ©). Turn Screw Te REMOVE PULLEY. Remove 6 Cap Screws ANU Lock WASHERS@). REMOVE WoooRuFF KEY @. Tap On Opposire Eno OF SHAFT@) Wit A Brass Hammer To REMOVE Enb SECTION®) Ano Agmarure From Case .[T Wit BE NECESSARY TOREMOVE SeaceR©® (Or THe Smuar Spacer On Tie Opposite ENO)ONty IF /r SLOOSE. MBAISC-BH-B3309| zuBASE SHOPDATA - Issue OF #lq/a2€ VEHICLE UNIT OVERHAUL SUBASSEMBLY ‘SWEET WA BY tree (elec B3 | 4 WE COUT CAP HERCULES MODEL ~JXD. MODEL"SD)~ABORA Fie Remove Cap Screws ANOLOCK Was HERS@), REMOVE Cover @). DISCARD Ou. RETAINERS © ANDO), Ano GasxeT ©. WASH ALL DARTS INCLEANING SOLVENT Ano Dar WiTH CompresseD AiR, Examine Bearinc®) FOR Wear OR ROUGHNESS AND REPLACE IF DEFECTIVE. @) Terma AssEMeLIES @ Ano @ May BE CrtecKED FoR Geouno By ConwectinG EacH ONE To THE Case Treouan Tre’ Han Frequency seo TestéR ®. The Tesree Svouwp Nor Lis. REMOvE TERMINAL ASSEMBLIES AND CLEAN. (5t¢ Fig 3 SHEET NO.5 for TesTER) MIAISCBHB 3-409) U2BASE SHOP Daia-issue OF 10/tha Ws / "By WERMALL | eieeRT oe B3 ana | ore ENGINE AUTO-L/TE cour cae | NeRuesmoneeo | AZOLE: FIELD CouS@)SHouLD BE TEST: ED WITHA HIGH FREQUENCY TesteR@(TRousLe SHOOTER Or Equal) ASSEM- BLY Suoutd BE CHECKED IN THE GENERATOR CASE. Cueck THE TESTER AFTER DESIRED SETTING HAS Been MADE Br ToucHinalfor Our A MOMENT) Trg. Two Test Proos©ANO®). WATCH THe REACTION fis.2 OF The TESTER. USE TESTER ACCORDING TO THE MANUFACTURERS” INSTRUCTIONS. TEST FOR GROUND FiG.1. Conwecr ErTHER ONE OF Jive WIRES ToONE TEST PROD Ano Tie Omer Test Pron TO Case ©. L1GHTE@) SHOULD NOT LIGHT. Tes7 For SHoerT CiRCut, FiG.2. CONNECT Owe TeST Pron To Eacn OF THE WiDES@) AND, @.LigHt ©Musr Lieu. METHOD OF FINDING THE LOCATION OF THe TROUALF 1S SHOWN On Nexr Seer. (MPAISCBH-BF- 5) 23BASE SHOP DATA-Issue OF w/the™ vee en SUBASSEMBLY SHEET WM3A/ OVERHAUL \SENEESIOR B 3 | é Keourcae | Héncues monet ~si0 | Yeo EE sacon ie TOCHECK OPEN FIELD CONS ‘OR Con: CONNECT ONETEST 1D To EACH OF THE CONNECTING Wires© InTuan, THe TESTER SHOULD Ligut Excu Time . IF Any Cou. Fans To Com- bere THe Cigcuit, IT (Ss DEFECTIVE. @, Find WHICH Col OR Cons ARE GRouND- © £0, Fic.2: Uscxcer Each OF Te Cot. CONNECT ING Wikes@).Connecr One TesT Prop To EsTHER END OF EACH Col ANDCONNECT THE OTHER TEST Prov To Tue Case. Any Con. Taar LiGurs THE ESTER IS GROUNDED. FIGL IF Te Fautt CAWNor Be READILY CORRECT- ED, REPLACE ENTIRE COW ASSEMBLY. IAN EMERGENCY Tite BAD Cou. May BEREPLACED BY A USED ONE , Bur/T Must Come FROM THE 2 Same PosiTiOn IN THE SET. ALSOA GROUNDED Wee May Be Tapeo AND Tar Portion OF THE Con REWRAPPED Witt LINEN WRAPPING, Le [M3AISCBH-B3-60a) 14+BASE SHOP DaTA-/ssue OF “filer 7 SHEL VEHICLE ONT Sus-ASSEM! BY SERIA IRI B 3 COUT Cae HERCULES MODELIIO| TTT aa0a oie Foon #3101 (Dp lo ee ae nlf € | Fel 0 fig.2 Os ©) WHEN FELD Col ASSEMBLY /s REMOV- £0 From The Case Eact Pott PIECE SHOULD BE NUMBERED AT@) WITH A CENTER PUNCH. CORRESPONDING MARKS ARE AUTON Case AS SHOWN@) ALSO REMEMBER WHICH END OF ASSEMBLY You NUMBERED FROM, THIS CAN BE REMEMBERED FROM THe LENGTH OF THE WIRES ©). FiG.2. SHows A Screw Driver Press@) SPECIALLY MADE To REMOVE Screws®.DISCARD INSULATING STRIP@) UNLESS In VERY GOOD CONDITION. Je Any Or Tie Pote Pieces @ WeRE Damacéo, Due ToFautry BearinGs Or ARM ~ ATURE, REPLACE THEM. AFTER Coits Have BEEN REPAIRED AND SOLDERED To- GETHER, THEY SHOULD BE PainTED With INSULATING Pali (GENERAL ELECTRIC, Gtrpra LaCQuER-Reb. Ne /20/) OR EQuat../T Wit BE NECESSARY To Day Ths Par In Av Oven AT 260°F. MAIS CE4 B3-71)| 2bBase SHOP DatA- issue OF ltl 7 vEwickE iF OVELHA SUB-ASSEMBLY Seer i | BH ae Sneek B 3 8 ‘Scour Cap HERCULES NobELUxD| MELE Er qaoze (tt D EXAMINE ARMATURE FORBREAKS AND BURNED INSULATION. DISCARD ARMATURE ‘Any OF THE COMMUTATOR BARS @) Have Come Loose. ALSO DISCARD IF SHAFT ts Nor INGOOD CONDITION OR IF SEGMENTS @)ARE DAMAGED. ARMATURE ‘Soup Nor Be USéD AGAIN IF Comnuraror & Worn ENOUGH THaT ITs DiA- METER Witt BELESS Tr 1.550 °AF Ten (7 HASBEEN TURNEDON LaTHE(SHEET 9). Examine COMNUTATOR Where LEADS © Connect To Commuraror Bars@. IF SOLDER Has MELTED AND BEEN THROWN FROM THE CONNECTION, THEY SOLDERED BACK IN PLACE. USE AHIGH TEMPERATURE SOLDER. SEE THAT ALL SuRPLus SOLDER |S REMOVED. THIS May BE Doné In THE LATHE WHEN THE COM~ MUTATOR IS TURNED. Any SOLDER THAT CawNor-Be REMovED FROM BETWEEN THE SEGMENTS WITH THE UNDERCUTTER (SnéeT S) May BE REMOVED WiTH A SMALL PICK. TesT For GROUND: USE HiGH FREQUENCY TESTER SHEET 5. CONNECT CommuraTor AND SHarT Wir Test Prons®). THe TeSTER SHOULD NOT Ligt. IF THE TESTER DOES LiGhT Tis SHOWSAGROUND AND THE ARMATURE Can Nor Be USED. MBAISCEHB3-80] 216BASE SHOP DATA -/ssue OF sojqar Waal | BA Sabie eRe 3 ENGINE | mene COUT Cae serous vena sx0 | ICE TE taoan oe SHEET. a @ JE ARMATURE HAS BEEN FOUND ELECTRICALLY SATISFACTORY, TH COMMUTATOR ‘® Swowo Be Torneo iy ALaTHe. Do Nor Cur Away Any More Maerua. Trew Ewouan To Smoora Tie CoMMuTATOR SurFice. DISCARD ARMATURE IF IT WAS NEC essary To Tor Commurarar To A DANETEROF LESS THAN 1.550‘DA®- @ The Mica InsucaTion © BETween Tie Commurator Bars Stoutb THenBe Unoercur As DEEpAS The Insucarion /5 WIDE (..020°). Thus Mav Be Done ON Amy Macnine EQuieren OR MANUFECTURED ESPECIALLY For Tus Purpase®. CLeay WITH Fine WiRE BRUSH AnD Aik. Paint WiRE Wir INSucaTinG Par. PLACE IN Oven AT 260°F. To Day. ayBASE SHOP DATA-Issue OF //4fa2 venice UNE OVERHAUL | SueAssEnaer SHEET, M3A/ | BH awcine|Goreearor BS | JO COUT CAR HERCULES MODEL “yO _| “Moped “Gb)-4B02A ore Seas E To DETERMINE The PROPER PosrTiON To INSTALL = = Tue PiECES@In70 THe Cows, How Cous OvER le Case As In Fic!. IF6./ L, Pats! 7 > ae OE ole (0) ‘ey BOE v © oe. Oo @ OBsEéaVE THE CURVE OF THE COILS, THE COWL <= ‘ASSEMBLY CAN Oncy Fit ONE Way. THE Two Eno WIRES c @©mMus7 Be Ar The Teeminat HoLes©, The Po.e Piece) | MARKED WiTH One Dunc Mark Wit CORRESPOND With THE 6 Winoow MarKEDONE@)AND THE Cou. ABOvE IT Whit NATURALLY Fis.2 CoaResPOND. PUTPOLE PIECES IN THEIR RESPECTIVE Consfic.5) Assemace Aemarure®) Ano FieLo © Teammvars. ASSEMBLE IN THE ORDER THAT Tue Numaers INDICATE. ALL FIBER WASHERS OR INSULATORS (INDICATED Br CROSS- narCHING) Must Be DRY. Reo. ACE ANY DARTS NECESSARY. SEE THAT TrQéADs ON BOTH TEAMINA.S ARE In G200 CONDITION. PUT FRICTION TAPE OVER THREADS OF Two Tepmiva. Cases@. (BAISC=BH-B F106) 2BASE SHOP Data-Issve OF wpe € VEMICLE UNIT. SUBASSEMBLY SHEE T ih [3A QVERHAUL | CEN ERATOe B3 / ENGINE | RaTOLITE ‘cour Cae | wéecwes modeL-~IXD oe “Say-4a02A ore @ OPERATIONS ON Previous SHEET With HAVE Pur FELD COlL ASSEMBLY @)IN CORRECT RELA- TION WITH GENERATOR CASE@), PUNCH MARKS) MUST CORRESEOND. INSERT SCREWSO)}AND TIGHTEN Wir Hano ScrewDawer. See Tuat Con. ASSEMBLY 1S Property LOCATED AND TIGHTEN Witt SCREW- Drwer FixTuRe®. MBAISCBH-BF IN) udBASE SHOP DATA-Issue OF nfgjere WeneLe oni SUB-ASSEMELY Ba) | “Byy OMRHAUL CiiieearGe B 3 IScour Cae ENGNE ee Hencwesmooersxo | UIC ETE saoen SHEET, ort © 8) INSERT NEW INSULATING SraP@ S— Ce IDK Arouno Tie UPPER ENDS OF THE FiétD CT TES Cous. Tats Sra iS To Keep THE JOINING t= = = ip WirEs@) FROM ToucHinG THE CASE. RE- Ptace Tue Eno SECHION © WITH THE Ott FitTinG@)AND TERMINAL ©) ON THE Same Sipe. SECURE END SECTION WiTH Six FitusreR HEAD Screws AnDLocK WASHERS @ Now Assemate THe Opposiré ENDSECTION. USE ®s New OWSEASE)AN0@, TaPOnSEAL@ IN Ptace AS EE Snow, Pack BEARING @ Wit Grease (H/- TEMPERATURE US. 508--AmErican BoscH Care SPRINGFIELD, MASS, Ano Press In Pace. BEARING SHouLb Have A cat Press OR Supfir. Tap On Sea © INTOCOVER@) ANDATTACH Cover To Eno Secrion WiTH Four FuuisTeR HEAD SCREWS ANDLOCK WASHERS @. MSPISCEH BRU 220BASE SHOPDATA - ISSUE OF Mefapen MSA| |BH TUEBHAUL ereRiroR B3 f°) SCOUT CAR. HERCULES MODEL -JXD monet~ehs-4a024 @8) Reptacs Tie Soncen@le 7 Was rEMoveD PeEss Eno SecTian@) ONTO ARM ATURE, FiG.2. PROTECT THE ENDOF SWAFT With A SoFTMeTaL PLaTe Or EQUIP PSB Peess Wirt Too. ©. LOWER ARMATURE INTO GENERATOR CASE @). ASSEMBLE THE END SECTION Wit THE Ott CUP@ ON THe SAME SuDE AS TERMINALS, F/G. 3. SECURE Wit Six FiuusTeR Head SCREWS ANDLOCK Wasner ©. TAP WoooRuFF Key © ty THe Sior@.Line Woooruer Key Ue Wirt The Stor InPusuerAssemecy @)ANo Peess ON The Pusey Assemacy, iG.3, ADD WASHER®, © NewToorw Tree Wastien@), AND Wi Nur @. xBASE SHOP DsTA-Issue OF Wyfar VERICLE UNF OVERHAUL | SuBAssensey [ smeer (isa, |B _ oe Bete 53 [74 iGINE COUT CAR HERCULES habe JXD | "modes ~6Bs-4802A AD0OK. SEAL SPRING WASHER @, Flat WASHER@AND Oi SEaL©. Aur (Choseb Soe OF Benne © WWE1T TO THE Oil. SEAL. PRESS BEARING INTO PLACE. Abo NEw GaskeET@ Ano Cover © ANd SECURE WITH Four Fister Hea SCREWS Ano Lock WasHErs ©. Brushes® Suouto Be Examneo AND DRESSED WITHA FINE Fite fe Neces- Say. le THe Beusn His WORN 3/16" OR MORE, [7 Shou.b Be REPLACED WitH NEw. Discaro Any CracKed OR CHIPPED BRUSHES. If One Brusu (s Worn Our, INSTALL New BRUSHES In ALL Faue HOLDERS: [M3AISCBH BF He) 222BASE SHOP Data -issue OF with oir OVERHAUL | Sueassemeny weeT ee | GENERATOR COUT Cae BH ee ae eI soo24 3 B venice >I ore Commuraron fie./ @) INSERT A strip Or Na 00 Sanopapée@(LiTTLe Winer Than THe Bausy) UnoeR Brusu HOLDING Bracner ©) WiTH ABRASIVE SiDE Our. CAUTION: NEVER ‘EMERY Parven, Pur Baus © |NPLACE,ANO PuLt SANDPAPER STRIPIN THE DIRECTION THAT The ArmaTure Tuans(Clock wise Looxing From Tae Front Eno). Remove Busy Ano RepeaT Opeparion lr Brusy Has Nor Mane AN Even CONTACT OF Ar LEAST 15% OF TWE CONTACT SURFACE, FiG.2. panes h i Arracn Bano ®.NorcH® Firs AROUND TERMI @ AL®. ATTACHMOUNTING BRACKET @ WITH THREE I CAB Screws AND LOCK WASHERS@)AND ONE = oP © Ss) Counrer Suna Screw @), SZ MOUNT GENERATOR ON GENERATORTEST BENCH AccoROING To MANUFACTURER’ INSTRUCTIONS. 2 Anwsr Tes? Gencu Speen To 080.R.2M Céweparon Our. ® Par SuowupBe 55anes.Ar/5 Yours WITHA Few Curbemr OF 1.48 To 1.68 Aups. Run Genenaror For 1/2 Hour; CHECK For BRUSH, BEARING, (Op Orme Unoue arses. ALSO CHE FOR OVERHEATING. Inprovep.y Seareo BRusves AND WoRN BEARING Wilt Cause THese Norses. Oveauearine Wits Paceasiy BE Due To InpropeR Or BAD CONNECTIONS. UsBASE SHOP Data-tssue OF Wehyes 7 Risa) | By Slee [BEBE 3 | MAL | oer, nee [Sore ors * Fig.t. 33) Test CONDENSER; USE HIGH FREQUENCY TESTER SHEET 5. Toucu One TEST Pro To Case Ano THe OTHER TEST Prod To SPRING ®, USE THE SAME CONTACTS FoR ALL THREE TESTS (Swonr, Capacii,ANOLEAWAGE). THe Capacity SHomoBe 1. Miczo- Farad. Use New Conoensea iF A Derecr /S Found, Toots Reaurep Too Dues Nal See \Oren.[ Der. Em w ‘y0e713 | 7 soa7ez | 3_ | 7 |B #31017 717 Lo n4BASE SHOP DATA-Issue Of 8-42 VEHICLE WT ‘SuB-ASSEMALY (SHEET WAl |F eeee rearer FZ) 1 DISMANTLING HEATER NOTE: If Enrrer OF Tue Two Pes @ Ane BENT, STRAIGHTEN By INSERTING Toot ‘Avo Thee Wirt ASAT FACE ‘Hammer. Repract DEFECTIVE RUBBER FARTS. Remove Four SeuF TAPING SCREWS ©. Ler Evrine Heater ASSEMBLY Our OF Geuwe ©. Lirt Blower Housins ©)_Fram RADIATOR Assemety ©. Remove BAFFLE Ans @. iF Be Two Ruseer Custos (@) ‘ARE Loose They SHouD Be Recut b Rapuror ©), On iF DEFECTIVE REPLACE WiTH NEW, Remove Seif Borne crew (B). REMOVE NUTS, LOCK WASHERS, AND PLAN wasvers QD. Pe We © From tov © Ano Lit Motor Avo fw Oar ©) OF Bower Hass ©. Renove fieer Waster @. Loosen Ser Screw @) Ano Sepaeare fw © fom Motor ©). |M3AISC-BH-Fl2—1(7) Sm he, Heater.........3 2sBASE SHOP DATA-Issut OF 3-424 = UCL Unt. OVERHAUL | Suerssenetr 7 Maal | Sree rarer 2] 2. j°@ oy DB eewe TwoNurs@®. Pey Moor Housings @) Ano © Apart. Remove AeMarureQ. LIFT Brusties © Away FRon COMMUTATOR © 70 ALLOW ARMATURE ©) Td BE REMOVED. REMOVE THRUST WASHERS @) Ano ®. Putt BrusHes © Our OF HOLDERS Q)AND INSPECT FOR LENGTH. IF BRUSHES ARE LESS THAN 68° LONG, PROCEED AS FOLLOWS: UnsoLDER BeusH LEADS AT @) ANDPuLL FROM HowoeRs D). LeAns OF New BRUSHES ARE THREADED INTO HoLOERS QD AND Our OF SLo7s In The Sioes OF HoLoERs@). Souper THE LEADS ToLuss AT®. Remove Series © Feom Hovogrs D Avo inspecr Far DEFECTS. REPLACE WITH MEWIF NECESSARY. REASSEMBLE SPRINGS © INTO HOLDERS @). REASSEMBLE Brustes ©)INTO HOLDERS Q. M3AISC-BH-Fi2-2(7)BASE SHOP DATA-Issut OF 1-3-424 ELECTRICAL COUT CAR ACCESSORIES. ory Vea | Cia nearer Fe 5 ‘USING TéST LAMP FROCELD A> roLLows: Place Owe Test Proo Ar ©) AND One Ar ©. Lame Snow Liger. IF tam Does Nor Lise, Insta A New Conn Pace OF, Con ©. Ace One Test Prop AT © Ano Out Ar @. Lamp SHouto Lise ip Lamp FAILS 70 Lit, Wnsiai A New Con Wn Prace OF Con D. Rertar TEST. sTIN QD Qo Owe Test Prop On. fitto Wmos Frame ©. @) Place Orner Prop Ov ©); Lamp Sou Nor Gent. How One Test Prop On Fitto Winns Frame ©. Pace Omer roo Ov ©; iF Lay UGHTS In Ermer CASE, REMOVE GROUNDED Coit. And Reecace Win New. REPEAT Test. (0), Reece Derecrive Cons QAno D, Remove Nurs @ Ano Pun Fie Con. Uni ® frou Cover ©. ~-O Remove Nuts @ Ano Take Our Stues D. MSAISC-BH-Fi2-3( | 227BASE SHOP DATA- Issue OF -3-42 4 VEHICLE ‘UT. ‘Sua- ASsEnay SHEET Maal | F eee fl2\ 4 zecratca, | EATER ACCESSORIES or GROUND TEST D) Place One TEST Peo ON CoMMUTATCR ® Avo ee Orne Poo On Anmrine Core @. I Hest Lame Does Not LiGHT, THe Commurator is Nor GrounoeD. IF TEST Lamp LIGHTS, INSPECT ARMATURE WINDING AND RepaR IF POSSIBLE. REPLACE WITH New ARMATURE WHEN Necessary. INsTALL_ AaMATURE INA STANDARD owe ue © Aw isr eR 0ren Ao Sot Grcurr. IFARMATURE Is DEFECTIVE, REPAR IF Possipie. REPLACE Wi New Armarue WHEN NECESSARY. IF Commuter @) s Gaooven, Pact ApMATURE In LATHE AND Ton Down Commuraron. Tien Down Oney Fae ExousH TO Remove GROOMING. CLEAN WITH COMPRESSED AR. NOTE: 7 1s Apwsabze To REPLACE Wit AN ENTIRE New UNIT IFAVALABLE IN PREFERENCE To BEING OVERHALED. [M 3AISC-BH-Fl2- #7) 216BASE SHOP DaTA-Issue Of /-3-824 ey “~~ OVERHA eee naae F “demee” | reser — FIZ | Se ASSEMBLING MOTOR Place TuRust Wasvers @ Ano @ onro ARMATURE SHAFTS © So THAT A FIBRE WASHER G BE BETWEEN Two STEEL WASHERS. inspect Stuos @) For SrRIPPED THREADS. REPLACE WiTH New iF Necessary. AowusT NuTs © Tite Tey Are 14° From Tor OF Stuos Q: Screw @ ® Ur Swue © Pract Fret Leavs © ‘Tau Hote @. InsTale Fieto Cou Uni @ in Cover D. Teen Nurs Q @ Prace Aimarure. Siarr.@) Tau Hoe BRUSHES. May HereTo Be HeLo Back In HowoeRs To Atcow. Armature To Go Into Gover @ Far Enouse. PLAGE ARMATURE SHAFT Inro HoLe ®) Ano Bring Covers D Ano @ Toseruer. Tisuren Nurs @) Test Moror By Connecrine Leaps @ To A IV. BATTERY SHAFT SHOULD REVOLVE COUNTER-CLOCKWISE, VIEWING FRow CommutaTor END FF IT REVOLVES CLocKWISE, Remove NuTs @, Puce Orr Cover @) Ano. RevowvE Gover @ ONE-HALF Turn IN Exner DiRECTION. REPLAGE Cover ANo TieuTen MuTs @. RecHEcx Direction OF MOTOR. [M34ISC-BH-Fi2 -5(7) 229BASE SHOP DATA-issut OF 7/-3-42¢ VErICLE Un SUB ASSEME EET OVERHAUL ax 7 Mal |F See reser FZ] 6, Uf! @ SUBMERGE RaDUTOR ASSEMBLY @)/IN WATER. CONNECTAIR Hose AT PIPE®. InséRT Puc © InTo HoLe®). USING AIR PRESSURE Gauce ©ANDAIe REGULATOR ©), MAINTAIN TWo LBS. AiR PRESSURE WHILE TESTING RADIATOR. AIR BUBBLES WiLL APPEARIN THE WATER IF RADIATOR LEAKS. IF RADIATOR LEAKS BADLY Mane A REPLACEMENT. SOLER WiTH A SOLDERING ToRCH, USING A 50-50 SOLDER. REPEAT THE ABOVE TEST. AFTER TESTING AND REPAIRING, ORY THOROUGHLY. M3AISC-BH-Fiz-6(7)| 730BASE SHOP DATA-Issue OF 7/-3-#2 VEHICLE Ur OER HA Wi ‘Sus-ASSEMBLY (SHEET MA / ih ecectaicae — | EATER fv? SCOUT CAR ACCESSORIES. OFZ @—= 1,2 OAG ISSEMBLING HEAT! oe R = W, Insert Moron@ In FAN ®) @ AND SECURE FAN To ARMATURE 7 SHAFT © With Ser Screew® @ PLACE INSULATING WASHER® On Moror @. 7 InsERT LEAD Wires@ Tirous x © Hote @ Ano Sruos@ Throvs E RuBBER GROMMETS®@. PLACE FF 1H 4 A WasHER@ Ano A Toorn-Troe. Locn Wasiter© On Each StuoD And Secure With NuTs @. Ground UNsHiELDED WIRE IN HouE@ WITH Setr Tapping Screw. Ptact BAFFLE@ On RaviaToR®. PLACE RADIATOR®@ IN Gre S So Thar Pie® tloncest Pre) JS In Top Corner OF Crue ©. PLACE BLoweR Housinc @ To AADIATOR® So THAT THE DRED Witt Pass Thru HoEQ AND Pwe@ Wii Pass THau HoLe®. The Top OF THe BLoweR Housine Has A LARGE DeFROSTER HOLE In ft. IT 1s ON THE Side Opposite THAT SHOWN IN ILLUSTRATION. Pur IN Four SELF-TAPPING Screws@. 700s REQUIRED [Foon owe. nal sneer | ope [DEE ‘soamse [1 [1 [8 M3AISC-BHFl2-7(7) 23232BASE SHOP DATA-Issue OF 1/ryfeet™ VERE oar Sum Asseweur SHEET Msp), Ea QUERHAUL FQ / HORN ee ELECTRICAL — | DELCO-REMP-CORP Scour ACCESSORIES OF 2. MOTE: NUMBERS IN CIRCLES DENOTE OPERATIONS. FOLLOW IN ORDER. Dmg LUETOFF BELL COVER 'B). lane Orr Bett Coven Bracrer©. Drscowmecr Horn Wire(D) Br REMOVING SCREW ©. Jane OFF Horn MOUNTING. BracreTE) By Removing Twolone Bouts Awp Four Nurs Wirn Lock WasHers©@). Remove THe Four REMAINING Botts With Nurs AnDLocK WASHERS) AND SEPARATE THE DIAPHRAGM FRAME ASSEmBLY@) FROM THE TRUMPET ®. Use Pures To Tae SCREEN] OFF THE Trumper®). Wash ALL PARS EXCEPT THE DIAPHRAGM FRAME ASSEMBLY @) Q) WITH CLEANING Sot vent. Dry WiTH COM PRESSED AIR. INSPECT THE HORN MOUNT ING BRACKET ME\ For Loose Rivers ANDBROKEN LAMINAT IONS AT@). TIGHTEN ANY Loose Rwers. Discard ANY BRACKETS WITH BROKEN LAMINATIONS. InsPECTCASKET®) OW TruMPeT(K). RENE W BROKEN OR DAMAGED GASKETS. REPLACE SCREEN(L)ON TRUMPET. ASSEMBLE DIAPHRAGM FRAME() WrumPET® Wir Four Bars AnbNu7s@), ANoTHETWOLONG Bours Ano Nurs@); Fasren Bracner®wita Twobars@) ALSO. 233BASE SHOP DATA-/ssut OF softe/uat VEHICLE wir OVERHAUL | Sa sssewstr - TSR M3Al| F “geemee™ |i FI" 2, jue AEE, = Ciamp Mounting BaacneT @) INVISE. MAKE Sure NoParr OF HORN ASSEMBLY TOUCHES VISE. Cean Contacts® WITHCONTACT FiEORSTONE. CONNECT TEST Wires From (2 Vor BarTery As SHown. Cost Hornswitcu© Aub ApsusT LARGE Mur®) FoR Max- Wédumt READING ON AMM ETER@) WHILE Horn |S OPERATING. TIGHTEN LocK NoT® WHEN MaxiIMuM CURRENT READING IS OBTAINED. INSTALL COVER BrackeT @). CONNECT HORN WIRE UNDER Screw@. Fasten BeLtCoverD ON ASSEMBLED Horw WITH Screw®. 234BASE SHOP DATA- Issue OF pjen _ Sub Assenery “SHEET WHILE wn OUERHAL MBAI fe neta. | HORN BUTTON Fi /0| Nove: Numbers IN CRLES DENOTE OPERATIONS. Fo.ow In Orver. Dismaw Tle How Burrow ASSEMBLY By DEPRESS- ING THe Horw Burron @ Down As Far AS Possinié And Tuenine THe Burrow Unri Tue Peosecrions © Oy Ti Burrow Are BETWEEN THE RETAINING SEG ~ ments © On the Base Prare®. Revéase Te PRESS- uRE On Te Burrow AnD Lif7 OFF THe CAP Conracr © , Spens® , Ano CaP Conracr ©. UnsowDer Tie @ Ayo Remove Ivsunarinc FerruceD SPeing @, Base PareD Amb Contact bisner@)Feom Wee. LEAN THE Teee Contacts ©, ©, AndD© WITH #00 Sahioparee. Inspect Springs @AND®. DISCARD SPRINGS If THeyAee Beoxen Oe Baoty DAMAGED. Dever Base Prare © Avp Reraning Seorents© . Ie EGMENTS ARE Bader Worn Discaep Pare. stat New WiRe . Cor Wike 48’Lone Ano Cem (ue Teznna @ OW Whee. USE A HA Douaias Cempine Toot for eavat) For THis OPERATION. (ye A loose Kor @ Asour One Foor Fron END OF Wire. IHS 65 lo Peevenr Losing Te Wasner Cammacr®) Ann Sprinc® Wace Age THREADED Ov Wee Jw Thar Oger . Inseer Wee IN Base Praté® Ano Insucaring Feeeme®. Source Tie @ Ov nb OF Wee . Mane Suee InsucaTion On Wee 15 Iusi0e HOLLOW Tip Berore SouvERING. isémeLe Burrow AS Swown. Lock Burron On Base Flare By Peessine Down AS FagAs PossiBle Anp Tuenine THe Burton Unrn THe Prose crion®@Cowvcide win THe PETANING Seonenrs ©. asa me Horn Button—_____ 32 Bs236BASE SHOP DATA — Issue Or 90s @ VEWICLE oir Sus-Assemety SHEET Maal |F Geeta | actina ELECTRICAL ‘DELCO-REMY-CORR [ Seour Gre ACCESSORIE: oF) Nore:Nungersin Cractes Denare OpeRarionsFoLLow IN ORDER. rEMOVE COVER@)BY STRAIGHTENING EARS @). EST Rear Cou For Put BY ConmecnnsTo !2 Vout BATTERYAS SHOWN. RELAY ARMATURE® SHOULD BE PULLED TOWARD CONL,CLOSING CONTACTS Out ArraTure Fats To Q.056 CONTACTS ReLay/s DE FECTIVE, CLEAN CONTACTS) Wit CONTACT FILE OR STONE. IF CONTACTSARE BURNED EXCESSIVELY INSTALL NEW RELAY. (GS ercace Coven@ Seno bins ® Unoen Base OF RELAY. W34/SC-BAFTI-T (| Sn Me Horn Relay. 237BASE SHOP DATA — Issue Or 1/s/ru0° Tae oer BAT Tae uF Mad) |b ORI ere 64] Scour Cae ACCESSORIES [Ano Lines os Nore: Hroraulic. Bane Sy5Teu 15 MANUFACTURED By Tie Waawen o-e Exectric Co. CocKHEED) Us A ScREW Dower To FORCE SPRING Cup @ Qvro Ca.Lae ®) OF MasTER Crunver ©. Dust Boor © Aw Psran Reo © Can Then Be Removed. Remove Spec Cue @ Fan Counar ®). Remove Dust Boor © Feo Piston Roo oR Wenens Pine Cup © Over Nur $ Remove Dust Boor AND Rine CLIP From Nur @. Remove Fitter Cap @) Ano Gasxer Q). domino db sp © ame Wire Lock Pisrow Srop@,Wasuer ©, Piston @, Pisraw Cue @ “Ano Piston ReTuRN Sprins ©. Remove VaLve Assemery © Freom Pisrow Rerun Seine ©, @ Wasy Alt 29e7S In NapHTHA. [M3AISC BH-E4-1 (3) 5a me Hydraulic Master Cylinder & Lines... 34 239BASE Sip DATA— Issue Of “fat VEHICLE Nr Oh ERM: JAU/[_ | SunAssoweay I M3A/4E wmecranicar ooret Caner EP SOT CAR ACCESSORIES | Ano Lines: inspect Piston ® For Nicks OR DEEP SCRATCHES On SuRFACES ®) Fig. !., /F Nicxed OR SCRATCHED, REPLACE With New PisToN, ©) Atways REPLACE WiTH New SEconoary Cup ©) WHEN OvernsuuinG. To REMOVE OLD Cup ©, Push Rinc ©)Over Seconoaer Cur Wn Adure To CENTER OF PISTON AS IN Fig.l. THEN REMOVE SECONDARY CUP © Wir LARGE END OF Seconpary Cup ©) Toward PISTON @), STRETCH ‘Over Piston ©) AND SEAT IN GROOVE@) AS SHOWN IN Fig.2, Ris @ 1s Worked OveR ecancany Cue me In Postrion Q). it = 24BASE SOD DATA — /ssue OF sap3jp2r VEHICLE MT (Sus-Assenacy SHEET M3A/ | & CERHALL. | iin’ rag | Stour Car. ACCESSORIES AND LUNES OFS ® Use Hone @) To Powisw InsioE OF CrLinDER @ OF muster Crunoer ©. Caution: Wire Our Fiincs Wir A Rac, WasH CyLiNog® INNaeHTHA AND BLOW Out With Air Hose AFTER PoLisHiNG. INSERT A Fine Wik THeouGH RELIEF PorT @ 70 Make Sure it Isn't CLoeceD. ALWAYS REPLACE WITH NEW VALVE Ass| EMBLY © AND ASTON Cup ©) WHEN OVERHAULING. LUBRICATE InsiDE OF CnogR © WH LOCKHEED HYDRAULIC FiviD, ALSO VALVE Assemaiy ©, PISTON RETURN SPRING @, Piston Cur ® Ano Piston ©. © INSTALL VALVE AssemBLy © On PISTON RETURN SprinG @. PLACE Piston Cup @ Over OTHER END OF PISTON RETURN SpaING @ WirH Tir @ OF Aston Cup © Into OPENING © OF PISTON RETURN SPRING. INSTALL INTO CYLINDER © AS A UNIT. INSTALL PISTON Q), WAsHER-@,A Wire LOCK PISTON STOP @. ISC-BH-E4 - 3 (5) ruleBASE SHOP DATA Issue O¢ 10/3/a2f— EME Gar SueAesensiy EL A/ \E HAUL | Sueessossty i A bene" Becuanical |Psee Onmocr Ke ACCESSORIES | AND LINES oS © Force SPRING cLIP@ OVER Hex.NuT@) OF Piston Rop©. IsTALL. Dust BooT ©) INTO Position ON PrsToN Rov ©, AND Move SPRING ‘Cup @ OvER Neck OF Oust Boor). IF Dust Boor ls Ceacgeo OR Worn REPLACE WITH New Boor. Fig | Force Serine Clip @) Over Cota © OF MASTER CytinceR@. Fic.1. INSTALL. PISTON ROD ©) INTO MASTER CYLINDER @ AND STRETCH Dust Boor ® Into Position. Move SPRING CLIP OveR ONTO DusT Boor ®). INSTALL New GASKET @ ONTO CovER® IF OLD ONE IS CRACKED OR WORN. (2 WHEN COMPLETELY ASSEMBLED, POUR LOCKHEED BRAKE FiuID INTO ©) Cyunoer @ UnTi. HALF FULL. MAKE A Test By PLuccinG OE OF Two CoupLin Hoes ASD Ano Pustins Pisron ROD @) In Ano Our UNTIL Fiuio SauieTs Our OF Hoe ©. Dram Fiuio, CORK UP CoupLinG HoLes © AND STORE IN AN UPRIGHT Posimion IF NoT To BE USED IMMEDIATELY . [MBAISC-BH-EA- AUS) 242BASE SHOD DATA —/ssue Or v/e27 Aisa) | OGRHAUL | Sete “E sage |MASTER Cv. My “pee er eee £4) 5 © INSPECT ALL HYDRAULIC LINES, IF Te Sroer Rusper Fig. LINES ARE CRACKED Oe ROTTED, REPLACE THEM WiTH New Lines. F Te Copper Lines Are Bent Too Fae AS® Qe Ceacred Oe Spuir As Ar 8), Rep ace Win New. IF Flared Eno ©) OF Coprer Line © /5 CRACKED, IT CaN BE REPAIGED IF THERE IS ENOUGH SuRPLUS LINE To Compénsare For Te Avount Thar Wie Have To Be Cur OFF. @ Move Firtins © Back Ov7o Line Q) Ano Out OFF FLARED END © Just BEVOND CRACKS With A Fin TooTa Hack Sam PLACE THe Gut Exo UPwaeb INTO OPENING FITTED For IT In Too ©, Fic. 2. Fite Line © FlusH With Suerace OF ho. ©. THEN Win A SMALL Tikéé- CoeneReD ScRArER Tuen A SuiGHT RabIus AT THE.END OF PRE. PLACE Toot @ FiG.3, Over Line © Ano Clamp Swit Teow ©. Toen HANDLE ON. ee. ® Uvru. Line @ /5 Fiaren. © ALL LINES SHouLD Be BLOWN Our WiTH Ale HOSE Beror BEING INSTALLED ON VEHICLE. 243 Fig.3244BASE SHOP DATA- Issve_Or Y2/42 VERICLE UNIT Sus-Assemay ‘SHEET M3 |BH CORAL ite Ae p57|" Scour ar Heecues-Mooe. JD. Ff ® Inspect SHart @ For Scares Or Any IRREGULARITIES. CHECK For SIZE. THE PROPER DIAMETER OF THE SHAFT SHOULD BE 1.90" 1.195: Je The Start Dogs Not Meer irs REQUIREMENTS, Press Our AND REPLACE WiTH New SHAFT. 9 @ InsPECT THE Two Oi. HaLes @) To See THar BLOWING AIR OR PREFERABLY RUNNING A CLEANING 8 SOLVENT ThrousH THEM. To Assure OPEN OIL. HOLES, REMovE PLuG ©) AND CLEAN THE HOLLOW NY © TWEREISA CLeaR Passace, This May Be CHECKED By ® fil — Spart Wind A Drie ApPRoximaTeLy Te SiZé OF Tie Hove. BLow Our Win COMPRESSED AIR. REPLACE THE Pluc ©. Inspect THe Gear TEETH FoR ScoRES, CRACKS, Wear Or BROKEN TEETH. DiScaRd GEAR AND REPLACE Ir New IF CONSIDERED UNSERVICEABLE, INSPECT THE GEAR FOR SMALL CHIPS,OR NICKS BROKEN OuT OF THE TEETH. THESE May BE. GROUND Out SMOOTH WITH A SMALL DIE OR HAND GRINDER. This Is To PREVENT FURTHER DAMAGE. © JF IIs EveR Necessary To REMOVE THE PLUNGER ©, Remove THe Screw © AND PUNCH Our PLUNGER.WITH A SMALL ROD, OR PUNCH AND HawiMerR. IT May BE REPLACED Iv REVERSE MANNER. GAL SCOHB27-1 UN Bsa me Idler Gear —_——.. 2sUEBASE SHOP DATA-Issue OF F->4-428 VEHKLE UNIT: O} VERHA iA U) SUBASSEMBLY ‘SHEET M3Al | BH SORA Sere caunoren, Bl| / ANOFLTER ASSEMBLE Scour Car. HERCULES“ Monet seo a NOTE: NUMBERS IN CIRCLES DENOTE OPERATIONS. FOLLOW IN ORDER. oO 7B REMOVE IGNITION Coll, FROM MANIFOLD: Remove Tio MOUNTING BOLTS,WASHERS;- LOCK WASHERS, AND NuTS @). SUDE CoiL®) 7 END OF ManiroLo ©. RePuace Bowrs@ In ManiFoLD AT © To PREVENT LosinG BOLTS. REMovE WiRE ©FROM POSITIVE TERMINAL® On Coit. REPLACE NuT ON TERMINAL TO PREVENT LOSING NUT. 7° Remove IGNITION Col @ FROM ManifoLD ©. CONNECT Coit (B) TO ANY COMMERCIAL TESTER FOLLOW MANUFACTURERS. INSTRUCTIONS 76 TEST Colt... IF Cott, 13 DEFECTIVE, REPLACE WITH NEW CoiL.. Do NOT INSTALL COIL IN MANIFOLD AT THIS TIME. (M3AISC-BHBI-/ (4) esa me Ignition Coil, Shield & Filter Assembly _____. 3¢ 1BASE SHOPDATA- IssueOr 774-42 4 » Revove END Cover @ From MamiroLD ® By REMovinG Tho Screws ©. DISCONNECT FILTER CONDENSER LEAD (O) FROM FILTER Coll. TERMINAL ©) BY Reuovine Nur ®. ae @ TEST CONDENSER) FOR LEAKAGE AND CAPACITY WITH ANY COMMERCIAL TESTER. CONNECT ONE TEST PROD ON MANIFOLD @ (SCRAPE. Faint OFF To INSURE. GOOD CONTACT). CONNECT OTHER TEST PROD To CONDENSER LED @. CONDENSER SHOULD Have CAPACITY OF 470.5 MICROFARADS. CONDENSER (5 DEFECTIVE IF TEs? SHOWS LEAKAGE OR Low CAPACITY. REPLACE DEFECTIVE CONDENSER By Removina Two Nuts @. DoNor RECONNECT CONDENSER LEAD © ON TERMINAL ©). MSCHFET2 A) 248BASE SHOP DaTA-IssueOr F->9-42 5 VEHICLE CRF Ow SUS-ASSEMBLY SHEET M34 \BH CORAL | ser eiman con, fe) oe Bl | Scour CAR. HERCULES-MODEL‘UXD ip FUTER ASSEMBL org © A TEST LaMP OR THE CONDENSER LEAKAGE TESTER MAY BE USED TO CHECK Firer Cou. @. 7% CHECK FoR ConTinums PLACE TesT Props (6) ON COIL TERMINALS ©)AND ©. Cou. ks DEFECTIVE IF LAMP FAILS TOLIGHT: 1 CHECK FoR GROUND PLACE ONE TEST PROD ON ETHER Cont. TERMINAL ©) OR. PLACE OTHER TEST PROD ON MANIFOLD ©). Coit. /S DErECTINE. dF LAMP LIGHTS. ” JF Coi@Is DEFECTIVE, REMOVE Con. By REMavING Six Bours @) MT NuT-S, LOCKWASHER', AND SPACER S REPLACE WITH NEW COIL. MAKE CERTAIN To RE-INSTALL CONDENSER ANo Cou LEAD @, — CONNECT CONDENSER LEAD@' Terminac ©. AIC BH-BI- 3 (4) ztBASE SHOPDATA-IssueOr 9-18-42 # venei Tir OVERHALIL | SomAssenacr SHEEF | ‘ENGINE SHED GMTION Cou. (ey |éH emt ono] ee: Bl| FASTEN END CovER@)ON MANIFOLD ® WiTH Two ScREWS©. INSERT IGNITION CoiL@)/N MANIFOLD ©). CONNECT WIRE Q)ON POSITIVE TERMINAL. OF Coi.®. SudE Col. INTO MANIFOLD UnTiL MOUNTING BRACKETS ON COIL AND MANIFOLD Line UP. FASTEN BRACKETS ToGeTHER WiTH TWO BOLTS,WASHERS, LOCKWASHERS, Ano Nurs@®). Pain Witw Ouve Drag LUSTERLESS ENAMEL. [MIA/SC BH BI (A. 150BASE SHOP DATA-Issut OF W-2-424 VEHICLE: ‘ONT. - OVERHAUL ‘Sus-Assemary (SHEET YA f ee nS foe oFta NOTE: The InsTrumenr PANEL Is Renoveo FRoM THE Scour Car WITH ALL WiRES INTACT. THE RADIO FiLTER Is Auso ATTACHED To THE PANEL. SEE BSDUNIT NOZh ELECTRICAL ACCESSORIES, FoR REMOVAL AND OveRHAUL OF FILTER. © PLACE INSTRUMENT PANEL ASSEMBLY ON BENCH IN THE POSITION SHOWN, Rertove Two Wine Nurs @ Ano Taxe Orr Cover @. Disconnecr Box © From The Panex@ Ano Pur Tre Box Away From Pane Agour Five incHes To ALLOW SUFFICIENT SPACE FOR WORKING. DISCONNECT ALL WiRES From GAUGES, SWITCHES, FUSE BLOCK, ETC. Remove ALL UniTs AND WiRES From THE PANEL. (WaASEBH-FS-1 (2) 25D, Instrument Panel... 37, as!BASE SHOP DATA-Issut OF W2-414 We i a a Ria SHEET 2 ria Usal Ee | einen Breccer Tie Pane. ©, Box ®, Ano Gover © For DENTS, BREAKS, ETc. STRAIGHTEN, REMOVE Att DENTS, AND WELD ALL BREAKS. CLEAN WITS @), ©, AND © THOROUGHLY. PAINT UNITS WITH OLIVE Drab LUSTERLESS ENAMEL. FIG. 3 Qacseer ALL WIRES, CONDUITS, ETC. DISCARD ALL BROKEN OR DAMAGED WES AND Conouirs. INSPECT, TEST. AND REPAIR OR REPLACE ALL INSTRUMENTS, GAUGES, SWITCHES, EtC., AS OUTLINED ON THE FOLLOWING SHEETS, M3AISCBH-F3-2 (2) 192BASE SHOP DATA-/ssue Q0-2-424 Ti Ow ‘Sua-Assemeiy ‘SHEET ay [eae me? 3 3 HEL, ACCESSORIES INSTRUMENT ‘ore NOTE: CLEAN Alt SWITCHES WITH CapeoN TeTpecrio@ne. TesT AlL Swircres Witn A 12 Vout 21G2 Test Lamp. REPLACE Au _Derective Smircnes Wirt. New. CownecT TesT Lamp Acko3s The Teemivaus OF Eacn OF Tne Fowuowine Swiroves: Instrument Swircn ©, Vecrmerer Surren @, Avo lewiron Smiter ©. THe Lame Srouo Licrir Ween The Swrrcn 1s Tore Ow AND Nor Lent Ween Swirce bly Irs OFF Posirion, Doerner The Test Laue Across Tne Teewma.s OF Hearte Swircr QD. Turw ON Hearee Switcn To THE First Postion, Lamp Stow Sow A Beir Licht: Turn Switcn To THe Secono Pastrion Ano Lam Sroup Suow A Dw Lianr. Toe Swrtca Orr Ano Lap Saouo 60 Wr POSITIONS TWO POSITION SWITCH TAREE POSTION SwiTcrt FIG.3. FG. 4 (Qane The Nowaee 5 Avo 6 Teemmats OF The Lint Swen ® Witn A dumeee, Pute SwiTcn kwos To Te Muber One Pasirion. Connecr Test Laue To Terwnas 2 dio 5. Lame Snouo Lisnt In EITHER CASE. Now Pat SwiTcH knoe To THe Maece Two Posrrion. CONNECT TEST Lame To TERMINALS 3 AND 5 Ano ThEN To TeRMINALS | AND 5. LAMP SHOULD Lint IN Errner Case. Ip The Swircn i A Tree Posirien Swircn @ Putt SWITCH KNOB To THE NuMBER THREE POSITION AND LAMP SnoULD Licht Wren Tesr Laue Js Conwecren To TeRMNaLs 3 AND 5. 253BASE SHOP DATA-Issut Of U-2-424 VERICLE Tir ‘Sue- ASSEMBLY er Mia |F CRRA ae £3 [4 Scour Can ACCESSORIES INSTRUMENT ow DASH LIGHTS AND TROUBLE LIGHT SOCKET Dre var SCR Bus Ww insreumenr Lent Socket @ Ano CowecT WIRE @ dno Tesr Lao © To Teemmac OF 12 Vour Barreer. if Bure Fas To Lice, EXAMINE Alt CONTACTS, WIRES, ETC, Test Vourmerer List Q) In SAME Manner. Test Teouste Lich Sacre By Connectins Wes ©) Ano © To Termnas OF 12 Var Barrery. insert Test Lamp Puc @ In SoceeT @. WF Bute Faits To Lear, EXAMINE Aut ConTaCTS, WRES, ETc. REPLACE With NEW UNITS When Necessary. FUSE AND JUNCTION BLOCK Oe Att Fuses Feow The Fuse Ano Juncrion Btock QD. Xe (6.2, Cutan The Bock Torousney In PETROLEUM MapHTna AND Der Wirt Cowpressco Aik. Examine ALt Terminats For Osvious Dkrects. IF Any OF The Ques RARE Beoren , Replace Wirt New Cups. Grece Avo Test Aut Fusts. Morale Tne Fuses On Eioce In POstrions Snows. CONDENSER Dar Comenser © (Se6 Fis.3) foe Swoers, LEAKAGE, Ano Capaciry. RaTeD Canacrry OF Conoensee Is SMD. IF Conpénsee Is Derective, REPLACE WITH NEW CONDENSER. M3AISC-BH-F 3-4 (/2). 254BASE SHOP DATA-Issvt OF 122-42 £ VEHICLE UNIT. VERHE ‘Sue ASSEMBLY (SHEET. UA | f e mee” F3 > To CHECK TRE On Gauet, PROCEED AS FolLows: CONNECT THE On PRESSURE CAUGE@ 6 Hose OF AIR PRESSURE REGULATOR AND GAUGE®. CONNECT Aik Host©.To Air Supp.y. GRADUALLY INCREASE AIR PaessurE To 40 Pounos. iF Tit READING ON O1 GAUGE Does NoT CorRESpOND Wir READING ON ThE AIR Pressunt Gauce ®, RepLace With NEW PrEssuRE GaUcE®. 255BASE SHOP DATA-Issut OF U-2-42 6 VEHICLE war OVERHAUL | S-Assinacr ELECTRICAL PANEL, sect | ssaenenr FO SHEET, 6 are SCOUT CAR TESTING OF THE AMMETER @)nercer ‘AMMETER @). IF THE INDKATOR HAND®) RESTS AT THE NEUTRAL POSITION ON AMMETER WHEN DISCONNECTED, THE AMMETER Is LEFT ON THE CLUSTER. REPLACE WITH New IF NECESSARY. Dovcor bse Thar The WATER TEMPERATURE GAUGE © FUNCTIONS. PLACE THE Bue Eno © inro Paw © OF Hor WATER, BETWEEN 160° AND 90°F DO Nor Bow. WATER. IMMERSE THE THERMOMETER © INTO WATER AND COMPARE ThE READING OF GAUGE ©) AND THERMOMETER ©). IF READINGS DoNoT CorRESPOND, REPLACE WITHNEW GAUGE Ano TiginG @. HANDLE TUBING WiTH CARE So AS Nor B DEVELOPE KINKS AND CRACKS. useBASE SHOP DATA-Issut OF /-2-82 4 Mal [7 OVERHAUL |r” ‘ELECTRICAL ACLESSORIES. INSTRUMENT HEFT f3 oF - TESTFUEL Dow. 2387 UGE AND RHEOSTAT. @ Test Fuel Gauct Tne Unit @) Mo fiet Gauce lane Unt @, Wee As SHown. Tew On Doue.e Throw Sa SWITCH © TOWARD ThE SIDE LE opeosire Comection ©. Gause 23 Soun SHow EMPTY When FloaT®) GRADUALLY RAISE FLOAT 70 TION ‘©. GAUGE SHouLD SHOW Fut. IF GauGé Hand TICKS AT ANY PosiTiON WHILE RAISING FLOAT, REPLACE TANK Uni. Cet FLOAT For LEAKS. REPLACE IENECESSARY. IF GAUGE IS BADLY DAMAGED, REPLACE. NOTE: THERE ARE TWO RHEOSTAT AND Fioar Assemacies @) AND Ose SwircH ©. Test Bor RHEOSTAT AND FLOAT ASSEMBLIES @AND . _ Born Tepminacs @) OF Swirch ©. REPLACE SWITCH © IF NECESSARY. SAISC de)BASE SHOP DATA-Issue OF /-2-424 VEHICLE UNIT Ri ‘Sus-Assemecy SHEET Mia |'F CRRA Pole. “Ficrecal | PANEL ELECTRICAL Bs Scour Can ACCESSORIES _|_ INSTRUMENT. 2 Fig. : DismranTie IF 6Lass @ bs BeoKen, Beno FLanse @ Ue Wir A Screw Driver ‘Ano Remove Bezes ©, Gasxer OD, Broxen Gass @ GaskeT © Ano Dia ©. @ © Fig. 2. MOTE: Dismanruine Wut NoT BE Necessary IF Tests Sow THAT ALL GAUGES ARE IW : WorKine Onoer, Repace OnLy THOSE THAT ARE DEFECTIVE. @ FF Ox Gause © OR HEAT Inoicaroe @ Neeo Reecacine, Tawe Our Two Screws D. ‘Avo Stuo @. Remove Part Q. Remove Nut GD Ano Tare Our Ou Gause @. Reptace Tie Derective Oi. GAuse OR HEAT InocAToR WITH NEW UNITS. ke Amtrserer @ Or Gas Cause Ur @ Need Peecacine, Rertove Two Screws @ ‘Ano Stuo @. Tanke Our Gauses @ Ano @. Remove Nurs, Lock WASHERS, AND Far Wasrers G), Take OFF Stunt D AND Rertove Gas Gauee ©. REPLACE Avmerer @, Gas Gave @ Oe Born, wire New UNITS. MBAISC-BH-FS 8 (12) 23t— BASE SHOP DATA-Issut Of W-2-#24 wr, al JERHAUL (SUB ASSENBLY SHEET We | | f egeree eae 31 oe ASSEMBLING @: cE Cis Cuuce Terenas Pasrs @ Tirousy Two Hoes @ in Auwerer Asseuaty ©. ists Suunr ©, far Wasners ©, Ano Looe Wasners ©, Ow Terwmue Posts @, Avo Secure Wrn Two Nurs ©. INSTALL Assematy Wy Cluster @. Secure Wire Twa Screws Q Ano Srw ®. WysTaLL On. Gauce Firrinc © Teouce HOLe @ AND Secune Wine NuT @. Auce Heat invcaron ® Avo On Gauce © CLuster @. Secure wm Two Screws @ Ano Srv ©. Dassoeve ee OF The Cust As Fesows: Pe Dut © ‘Cluster. insta. GasKeT @) NEw Geass @ Ano Gasxer @ Ov Top OF Dat. Ante Bezet Fiance ) Quer Cluster FLANGE @). Tao Down Fiance ©). [HGAISC-BH-F3-9 (2) 25%BASE SHOP DATA-Issut OF 2-82 VEHICLE. e / “E OVERHAUL eee F3 SHEET CAL We Scout Cap AeeSsonts | NSTRUMENT eis TEST FOR SPEEDOMETER: Too, Dut.No. ‘207k 7904 Owe Ve a510rs 1 TEST SPEEDOMETER, PROCEED AS FOLLOWS. ATTACH THE speevomeTen @ D Ester ©, Usine AnsoreR oat ©. Swat Up ie Ester Ano INCREASE THe SPEED. IF THe MPH. ReAdiN Ow Seezpomerer (@) Does Nor CoRResrono Wit THE READING THAT REGISTERS ON THe MASTER SPEEDOMETER ©, Repurce Te Fanner Wimn NeW SPEEDOMETER. ‘Atso Repeace F Oomerer (©) (ap Recoroer) fats To REGISTER. (NGARSCBH-F 3-10 62) 260BASE SHOP DATA-Issut Qe (-2-424 (SHEET LE UNIT. OVERALL [Sem ey ee ee INSTRUMENT CHECKING OF THE HAND CONTROLS. @ THE VENTILATOR, THROTTLE, CHOKE , AND SP&:2K CONTROLS ARE INSPECTED AND CLEANED IN THE FOLLOWING MANNER: REMOVE Wire UniIT@ FROM CABLE UNIT @)AND CLEAN IN NAPHTHA. IF WiRE OP CABLE 45 BROKEN, REPLACE WITH NEW CONTROL. POLISH OFF ANY RUSTED SPOTS WITH SANO PAPER, IFLENGTH OF WiRE Is SHORT, REPLACE WiTH NEW CONTROL. THe CORRECT LENGTH OF THE TWOVENTILATORS, CHOKE , THROTTLE, AND SEARK Cowrrous Are Listed BELOW: VENTILATOR Ley @ Ronr@" CHOKE Throrme | SPARK gy NOTE LUBRICATE ALL PARTS WITH LIGHT OIL AND REASSEMBLE. 261BASE SHOP DATA-Issut OF #-2-42.¢ Mos F OURHAUL Sie SHEET ELECTR PANEL ACiSSomes | INSTRUMENT le. 3 Y OF IN INPA ASSEMBLE GAUGES, SMITCHES, CONTROLS, ETC., IN PANEL IN ‘POSITIONS SHOWN, For Weans OF insteuenr Pave Sée B.S.D. Unit No. 70, Wire, nD. ORL ET] #32074 [10 |22] 0 43/015 10 |22| 8 /M3AISCBH-F 3-12 (12) 2erBASE SHOP DATA-Issve Or Yo & " VEMICLE OMIT OVERHAUL SUB-ASSEMIBLY ii r a \/DA @| Fo Becrmea |e uagnour,, F 7 a ScOuTCAR ACCESSORIES | ere | Nove: NUMBERS a DENGTE OPERATIONS, | W ORCER O08 a { 4. ( <5 eee nt wD AMD. SQ). Renove Screw @)Anp Tart Orr Cour & Br Putin (Our Ar Borran OF Cover AND PusHine UP (2 )fewe Lens Assenecy © Front Cover@ By PULLING ‘On Rueeer GAsKeT®. Gres Gusss Lens®, Lin Screen @)Ano Bue LENS © on Or Russer Gasrer©. Fut Connector & OFF OF Wire ®. WASH ALL PARTS, DR«, AND REASSEMELE LENS ASSEME-7. ©. Use New Farrs Te REPLace Aur That ARE BROKEN OF CaraceD. Fuse Lens Assenetr© nro Cover ®. 4 Remove Ano Test bas D. iF / Bub Is Derectivé, REPLACE WITH No. 67, 3CRIZI6V Bue. (J) weer Bete iv Socner Ano Tesr For Cowract, See Fic.2). See THAT Fi 2. Tol2 Vout Eurrery ButB Firs TicHT In Socner, I Bue Fans To Licus, Ir May Be Necessary To REPLace Wee ®. PBASCOFFT- 12), as. Lamps, Blackout... 38BASE SHOP DATA — Issue OF Wijen & SHEET, VEHICLE UNIT: Sue-Assemary Mal | PEBHAUL | ie Rena | f7| "5 ACCESSORIES: OFZ ScourCar To REMOVE WIRE FROM LAMP CUT WIRE AT @.SLIP RUBBER TusinG ® OFF Wire. UNTIE Kor In WiRE, AND PUSH WIRE UP TiRousH Boron Or SocxeT ©. 1ELT SOLDER ON CONTACT POINT@)AND USE OLD CONTACT WHENASSEMBLING NEW WiRE.USE "16 (Fe BLACK WIRE CUT 10 SAME LENGTHAS THE ONE REMOVED, INSERT WiRE THROUGH SPRING @)AND FIBER WASHER®). PLACE SHALL ENDOF SPRING TowWARD WasHER ©). SOLDER WIRECONTACT ©. 8 THREAD WikETHROUGH SocKETAND Tie Knot Wire So Tat Knot Writ Tan Putt AGAINST HOLLOW MOUNTING STUD@, THE WiRE BETWEEN KNOT And SocxeT SHoutn BE FREE To Move. Q) Sie RuseeR TuBING® OVER WiRE. Crip METAL TIP@ON END OF WIRE With HA.DOUGLAS CRIMPING TCOLOREQUAL .INSERT BULB IN SOCKETAND Test (SEE Fig. 2,5HEET |). PUSH CONNECTOR@ ON WiRE.REPLACE COVER®) AND TIGHTEN SCREW®,. 264BASE SHOP DATA -/ssuc OF 1x78 © SS Shae eer MAL |\F QEREAUL Hea 5 |) SCOUT CAR ACCESSORIES Guioe AMP CRP Moo 364-E oF 2 DO REMOVE SCREW@)FROM LENS CLAMPING FINGB). SPREAD THE & ng, Ano Putt [7 OFF Lamp Boor) Be @rerut, do Nor Drop The Lens©).IF Lens ks races OP Bronen, REPLACE WirtNew LENS. WASH AND CLEAN LENS. @) REMOVE RUBBER GASKET©FROM REFLECTOR @) GASKET / MUsT BE WHOLE. IF NOT, REPLACE WITH NEW: REMOVE BULB®) FROM SOCKET AND TEST. IF BULB IS DEFECTIVE, REPLACE WITH 2132 CP 12-16 Vour PREFOCUSED BUL8, MAZDA # 23-26. ‘o) Remove REFLECTORE) BY PRESSING INWARD ON SOCKET FRETAIMING PiIns@)-/F NECESSARY To REPAIR SOckETS AND Wires Cur THe WiPES ATODAno Tan Our The SOCKETIR). REMOVE THE CONNEC TOR SOET © From The LamP Booy© BY LiF TING THE SOCKET RETAINING SPRING @® OVER THE CuiPS@)ON SOCKET. @ REMOVE NUTAND LOCK WASHER®). REMOVE The Two ECCENTRIC Mounring Block). CLEAN Ano Fawr Lamp Booy© ANDGAMPING Fine) INSIDE AND Our. [M3AISCBH-F5-7(2) BSB Me, Lamps, Head——... 39BASE SHOP DATA- Issue OF 1-#-4 & VEHICLE WIT OVERHAUL Sus Asseveny ‘SHEET ea |F SE ete Fo [2 INSTALL Ew Wiees AS Berween Bue SocneT Avo Cowecroe Socer ©, Cur New Wigs Saué LencTa As Cup, Pus Wires @ : Treouc Soorer ® Ano Suc Sees Over Wines. Fee Wiees (Or Treous INSULATING Waxice ©. Soucee Eros OF Woes ® FooM —) CoracTs, Wire Must BE INSULATED UP 716 CoNTACT SO THAT SPRINGS Cannor Toucn Bare WIRE. Same Peacepuee Appies BOTH SOCKETS. ‘Reruecroe ©) WITH Paste Made OF LAMP BLAGK AND Aucowot ON Corton Pius. AFTER Pasre Deles, REMOVE WiTH CuEAN COTTON. DiscaRD Rertector IF Sumrace [s CoRRODED Oe IF SinvER PLATING HAS WORN OFF. Caurnon: Do Nor Touch Powis Suerace Oe Rerecroe WiTH FINGERS. ASSEMBLE LAMP: REPLACE EtcenTRIC MounTine Biocxs® On Mouvrinc Bour ©Ano Fasten Wit Nut Ao Loox Waste ©. Wscer THe Cownecroe SocKer @ In Tie Lamp Bony ANo SécuRe Bv PusHine RETAINING SPRING @ Over GuiPs@DON SOCKET. - Qarrer Bure Sooner Tb Peruector AND InsTaLL Bure ® In Sock eT. Pus Russee GasxeT© InTo Geoove in ReruecToe ©) Ann Lay REFLECTOR In Lamp Booy. PLACE LENS @) AGAINST RUBBER GASKET AND SLIDE LENS CLAMPING RING @ ON Lamp Secuee Pins By TicHTENING Sceew ©. WSAISC-BH-F5- 2(2) 266BASE SHop DATA —/ssue Or “1/2 Wee a OF Ae {M3A4l Ff QVERHAUL LAMB.TAlL chem 6 ELECTRICAL ACCESSORIES | CORCORAN BROWN LAMP-CO, ee H L remove Coven@ Fron LAMP BODY @ByRénovinchoScaéws©. ‘SHEET Nore: Nyetgees In CiecLe DENO ITE OPERATIONS. Fé 7 pppER. Fig./. Cake Our Butes Ano Test: Repiace DEFECTIVE BULBS With [AZDA* 67-3CP, 12-6 VoLT.INSERT BULBS IN SocreéTs@ Ane lest (See fia2) USinGANAE CONNECTOR ON One Tes Leab. /F Goo Bu.8 BURNS ff Din ORFausToLicnr/timpicaresADErEcTIVe Ml Ground. THESOCKET SHOULD BEREMOVED = ToTuawe our By REMOVING SCREW@LOCKWASHER@AND er Fig. 2 CLanP@. OG» HE SURE BULB FITS TIGHT IN SOCRET.CLEAN INSIDE OF SOCKETANDITETAL ‘SiS OF Bute With FINE SAND PAPER. CLEAN CLAMP@ WiTH SAND PAPER. REPLACE RUBBER Wa sHER@IF IT Is Baoty DAMAGED. (Bolter Must Nor Be ANyHovesin Lane BooY @ har Wie EntlicHT Siastt HOLES MAY BE SOLDERED OR WELDED SHuT. DISCARD LAMP BODY: JF ITHAS LARGE HoLeS I ITOR IF It Is RUSTED THIN. REASSEMBLE SOCKET IN REFLECTOR AND TEST AS SHOWN IN FiG. 2. DRC BHTETO) asm me Lamps, Tail__. 260BASE SHOP DATA — Issue OF Ysee ke. Toa | ORRYALL | itt none G | LECTRICAL Soutlar Accessonres | COASRN BROWN LAMP CD. Gye Cover@APeraximaTeey ONE INCH ‘Fron Top OF BENCH. PUSHLENS ASSEMBLY Our OF CoverWiTH THuBsAS SHOWN In Fis. BE Carerut Not ToHown CovER Too HIGH ABOVE BENCH OR THE Two Gi LENSES AY BE BROKEN. . fig. ©)sreerenhuszes RETAINER) TO REMOVE THE RED ANDAMBER BLAGKOUTLENSES Q\ANO@) AND THE Liat SCREEN ©).REPLACEANY BROKEN LENSES Wi NeW ONES. RUBBER RETAINER@)AND Ruaser GASKET @/1usT BE WHOLE, IF NoT REPLACE WITH NEW. VvsTaLe CoLored Lest © ANDO) AND LIGHT SCREEN®/N RUBBERRETAINER@).LAY RUBBER GAsKET®@)INCOVER@ANOINSERT TWOGLASS LENSES@AND@. PUSH RUBBER RETAINER IN Cover. INSTALLCOVER ON Lamp REFLECTOE,AND SECURE WITH TWO SCREWS.SEE Fi6.| SHEET ONE. (MBAISC-BHY 6 - 2(3)}| 268a SHOP DATA = Hes oe Yafes & Mes ih iF F QUERHAUL ie | TAMP. TAIL emer AL CED EG 14 ELECTRICAL Aecessonves | CORODRAN BROWN LAuP Co. ae =e OpeRanons © THRouGHG) SHEETS!AND 2 OF Rist S108 Tait List. Nore: Service Srop-Tait LignT Bu. OF Leer SweHAS A Douste Fianenr, I THis Bue |S DEFECTIVE, REPLACE WITH MAZONNT 2I-6CPIZK STRETCH RUBBER RETANER® To REMOVE The Reo Buacrour Lens© Ano Tie Lis Screen®. REPLACE LENS IF BRONEN. RETAINER @Ano GasneT@sus7 BE WHOLE, IFNor REPLACE WITH NEW. FOLLOW OPERATION) SHEET 2, RIGHT SIDE TAILLIGHT For ASSEMELY. \M3A/SC-BHF 6-3 (3)] 269LoBase Stop DATA —~ Issue OF afayyeg™ VEHICLE UNIT OVERHA\ IL | Sue AssEmecy ‘SHEET MsAl | A “Bony \™eanecime AS | I ag NOTE: NUMBERS IN CiRcLES DENOTE OpéRATIONS. FOLLOW IN ORDER bo AND Al INE Guy TRACK. @ Je Quassis Is Sprune Oe Twsren, Examine To See le Tae Track Has CHANGED Irs Oran. Pasion. CHeck Ann Ansust The Teack, Foutowine THe MeTHa0 LESCRIRED: WITH A Scriger Lay Qur. THe CoRRECT Qursibe Ano Insite DiMENSION LINES OF THE Track AS~ semeLy Ow A 78’ Suerace Taare @, Place THe Teace® In Pasion Over Serie Lines On Surface Taste @. REFER To Dimensions On FoLwowinc PAGE. REST Th Six KNEES © Ow THE TABLE WITH 175 UPRIGHT SURFACE ON THE StRIEED Ourer Line, Bur Station Eaca Knee SOTHAT IT Wi. Mare Contact As AT BracreT ©. Bowr THe Knees To Taste. ADJUST THE Track: AGAINST KNEES AND WiTH Two STRAP Cramps © Deww Dawn Tie Rear OF Track To Tague. In Tuis Posrrion Examine For TWiST Or Kinks. Atso Check The Rise Fram Taste To Front End OF TRACK, CHECK THE wnsice Curve OF THe Track Br PLACING A SQUARE © ON THE TABLE WITH ITS UPRIGHT EDGE On Tie Inner ScriBep Line AS SHOWN, AGE: THE LeTTER@Is Commoner REFERRED To AS KNEES ON THE FOUR FOLLOWING SHEETS. HOWEVER THESE AcE ANGLE PLATES, (MiMISC-BA5-/-(4) esp me 4] Machine Gun Tracks. a7a ‘SHEET A5 TRACK, MACHINE GUN = /ssue Or eee e “Sue ASSEMaLY Base SHOD DATA QUVERHAUL BOvy our M3A/ Scour Car ~ 62080 QNIMYAD ADU NID INDY, TNTBY ‘S377 O2L10] AJ O2vaION) 5) $1309 EAP MTT aE z ae SQ UUINTD ALO] THAW] TH] NOY I51Y FHL USC-BH-A5- 2 (4) i art wana F801 NOISNaHIG 30ISNr WIVAL NID INIHIVWY OF SNOISNINIT ONIGRIIS ONY ONINFLHO ILS LILABASE SHO2 DATA — /ssue OF Yar VEHICLE Mir ‘Sue-Assemany SHEET A id ee BObY ANGIE: THe Macrine GUN TRACK IS STRAIGHTENED waTHOUT HEATING. To Remove Twist Oe Ceowrs iv Lower Ese OF Track, Bow Knee @ To Taare Ano Acamst Tue Teacc@) As Shown in Fig1. Secure Trace To Knee Waw'C'CLames©). Orerare Hrorauic Jack ©)Unoer Toot ©) Unni. De- SIRED CORRECTION IS ATTAINED. Fig! IFA Corner 13 SrRuvs Qur OF SHAPE OPER- ATE HrorAuic uace © BETWEEN Too @) Ano Knee®) SHOWN IN FIGLREZ PLACE THE KNEES (AND(CACIINST Tite Bracxers Fae Exoucn Fron Tie Seung Carvier, Avo Baur To That. Cuanp Tre Trace (QTo The kee WITH C’Cuames @ Ano WW). Then OPERATE Jé0c UNTIL FOE OuTLne Comcwes Wir Sceisep LINE ON Tasxe. Sei Necessaer To Remove Bow ly Rack, Bor Two knees ©)Ano(@)0w One Sive Ao Knee @ On Omer Side OF Track(S) Baur Knees To Tague. OPER TEAK ® Acawsr Trace Uma. Bow ks REMOVED 2%BASE SHOP DATA — /ssu Or Ye1/ae€ oy OVERHAUL | eae A BODY TRAC, MACHINE AS Venice SHEET M3A/ [sourTae or 4 ©) Witw Te Rear OF Track CLAMPED To Tate AS Swown In fig.1 ON SHEET |. CuecK THe Rise. Fron Taste To Top OF Trace Ar Tue Front Ena. Ip Tracn Rise 15 Too Hicn, TweN Proceed AS FoLLows: Bor Down Fixture @) To Tabee, SO THAT ack @ Wut Be BETWEEN TRACK © Ano “T° Bean OF Fixture @, As SHOWN. OPERATE JACK UNTIL DESIRED DIMENSIONS ARE ATTAINED FoR Dimensions OF Rise REFER To SHEET 2. TOOLS REQUIRED oo. OWE, Wa |SHEET| OPER 90876 712 05762 313 908765, 3_l4 "933038 ae iajoolal| GBAISC- BH: AS- 4 (4) 2HBASE SHOP DATA — Issue OF uflan Piss eae SutAssemary ET MGA) |BH iar | “ir 633 |™ ®O INSPECT ManiFoLp @ For Cracns, OR Breas. DiscaRD MANIFOLD For NEW JF ANY BREAKS OP CRACKS ARE APPARENT. InsPECT Tareaos Ar @) AND ©. IF DAMAGED, REPLACE BoLTs Or NuTS AS Necessary. RepLace Fiser AND Paper Gasnets At ©) With New Ar ALL TIMES. CLEAN ENTIRE MANIFOLD OF Excess CARBON AND GREASE. SANDBLAST FOR FINAL CLEANING. WHS HBB Manifolds... 275TEBASE _SwoP_DATA-153UE_OF W/¥/yao~ VERICLE | OWT Sue ASSEMBLE MOAI |BH nett no eee BS Aiton re Movke. Mau- 4006 [Scour Car DISMANTLING NOTE: NUNBER In OrcLes DENOTE OPERATIONS. FOLLOW IN ORDER. @) Was StazTeR MoroR in PETROLEUM NAPHA AnD Dey Wirw COMPRESSED AiR. @ Loosen Nut @ANo Sup OF F HEAD BAND ASSEMBLY ®@). inserT Hook Fic 2UNDER BRUSH SPRINGO, PULL Our On Sering Avo LFT OuT BRUSH®. REMOVE THE OTHER THREE BRUSHES INTHE SAME MANNER. Remove Tio Frame Screws © wire Lack Wasners Ano Tae OFF CommuTaTOR END PLATE ASSEMBLY@, Motor Starter. 43 neBASE SHOP _DATA- 1Ssue_or Mofvlenl RCE TO GVFREAUL ase SET] M3AL |BH ~ cicerecn, [MOOR STARTER B5) 2 ‘aon ACES SONS | nosetnas toe oe REMOVE PINION HOUSING AvodeMATUREG)/ ROM YOKE Massemeur©). IFARnarue Au Prwon House bo Mor Come APART EASILY, INSERTA Brass DeirT AT ©), Fe.2 Ano Diave ARMATURE SHAFT Ano BENoIx DRIVE Assemay Our OF Pinion Housine- ve figs Yi Remove Beworx Drive Assemeey fron Anmarvre SMT: Sremeuren One ProneOn Exc Loce HAsneR@) Avo REMOVE HEKAsGN Head ScRENS(G)AND @). i ‘loosew Benoin ave Assemety Wire PENETRATING Ott IF, Necessary. Dre Assematy Sneoed Come OFF OF ‘Swarr Easity. IFIPISALITILE Tse, Pate Wirt STanparo GEAR FULLER. ‘Press ARMATURE SHAFT QUT OF Busine Die Stannard OD sy) ‘reor PrESS)REMOVE WoooRUFF Key @)AWTKE INTER — Uys MEDIATE BEARING ASSEMBLY QOFFOF ARMATURE SHAFT. TAKE fi2 OFF Ove FIBER WAsHER@/IND ONE FIBER WASHER @ yy Fie. 3 eee e2 (GO ymesiaurers SuprepMoror Thorous er lv Perot E UMAAPHTHA. DRY WITH COMPRESSED AIR. MAI SC -8H- B52) LIBasé__Sx00_QaTa-issve_or WhilinT venicte T wt OVERHAUL | Su8-ASsEMBLY a MOAL|BH = zone (MIG STARTER BS 3, newouies- mover v0 | ode” td oo TEST AGMATURE Foo GeouNo Ov Stannaen HicH FoeQuENCY TESTED. HeLD ONE TEST PRONG Ov ARMATURE SHAFT @)AND Make CanTACT Qn CommuraToe BARS im Te Orne Test Aoone if Hene 15 EXCESSIVE Senor, Exauine: AQMATIOE ‘FoR FaEIGN MATTED On Tre CommutaToe 8423 Qe In THE ARMATURE ITSELE IF TROUBLE 18 Aor Visieie, Was Mave Tragousuuy Ano Faace AL Fookion MATTER QuT OF AaMATUDE Wit GompersseD Alo AT Hig PRessuce. RETEST AQMATURE, AND IF IT Is Stk DEFECTIVE Ao Teousté Cano BE FauNo, REPLACE. 7 Commuraroe is StiguTiy Rous, Foust Wire Ne.00 Sanoparee, Tian Down In LATHE IF Necessaey. RETEST To Mane Sure No Guars Ger LooceD IN AQMATURE. AHO Var Test Uist Coun Be USED IF Hic Fequency sree |5 Nor AaLAaLE, TesT Foe Suoers AND Oren CiacuiT ON GROWLER. 7 TEST Few FoR CONTINUITY;MAKE CONTACT ‘At RanTs@Ano ©). JESTER Swoutb Stow A Carcurt. Then TesT For Group By Marans Cvracr AT© Ano Any WERE On Yore®. IF THERE Is NO Circurr, Fie.os ARE IN GooD QanDITION . JF There Is A ORcuIT When TesTins For Grounb, I Wie Be Necessary To Remove FeLDs. 21BASE _ SHOP DATA~ Issue or wheal venice] wer OVERHAUL Sus ASSemacr sar M3AI|BH “eane ~ |MOTOR, STARTER BO sears wercute no | nob 28% L REMOVE FIELDS @), JAKE NUTSAND HASHERS \ Avo ©) OFF OF Terminan Screw@). REMOVE SCREWEAND INSULATING FIBER). MAPK ENDOF ExcH Poce SHOEG)AND Position In Yore Wir H ACEnreR PuncH. INSTALL YORE In PoLe SweSorw Drwer@.Take Our Four ScREWS@)Ano Remove EACH PoE SHO8@). TAKE Out FIELDXA). EXAMINE Fiews For DAMAGED INSULATION. RECOVER ALL. WORN PLACES AND Paint With Rep GtiPrat LACQUER ON Bane Fietos Uvri.. They Are Dry, SCRAPE ALL Rus7 Ano Loose Paint OF FOF YORE. POLISH Surrace ON Wire Burrine WHEEL. INSERT FELDS IN YotrE It POSITION SHOWN. INSERT Termin Screw ©liousn ERMINAL©),FikER Waswer@yAwo Ha E®). PLACE FiBeR WASHERS, STEEL Wasner Ano Lock WASHE R@)ON TER MINAL(E. SECURE Tn Lock Nur @). Pur ON ANOTHER LOCK WASHER An NuT® INSERT EACH POLE SHOE@)/n 175 CORRECT POSITION. SECURE IN PLACE TH ScREW INSERT insu ATING FIBER@ BEHINDCaNNEC TOR@). \ RETEST Figto5 To Mane Sure ALL DEFECTS Have BEEN REMOVED. (M3ATSC -BH-B5~ 280BASE SHOP DATA - Issue Oe sl/r” weer ue oe ht ma [SA /|BH OUGRHALL Mor STARTER ps | g hee! nencutesnocce 1x0 | mod Skt ne os OQ BRUSHES WiCH ARE NOT IN GoD CoworTion. To Do So, MetT So.oeR AT @ AND O©Ano Pus Our THe Brusres©Ano©. Insta NEW BRUSHES. SOLDER AEW BRUSH LEADS IN PLACE AT@AN0®). REMOVE THE Tio BRUSH ASSEMBLIES © From Commuator Aare Assemenv® BY Removine Te Tio RveTs@ Which Secure Exc Brush Ho.beR@. ASSEMBLE. New BrusH ASSEMBLIES IW Position Ato SECURE ExcH ASSEMBLY With Two Aw RIVETS. @ Test Commutaror PLATE ASSEMBLY®) I For CaVTINUITY AND FoR SHORTS. MAKE Contact Ar FowTs@ And ®. TESTER Journ Show A Cicur. Make ConTact Ar PanTts© Ano @, QD Ano©.@ Ano ©. DAG, Aw@A0®. Tester Shoun Nor SHowA Circuit iF COMMUTATOR PLATE [5 DEFECTIVE, INSPECT For Cause OF DEFECTS Suc AS BROKEN INSULATION AT @), RUST, ETC. CORRECT ALL DEFECTS IF POSSIBLE. REALKE Wirt New CommuTa Tor PLATE F NECESSARY. @ oe ABSOREENT Bronze Bearinc Ar®) ‘Fae Wear, CHECKS, ETC. ALSO INSPECT THE ABSORBENT BRONZE BEARING@ WN PINION HOUSING ASSEMBLY® Ano BEARNG® IN Te WTERMEDUTE BEARING Assevenv@ RePLace With New Besrines WHEN NECESSARY. ISAISC-BH-BS 53)BASE_SHOP DATA-sssve_oF_tlifen VERICLE M3AI\BH aa te aaa ere OVERHAUL | MOTR STARTER. 25 HERCULES: maDEL:JxO | mobh Gaal S06 ora SCOUTCR cy ® Nore: Wie ASSEMBLING, INSECT EAQH INDIVIDUAL Part For Derecrs. REPLACE WiTH New Parts WHENEVER NECESSARY. Arwarire SturT(@). SLIP INTERMEDIATE BEARING Assemely©@) ie Tue Way ON SHAFT. INSERT Woaorut Kéy@) In Position. PLACE BusHinc®) Ov SHAFT Wit Keyway In BusHinG Qv Wooneurr Key@)IN SHAFT. PLACE SprING®) Qn Pinan Ano SHAT AssewayG) AND SLIP THE ASSEMBLY ON ARMATURE ShAFT. LINE UP HOLE@ IN Bushinc®©) WH Hote) WW ARMATURE SHAFT. Secure Serinc®)IN Posimion WH Two SET ScREWS® ANOO Why Lock WASHERS TicxTen THE Screws AND Lock By BENDING Ue Ove Pronc Ov Excn Lock WASER. B® PLACE ONE FIBER WASHER@)OV ExcH END OF SASC-BHBSCA 282BASE SHOP DATA ~ Issue OF ajiviga (~ “ASS Y He ] 3A [Bh CERHALL Torok SraTER_ ps) 7 | ENGINE z Iscour Gan HERCULES-MODEL-Ux0 | ObEP: HAV 006 oe WSERT AmuTurRe Ano Aerirn DWE ASSEMBLY @IN PINION HOUSING Q)YMITH © NOTCHO MN InTERMEDIATE Beaping ASSEweLYO)IN Line Wid Pin®IN Fintan HoUsine ®). PRESS INTERMEDIATE BEARING ASSEMBLY IN SOTHAT ITRESTS SotioLy On SOuLaéR@)IN PINION HOUSING. Cur A StRiP OF No.0 Sanoparer © 1'Wioe Ano Wear ir Arouno Coumuraror@ Wir Swot Sine On Commuraror So Tnar OVE END Laps OveR THE OTHER END. SECURE THE SANDPAPER To COMMUTATOR Witt A Rusber Bano@), PLACE ‘CammuTaror EN PLATE@)ON SHAFT©) AND INSERT Tie To BRUSHES@DIN THEIR BRUSH HOLDERS. HOLD SAND~ Fare R Feom TURNING WITH A FOREFINGER INSERTED BETWEEN BRUSH Ht ters Wherever Convenient Wait Turning THe ENDPLATE To THE RIGHT. SAND Brusnes UnTiThey Have A 252 Conracr On Gommuraror. REMOVE Busnes From Beusn HoLbers Ano Remove END PLA TE®. (SAl, 283BASE SHOP _DATA-Issue OF Miya? ene ERAT ae Be = M3Al\BH ‘ame | MOTOR STARTER B5) § TO-11TE Iscour Cam HERCULES-MODEL: KO | mot M4008 ore Inseer Amnarure @ Trou voxe® Wire Terninar© In Line Wire Hove © In Mouwrine. Put Brushes ©MID© OUT OF Winans As SHOWN Ano Por ComnuTaTor END PiaTe © Wim Nore Over Dower D.Haww Eno PLATE Ow AND Insert THE Tro BRUSHES @Ano Din These Respective HowveRs. Rorare Armature To The Ricx7 By Tortine Pwiow Iv Housine®. JF Sawo Pree Siies Ow ConmuTarar, Inseer Fincees Trove Hivoons Dano Aveuy Pressure Ow Sanoparee Iv THE DIRECTION IN Woticn The ARnaTURE Is Bene ‘Roraren. Sano Beusnes Uri. They Have 75% Cormac Ow COMMUTATOR. Penove Beusnes © Ano® fram Tete How vers: Tax OFF Eno Piate@ Ano Remove SAND Pavee@) Bow Au. Dust OuT OF CommutaTor Exo PuATé Ano Yore Ano AenaTuRE ASSEMBLY Wim ConpresseD Air. WASH THOROUGHLY. () Reassenace Eno Pare @Qw ARMATURE AND Yoxe Assemacy Ano Secure [7 Wire Tio ScRens nim Lock WASHERS. Inseer Aus BrusHes IN TherR Respecrive HouveRs Ao Por OW Wimoow Strap Assemey ® So That Name Pave Os Mn Line WiTH TénMinaL©.SecuRE Wawow Strap By Ticxrevins Screw®. LuepicaTe. i BED. Dia We| sweet | Oven [Der ens ft 2 hc | gion te TS Pat Unrr WiTH One Coar OF Btack ENAMEL. 77 3AISC BH 5-88) 284BASE SHOP DATA-lssve Or Mofajaet our OVERHAUL | S22: A8semecr G CHASSIS JMOEEEE Go SHEET / VEWICLE M3A/ SOUT CAR J ® INSPECT EXHAUST PIPE SEGMENTS @ Ano @ Avo MurrLer © For Dewrs Ano Brearace. | Baby DAMAGED, REPLACE With New Panrs, To REMOVE SEGMENTS From MUFFLER, REMOVE CLAMD OAno Spread Lip’ ®._ if THe ExtERwaL Parts OF THe MUFFLER Agee? % Be IN Goop Conpirion, Do NOT FORCE THE SEPAPATICN. USE A PENETRATING SOLVENT, AS KEROSENE, AnD TAP Wirt A Brass Hammer Uwrit LOOSENED. Atiacn Somer ®), Onzy, To MuFFLER ON Assimaty. Seemewr @® Wie Be ATTACHED Won Scour Car JS Finauey Assemecen. MOTE: UNITS IN CIRCLE ARE ATTACHED To PIE SEGMENT When DisMANTLED From THE Cae AND SHOULD BE ATTACHED When Overnau. Is COMPLETED. Muffler & Pipe..... 285186BASE SHOP DATA-/ssut OF yes 7 VEHICLE ONT O LE A L Sus-ASSEMBLY SHEET MAL LC C4 ‘Hoon, ANTLE rdw CHASSIS i 7 DO CHECK PINTLE Hook Unir For DEFECTS. IF SHar7®@ Is Beoxen Do Nor WeLD But REPLACE UNIT. IF, AFTER INSTALLING HOOK, THERE Is Any END PLAY, LOOSEN Nur @ ib RELEASE SPRING TENSION. KEEP UPPER JAW OF PINTLE HOOK WELL LUBRICATED. MSASCEH-CA-1c1) 1 BSD Me Pintle Hook 45 287288BASE SHOP DATA-Issut Or sofzlaz | veneie wr OVERHA ae ea i 7 "1STONS, RINGS (MQal BH extuted ce Waist Prvs B 2 JI “ort ® CLEAN PISTON THOROUGHLY IN A CLEANING SoLVENT AND Dey WITH Compresseo Ain. JF THE PisTon Is ScoreD, PITTED OR Has = BROKEN Op IRREGULAR RING Lanos() THE On Recwarns = € Piston Is Reptaceo Wit New. : x THe Pine Lano Sueraces Must BE Perrectty Smoot In Orver For THe RING To FUNCTION CORRECTLY. @ Cneck PISTON For Size. Trey Srou.o Br Fitreo’ With A 003” To.0035” CLEARANCE, MEASURED AT The BoTTOM OF THE Skiet ®. Tit€ STANDARD Bone OF Ths Eneine 1s 4.000" However, IF THE BLOCK IS REBORED, OVERSIZED PISTONS Witt HAVE TOBE USED AND FITTED ACCORDINGLY. @ THE PISTON Rings © ARE Auways REPLACED WiTH New. They ARE FITTED AND INSTALLED ON THE PISTON, IN THE ORDER SHOWN, WHEN ASSEMBLING ENGINE. @) CHeck THE Piston Pin © For Size. IT SHouro Measure |.000"3 IF Not, DISCARD. AT OROINARY Room TEMPERATURE, THE PIN SHOULD REQUIRE ALL THE Force THE Mechanic Can Exe rT WITH THE Pam OF His HAND To PusH THE PIN INTO THE PISTON. WATCHBBICD es. he Piston Rings & Wrist Pins... 46 2389290BASE SHOP DATA-Issue Or 1421-42 8 VEHICLE UNIT ‘SUBASSENELY SHEET yes ee ai, Numbers In CiRCLES DENOTE OPERATIONS. FOLLOW IN ORDER. Use NEW Cap SCREWS, NUTS, AnD Parts Ony When Necessary. LUBRICATE ALL Parts WITH LiGHT ENGINE Olt WHEN ASSEMBLING, ewe Tow @ w Vise As Shown, Serise Lines ArTac Fue. Pune) To Too. With Nuts AnD Bots. Serie Mark Ov Exterior Or ‘Pume With A Swap Too, As SHOWN, TS SIMPLIFIES ASSEMBLING MD Farts Cw BE MATCHED Consectuy. Q)yzee Ce Strew Ao WAsHer©, COVER), Avo GasreT© From Boor©. Remove Ten Boor Screws ©, (4 pew Spawe@ Ao RETAINER. Weaaseaeror- TO | om Pump, Fuel....__ 4; 211BASE SHOP DATA -bsye Or -2/-42 4 SHEET. WMA | BH SRRAL AEA By 2 y G) pom Dom Rocrer Arm @. Tie ~ Diaeeracn Assemety 6) In Position SHOWN An REMOVE. Ohana TapereD Spring AND RETAINER Assemety ©. (SHow BY Dortep Lines). Remove Fue. Pump From Toa In Vise Ano Tur Fue. Pume Over. Remove Cap Screw Ano FiBer © (pene (Q)Rewoe Bon ® Ano Caer®. (Orne Sree © Ano AR Dome @. (3AISC-BA-BIT- 2 (7) 292BASE SHOP DATA Issue OF /b2t-424 (Wea | BH Sele 5] 3 @ Remove TEN CaP SCREWS AD WASERS Frau Man Boor). 12) Pustt Down Ow Racer Arm@). Tit DurenscH Q 42 Som Br DormD Lees 0 Lion (3) Remove Sprinc ©) (4) Pam Our Ou Sea. Asseney ®, @) Remove CASKET ©). Wash AL Preis iv PeTRoLeum Nepean ANODRY Wit COMPRESSED AIR. Deane Rooen A Asstnity @) For Wear. IF 7 Nove Is Areepent, AD Links ARE Nor Worn, Assenely Can Beciw From Tas Por. IF Rocrer Aen is To BE Repracto, Drive Out PIN®), REMove FLAT Waster©,. Remove Busrine@). REMWE SPRNG®). OES es @ aime ho torn CGE) Busrine@) And: Reverse ea o PN® Is peren (Co <= ‘SPREAD Sor Ow Exp OF EX Pin Wire Quset To INSURE PIN AGAINST FALLING Our. 293BASE SHOP DATA-Issue Or /-i/-42-4 (ale elie a Z 2) Geer Maw Boor@ Wi A Stracet Eoce (Dorre Lines) In Posttions SHowN,@), ©, AQ). IF META Is High, CRIND OR HAND Fie Ura. Leven. If Bacty WaaPED, REPLACE Man Boor. Waae A Piece Or Emery CLOTH AROUND A FLAT Toot, AO Smoot Rocrer Arm AT ©) To Remove PTS AND CROOVES. po" SEAL CasneT Ano RETAINER@) ARE TaPED In, Spread Stars AT@©) Wir Chuser To Howd RETAINER In POSITION, DISCARD OLD DIAPHRAGM, PRESS OL RETAINER IN New DUPHRACM. SATURATE ‘Diapupacm In PeTRoLeuM SoLvenr-- SEE fe.4, [asc BHBI-40) 2a4BASE SHOP DATA-lssue Or 0-21-42 4 SHEET. ie By CRRA RR 1) oF MOAI | BH “iene Pus Rooker Aa Down, Tur Diaepacn Assemaly Forwarp (Sow By Arrow) An Hook Assemety On Cenrer Linnace As Show By Dorred Lines. Cruw ANSEMELY OVER IN VISE. Q ree Yue AD Coe Assemay® By first Remonne Screw, RETaneR © VaLves(é), Ao Cases ®. )REPLACE VALVES AND CASKETS WITH NEw AND REASSEMBLE. G)pz A Drop OF THREE-i- Oe-o0, OR Eau, Ow’ Exc VALVE. 25«BASE SHOP DATA-t m3 Or 14-2425 5 VEHKLE a 9UBA SSEMBLY SHEET 3A | BH SERAL eRe Bi | 6 Scout cae see 5-on a0) 7 DISCARD QLD. DIAPHRAGM AND REPLACE : With New. RepLace TarereD SPrinc (@), HEEPING “Smaue Eno Towarp Diararacm. REPLACE LARGE METAL RETAINER, LEATHER RETAINER AO SMALL META. RETAINER(E) ON Roo OF Diapiracm, 34 )Press Dom Ov Rocrer Aum, Tier ‘DapHRAGM FORWARD AS SHOWN BY Dorrep Lines Aro Hook Iw Position, C5 renee Spine Retainer Ano Sprawe®. CO soune® 1s REPLACED AND TIGHTENED Wit Tew Cap Screws Ao Wasuers®. ice A Drop OF THREE-IN-one Olt OR ‘Eau. On Vave WN CoER®). Renew Conk CasneT@©). REPLACE Vacuum COVER, WASHER Ato CaP ScREW©). G9)Revew. Vave Auo_Cace Asseweiy Frow Cov @. Renew Waves) Ano CAsneTs @). REPLACE, ReveRsinc PROCEDURE. a 296Base SHOP DaTA As Oe 0-21-42 8 Veer wir OVERHAUL | Seeassenair SHEET. M3Al| BH =tacne | FUEL PUMP BI} | 7 7 or 40) REMOVE FUEL Puvp Fram Vise AND TURN OVER. I) Replace Housinc@) Over DIAPHRAGM AND TIGHTEN Wit Tew Cap Screws AND WASHERS. Gare A Drop OF THREE-IN-one Ol OR EQUAL Ov VaLvEs In Housine. 43) fence SOREN. Renew Ano Repcace Cork CASKET ©) Reprace Ano_Ticurtn Cover (0) With WasHeR AND Cap Screw). TEST FUEL PUMP WITH VACUUM TESTER To Test inrane@), Pane Rocrer Arm Ano How Fil To Five On Six IncHes On CAUCE. IF CAUCE Dees Nor Stow Five OR Six IncHes AND Remains Art A SteApy Level, Coece VaLves, DiapHracn AND_ GASKETS FoR LEAS. To Test Booster) Puwe RocKeR ‘Arm To Six OR Stven inees OF Vacuum Ano Howo._ Cueax For Leas As Asove. To Test Ounce ©, Pu Rocer Arm Ato Brine To THREE Las: Pressure Ano Hoo. de Guuce Does Nor Hab To Taree Les, Ciecn For Leas As ABOVE. a oes Toc Dias We | SHEET] OPER. | DET, Grae Is Useb For ADAPTER ‘309007, pear eal 908779 7 4s [TH Tue Asove Ture Tests pense Bre 717) 2728BASESHOPDATA-ISSUEOF /0-2-42-6 VEHICLE UNIT” OVERHAUL SUB-ASSEMBLY SHEET iL PUMP. AIGAL | BH sat alte PUM? BOS) | oe NOTE: MIMEERS In CRCLES DENOTE CPERATIONG, FOLLOW ORDER. USE Oniy NEW FIBER WASHERS AND LUBRICATE WH ENGINE Ql. USE VISE WITH SOT METAL JAWS, Hou In Vise By Wraxé Section), AND Penne SRANER@) Wit A PRE WRENCH REPLACE IF Screen [5 Beoren Oe Bn EnouGH 70 Cease INTAKE PIPE. . REMOVE THE ‘Sux Cap Scpews Ano Lock Wastes @ To Remove inane Secrion@, lnise Pap GEAR May Be Pemoven AT Fas Te. Pump Boy In vise By Suee4ce©) Ano Pung OUT PI®), Use SUIABLE GEA PULER®)TO Remove GEAR®. Wasxee@ Wie Come OF Suaer WiTH Geaa @). (Qyresree te Ders2 Fe Sues 40 GEARS AND MEASURE THE POLES IV WHICH TH SHAFTS Fir. Pum CLEARANCES Aee SHOWN IN wel, SHEET Two, Tie Suetace OF Sw4FT @ SEEN THROUGH Opens © May BE ConsineReD AS THE OerciAL DIAMETER. © (Br sereesO cere seme Where The Ges0s Ano @ Touc Te Conr® Ave Baniy Scone, Rep ace THe ENTIRE Pum Pur SHAFTS INTO Pui Bopy AND MEASURE SDE CLEARANCES WITH FEELER Gace. Examine GeaesOAnn@ For Nors. WHEN ONE Geae Is DEFECTIVE THE COVPLETE SET MUST BE REPLACED. END PLAY OF THE Puupine Geaes (Due Weae) Mav Be xen Our By LAPPING (On Surface PLATE ) THe. Cover @)Oe Have IT PRECISION G2OUND. © i ABCBH-BZE TA tno Pump, Oil. 48 209BASE SHOPDATA - ISsuz Of 120-40 WERICLE wa OVERHAUL u SUBASSEMBLY OIL PUMP B26 WGAl | BH Sbeeee B LIMITS OF WEAR OCATION OF SPECIFICATIONS AND CLEARANCES, Si i ‘ARANCE OF THE MAIN SHA END CLEARANCE OF PUMPING GEARS TO THE PUMP BODY- (SIDE CLEARANCE _OF PUMPING GEARS TO THE PUMP BODY... FLT OF PUMPING GEARS TO THEIR SHAFTS___— STRENGTH OF THE RELIEF VALVE SPRING COMPRE SSE! REQUIRED CAPACITY AT ILSPED-FIDLB— HOR. 1600 REM ~2618- HI SOREM-391A. FIT OF DRIVE GEAR TOTHE MAIN SHAFT _ i [APPROX/MATE ADJUSTMENT OF RELIEF VALUES: THE LOCK NUT. SHEET © LoosEN Loc# NUT @ AND REMOVE RELIEF VALVE Assematy ®. SPRING © Must Have THE REQUIRED Tensiry (ee Guart). See THAT Vacié ©)/S IN Goon SHAPE, REPLACE ANY PARTS NECESSARY. © If Ar Any Time Gears © Ano © ARE 7o BE REMOVED, PRESS GEAR DOWN UNTIL Swap-Ring @ CAN BE REMOVED. THEN PRESS SHAFT FROM THE GEAR. SEE CHarT For Fir OF GEARS TO THE SHAFT. A WcoDKUFF Key /s USED WITH THE Main SHaFr Gear © ONLY. WSAISC BABE)BASE SHOPDATA - ssue QF (0-2-4124 VEHICLE UNIT VERHA I Sue-ASSEMBLY SHEET : OL PLUMP. LAL | BM atten OC PUMP BEG | 3, ASSEMBLY. REVERSE SEQUENCE OF DISMANTLING Awo LUBRICATEALLPARTS WHHENGINE OIL. WHEN REPLACING DRIVE GEAR @), PuT Man SHAFT ®INPLACE. ADD FIBER TurusT Waster ©) WiTH SMOOTH SIDE Next To THe Pup Boby. Pur WoopRuFF Key © In Place. © © 7 7 (& sersuerce® on ne focecriceen FLAT PLATE IN THEPRESS. LINE KEY SLOT®) Wir WOODRUFFKEY AND PRESS ON DRIVE GEaR @) UnTit Hove © Is In Line WiTH Ins RESPECTIVE HOLE INSHAFT. SEE THAT SHAFT TURNS FREELY, BUT WHA LiT7LE END Play AS POSSIBLE IN AND QUT. INSERT PIN @) AND PEEN EACH END. (Darn COVER OR INTAKE SECTION WiTH ThE SIX CAP SCREWS AND LOCK WASHERS SHOWN, SHEET I. SEE THATASSEMBLY Woens Freecr. MSAISCBHB3EBASESHOPDATA- ISSUE OF /0-21-42. 8 BH Brereton PUMP BCG ISCOUT CAR HERCULES: MODEL= XD ors TESTING I Conrrewsere Dave 0 OF Fhe Testis Fixrure RATHER THAN Is EXACT CONSTRUCTION. THE Pum 5 CONNECTED 70 AN OUTLET ADAPTER, PLATE 0 WoicH Av OIL LINE JS ATTACHED. This Line 1S ZQuiPRED Witt Av Ol. PRESSURE Gace) AND A SLOW ACTING Vave©, Neve SHUT This Va.ve Compcereny WHE Pama 1s OPERATING UNLESS RELIEF VALVE 5 PenpeRLY (Dre ame seanar ie seco ® SPECIFIED IN THe GHAgr, SHEET 2. The On (5 Pompe Feam A Deep Fan ©) Ano Our THROUGH LINE ©, Bie Vauve /s Geabuauty SHur OFF Ti. A PRESSURE OF 25 Peunos 15 OBTAINED, THE RELIEF WaLvE®) ‘Shouto Open AT THiS TIME, ADJUST THIS VALVE JF Necessary. IF Pump Does Nor TEST SATISFACTORILY, CORRECT THE TROUBLE OR REPLACE THE ENTIRE Pump, TOOLS REQUIRED rote sneer] OPER ETAL 900983 | T x MSAISC BHBB4A) 202BASE SHOPDATA -Issué OF 10-2146 VEWICLE UNIT Bi CRA RE Bue aye 7] ty scou car HERCULES MODEL, ore NOTE: NUMBERS IN CIRCLES DENOTE OPERATIONS. FOLLow IN ORDER. USE Onty NEW GASKETS, PACKING AND DISMANTLE LusricaTe Movins SURFACES. Le Q Remove ELBow@) ANo DISCARD GasKeT ®.“Ho.o Pune Boor ©) i Vise Wire Copper LINERS Upsive Down To The Position SHOuN. REMOVE THE FOUR CAP SCREWS AND Lock WasHErs©). /T May BE NECESSARY To TAP UP Np OW THE SHAFT Housinc®. Use A SoFr METAL OR Composition HAMMER, @) HOLD THE SHAFT HousinG HORIZONTALLY i Vise AND Punch Our Pv @. Loosen DN Hes PACKING Nor © WiTH WeencH @) Ano Howo Pome 6, I ©\/AssemBLy in POSITION SHOWN. PRESS SHAET Q) © 2 A of Down THROUGH IMPELLER @) Jusr Enousey To ss PF Stup AN ANGLE IRoWD) UNoeR OPPOSITE SIDES OF Hse IMPELLER (ABOUT 48"). HoLD IMPELLER Wi ANGLE IRONS AND Pes THe SHAFT ASSEMBLY Our RENOVE WoonrurF Key (4) Ano Pou Sarr AE FRom Housine. MAIS us F fsa ie Pump, Water. 49 303BASESHOP DATA-ISSUE OF (ere 4r4 VERICLE UNIT SUBASSEMBLY SHEET, WGAL | BH aA Mee HUMP BIZ | 2 [SCOUT CAR. HER ore ‘ @ RENOE@ From House ® AND DScARD Fiete Thrust Wasxer ©, Examine Pump Deve Gear O.Ano DISTRIBUTOR DRIVE GEAR ©) AND REPLACE THE ENTIRE SHAFT ASSEMBLY IF GeaRS Are Worn, ALso REPLACE THis ASSEMBLY, IF Sarr Is Warn Oe PITTED. THE GREATEST WEAR IS Usually WHERE ‘Yau Oe" Nn Paceine Ruys. IF vey Sticariy: ‘908767 Rusted Qe Worn The SHAFT May'BE Posted WiTu Fine Aapasive CLOTH. SEE CLEARANCE CHART-ON SHEET 32. Bearing © May Be Removed Witw Toot Assemely@. ° JF Woen (SEE O14RT OV SHEET 3). This BEARING AND THE SMALL BEARING In THe Pum Housing Usua.ty Have To BE REPLACED WITH ExcH MasoR Lied OvERHAUL. PLACE The OBLONG ART @ O Toon © Unnee THe Busvins Ano Inserr SHAFTD, Pisce HE = _fi2 SLEEVE® In Rosman As Sxonn Ano Remove earns By Ticurenne Nur. Remove Core Oi Seat. Assérasey @ Ano Descaen THe Cork.” Ths SEAL May Be ‘PusHED Up From The Bortom With A Screw DRIVER. 20%BASE SHOPDATA- Issue OF 0-21-4245 UNIT |SUB-ASSEMBLY BH SURWAUL WATER RIMPB/2 HERCULES MODELND VERICLE SHEET MAL COUT CAR 3.,] © Pur New Cork O1 a. ® AND RETAINER) IN PLACE Wir Toor ©. CauTion: ALWAYS REMEMBER TO INSERT THIS SEAL BEFORE InseeTing New Bearing ©. © yecer sur tone ® By Using Toot © Iv PRESS. Be Caperur To Line HOLE fa M0 NorcH © Witx Thee {?- RESPECTIVE PLACES @. Qrrae bomewre WITH WRENCH D IF NECESSARY. REMOVE PACKING GLAND ®) AND PacKins Res ©. [Clearance Locarion Lin [MAX. MSAISCBHBIZ 316) 30sBASE SHOP DATA Issue OF 1021-424 SHEET (Wear \BH ee it nw Be| 4, ® (B)assaae Toa. © Wro Aare ©. Scaew Tess Toot WTO Ot Beane ©. Hoo Nor © Ano REMOVE Bearing By Tunnine Toow @ Comrer-CLocKwise. WPeess THe New BEARING On Pace Wit Too. ©. Ir ls Ever Necessapy To REMOVE GREASE FITTING ©, Ue Titan SEALING COMPOUND WHEN REPLACING. [3AISC-BH-B12 - 4 (6) 306BASE SHOP DATA -|ssue OF 1024-424 VEHICLE UNIT OVERHAUL SUB-ASSEMBLY SHEET eee \WATER PUMP, SCOUT CAR 5H evo bes 10 Ble Dare ASSEMBLY f® Place Packins Nur ® Ano Packie. GLAND ® The Posrrion SHown. LuBricaTe Surrace© WITH A LITTLE GREASE OR HEAVY EnGine Oi. Ado New Thrust Waster © AnD SS) PusH SHAFT TiRousH THE ASSEMBLY. FiT ONE IJ fine OF New Packins © ATA Time AROUND SHAFT Avo Pust To THe Borrom OF THe PACKING Guameer. USE Three OR Four le’ PACKING RINGS. ” INSERT WooDRUFF Kev ®) Aub Line Up Witt Keyway IN IMPELLER@. THE WIDER SIDE OF IMPELLER SHOULD BE NexT To Pump Booy. Press MmpeLler ON ThE Swarr Unti. THe Ho“es For P34 @ Are Wn Line. SEE Thar Asemety OPERATES FREELY. INSERT New Pin AD PEEN (MSAISCBHBESE 307BASE SHOPDATA - Issuer (0-2h428 Toh, [BH eel iaite Eve ae |G SCOUT CAR. HERCULES MODEL. Oe @ AracH Pump Booy@ Iv THe PasiTion Suown WiTH Four Cap SCREWS AND LOCK WASHERS ®). USE New GAsKET©. THIS WiLL Give CorrecT PosiTion Iv RELATION To THE MOTOR. @ with Tio Cap Screws Ano Lock wasners ®) ATTACH EBow® Ano Use New GASKET ©. Pur A Few Drops OF ENGINE a1 ON MoavinG PARTS AnD Fit GREASE Cup © WitH WATER PuMP GREASE UNTIL BEARING AND CUP ARE FULL. TOOLS REQUIRED Foot bw Wa HEET OPER [DET [700 Ome. M0. 906 Th 712 |@ | 908766 g0s7e7 | £14 | © | 30679 308Base Shop DaTa- Issue OF- titles VEHICLE | Oi Sue ASSEMBLY Sree OVERHAUL WGA! A “sony ~ | RADIATOR A4| /, Wore: NUMBERS IN Cieciés DENOTE OPERATIONS. FaLLow IN ORDER. Use New Botts Ano Nurs Onty WHEN NEGE6SARY. For TesTInG Ano PEFwRins- EapiaToe@)FoLLow MeTH00 DescriseD: Dismamrur The Sueoun @ Heo Br Sheews Ano Nurs, Feom Te Rapumoe Swe BeaceT@ fe ‘SWown In Fie. WitH uur Bown THe Rinse coe O.noret — fy For Leaks By Osseemmion. Msex THe Leans To Bourrare Locarns f Théu Duewe Rerue. Ir Tae Reouroe QeeQ)Hss Any Mace Leaks Ok Qeacs, Tue Cot Suamo Be Reeucen Eeexe Sono Be Moe Oner By Aw ExreeenceD Tinsuir Ce’ Eapusroe Man. fie.L, Scour THe QecuLaTne SYSTEM By lnmeesine THE Exouroe In Scoueme. Tax, Feo Wir Sourrion OF Boruine Weree Ano Cuore Se0t-1 Pouno OF Gausric Soon. Tb Esc 7H GALions OF WATER. Leave RaouToe IN This Bowne Soumon For 10 Mires. THe OcuaTING SYSTEM pepo Ge Fivsneo Our Win Cea Ware By Qrecuarine The Waree In FeveRse Dieecrion, FROM Barron: To Tor Piue Te mer ©) Ano Ourier@) Wim Rubee ‘Sroppers@. The Fiuce Oring 6 Goveee0 Wir Toow@) Ae Peessure Is Arpuep Theousn Tae Oneerion Pre Q). The Pani ATOR IS IMMEESED In TEST Tink ®) Fatt OF Ware APpLy Ave Pressure. Learns Wi Be Deree- ined Br Buseves. Maer The leans To acu mare QR) ro Dwene #33039 Cocarine Them Durie. Eran. ‘o) QDinaa In Upper Tank) AnD Lovee Tank, Oe Aecuno THe Neck OF Orewies, Stouty Be Képateeo. Wirn Leany Aeea SceareD Bescon WITH Scearer, APPLY Aci Or So.08RINs FLUK: AND So.nER ithry Hor So.oreme lean Usine 50-50 SOLDER. Note: Do Nor Sueuect The Panatoe 1b A Geese Peessuee Tuan <4 Poon. M3AISC-BH-A4-/(2) Sn he Radiator... 5) 304BASE SHOP DATA- Issue Or- thes = VEHICLE UNIT tL ‘SUB- ASSEMBLY ‘SH WsAl | A OAL RADIATOR A4) 2 | ©) Minar Lewes Founo In Care Mar Be Souveren. ‘Cuczruy Specan The Fins Arwer, SHown In Fiat Ar @. Quan Leanr Azta Qn Tose OF Core Br Sceapinc. APPir Co. Tue Lean. Puss The Fins Bax Into Pace. UPA TUBE INTHE CORE Is DavuceD Bevono Repu fr Mer Be Buocren Our As Faxzowa: Cur A Sau Oval Hour I The Danese Tose) Asour 14” Fou Urrce@)Avo Lone) Tan, Scrape Toe Inne OF Tose Cean. Caray: Baw ‘Mueumic Acib Mer Be Useo For Cueanine Bur IT Must BE Fig.) Eewoven Arrerwaro. Fux The Insioe Wr A Smau RanTeD SowERING IRON. Flow Giouse Sawer into Tue To Bock Tie Gvos Nexr To Tank ©Ano®). To Ger THe ee Tat: Ratraror Do Not Back More THAN TWo TUBES IN THiS MANNER. When Tue Rapuroe Core) is Foun Beveno Rerae Ir SHeuo Be Repuacen As Fattows: Piace RaDiaToe On RePare Gencn Face Down, Play Tarew Flame Ar HOLES ©1@ And @. AT Save Tie Pevine Loose THe Sive MemBer@) From Te Tans ©) ‘ANo SHOWN IN Fis. 1. Wn Torcw @Ano Pevear Horm In Fie.2 UNSOLDER THE CoRE® From UPPER Tank ® AT Seam ® Ano Lower Tank@ Ar Seam ®. Metr Ano Sceare Away Oup SoupeR. Sueraces Formins THE JOINTS SHOULD Be CLEANED AND TwneD Berore Ersawneeine THe New Care. RESOLDER THE SIDE MEMBERS BACK INTO Oeieina. Fosmon. 8 AFTER AU. SOLDERING IS DONE, WASH Our Eapiaror In CLEAN WATER. IMMERSE EapiaTor In TesTinG Tan For Fina. CHECK Foe Leaks If RaciaToR Cap Is Fautry OR Worn BEYOND Repair REPLACE WITH A NEW CAP. TOOLS REQURED ea ue Ho. [SHEFT | OPER DET. eet tee SC BAA BleBASE SHOP DATA-Issuz Of E>s-47b TEE or Se AsSamaLy BOX, RADIO 4 MISA! | Fascia | PENA? F Remove Cover @ By REMOVING SIX SCREWS ©. Discowecr The Tree Wires Feow Tene TeRMmNALs Insi0E Box. Loosen Thee Screus © Avo Remove Cover SHEET Our OF Box. Sune FLEXIBLE @our® Aw Loom © Orr Wee Clea A Pant Box © Avo Coee @. Claw Flenete Comuir ©. Discaro Conour iF ir is Brory Daasép. Inseecr Wires Fae BeoKen Qe Woew WnsuLaTiOn. INSPECT A Geay TeRMaL Pe QD. EST Wies ‘For Continuity Wire Test List. Wives Aee In Goo Conarrion They May BE USED AGAIN. REPLACE Any DEFECTIVE WES Witt NEW. AssemeLe TEruinat Fave. QD In Box. Fasten Cowecroe®) Ov Box, Sune Wires Treouse Loom ©) Av FlemeLe Conor ©) Inscer Wires THroucn Convector ©), Ano FASTEN Wiees To Teemnars On - parole Pu, Reace Cover On Connector. SLIDE CONDUIT INTO Cowmecroe®, TicHTen Tiree Sceews ©. Tre Loom To Gnourr AT @ Aw Tre Loon B Wiees Ar @. Fasten Cover @ ON Box wiry Six Sceens ®. ABCBEFEG 18 Radio Terminal Box... 5]. 3BIZBASE SHOP DATA -/ssue OF /0.26- #4 VEMKLE UNIT OVERHA ‘SuB-ASSENELY SHEET Pe Fi4 | / (AL Zcecrarcan | “pgltaTaes ACCESSORIES. y oF B NoTE: NUMBERS IN CRUES DENOTE OPERATIONS. FOLLOW iv ORDER. USE Onty New GASKETS, Cor7ER Pins, Savery Wiees, ETC. WHEN ASSEMBLING. DIS/TANTLING @O Renove Coneg@ By Removine Two Nurs @awo lock wasners@®. Serarare THe Juncrion Bor © Feora THe Vorrace Pe Guiator Screws Anoloce Wasners®. Rertove THE Cork GasKeT © Fron THe RecuiaTor Base®. @ Remove Tie Mounrins Panet Wan Tae Taree Lor Arracnen Br Taxing Our THe Six Sceews, WasHers Aub Lock WasHees @ ~- SEE Fig.2. Wwase Base ©, Cover ®, Ano dincrion Box ©in CazBon TereacHoewe. FAG. Revove Resistor ©-~ See Fig.3. DISCONNECT REMAINING WIRES Br REDOVING THREE SCREWS, WASHERS, Anb Lock Wasnees®. Remove Nur, Washer, Avo Camp ©. Unscarée Wie dT @. W3ASCBH-FI4-' (8) BSD. Me, Regulator, Voltage... 52. 318BASE SHOP DATA -Issue OF 0-26-25 Sua ABBE mieLy SHEET. weweie cal /ERHAUL) ‘eevsaroe eee ee ACCESSOR/ES irene TRHUOZA RESISTORS. \nveer Pane Avd Remove Te Nuts Anb Lock WasHers@. ALC THREE UNITS ON REVERSE SIDE Wit Now Be Feee From PANEL, Remove THe Tneee Resisvors ©. Lscaurcra. CHECK THE RESISTANCE OF THE FouR CARBON Resisroes Wiry A HIGH QuauTy Owmeree. The Onmerer Reapive SHoutD Nor Dirrer More Than 10% From Tie Coreecr vae. Mere OvEacn Resisror. IF THE Onmeree Reapine Is Low The RESISTANCE MAY BE INCREASED By Fine OFFA SMALL AMOUNT OF CARBON SEE FiG.2. CHECK THE RESISTANCE REPEATEDLY WHUE. Aine Unric RESISTOR REACHES ITS RATED Value. IF OHPETER READING ts Hic, Discaen RESISTOR. [MBAISC: BH- F/4-2 (8) 34{Base SHOP DATA bsve OF 10-1424 Fae ees er cae Wel Fee ire FA) REVERSE CURRENT CUTOUT © USING AN AGCURATE OHVETER Cnttk THE RESISTANCE OF THE Voltas: WINCING ON THE RevERSE CURRENT CuTour. Connect Onwerer AT @ Aw ®. IF The OWvETER READING DitréRs Wore THan 10% Freom THE RATED RESISTANCE OF 407 OM, Dscaro Uni CHeck foe CONTINUITY OF Heavy Co By Lewins léAD OF QueTeR ConnecTeD AT QA Cowect OrHeR Les Ar ©. RESSTANCE OF Hear Got Nes isiBLe: CHEK Cows foe Suorts TG FrAwe By Co earne FIG.1 OwWEIER AT @ Ato ®. THERE Shoup BE No CircuT BETWEEN THESE FONTS. F QwETER INDICATES A CiRCUT, CHECK NSULATOR ©. /F Gaus Ae GrounoeD Intepnay Oe ARE OPEN, DISCARD Curour. @ CLEAN GoNtacT Powis By Fins Warn A Very Fine Fie. ‘Fle WiTH He LeneTH OF The ApmaTure. WIPE ConDACTS WH Clea Ras DipED IN CaRBON TETRACHLORIDE. © ©: SET ARMATURE Core Gap To @® 060% WiTH CoNTACT OPEN, sine Far Gases ©)AND ©). INSERT GAGE On Contacr Sioe OF Brass PIN In THE Care. Gie May Be ApiusTeD By Benois ARMATURE Set Contact Gap.as.' Use Gast Q. AnsusT Gp By Benowne Surrorr Aus @) OF STATIONARY FIG. CONTACTS. MaKe Sure Bot SETS ARE In PepecT AuswwenT AND THAT CONTACTS Bear ON 90% OF Theme SurrAce. © Bor Sens OF Contac Mur Mane Contact AP The Same Tie: ——— 7 16.3 WAS BY- FAS 3I5Basé SHop DATA: Issue Or (a 44-4 VEHICLE cana OVEPHAUL Sue-Assenacr SHEET MBA |F ~aacrercn |e F /4 [Scour Cag ACCESSORIES __\Aurotsre WRH-0RA ora VOLTAGE REGULATOR UNIT 07 @ © © Greck THe RESISTANCE OF THE Con. MwoNG By CONNECTING OHMETER To Cou Teaps @ And ®. Con Shoup Have A RESISTANCE OF /5.7 1/73 OHr7S. DISCARD UNT IF RESISTANCE IS NOTsITHIN STATED TOLERANCE. Cutan Covract Powrs By Fine Wn Avery Fine Fire. Wee. Conmacrs Witn A CLEAN RAG DiPPeD in Caron TETRACHLORIDE. SET AemaTure Cove. GaP Wn Rows Just BREAKING. INSERT Pry GAGE © ON THE CawracT Sioe NeyT To Te. Beass Aemamuee Stop Pry And Coynect A 3CP Test Light Across@ Avo ©. Mare Supe Fiper Bumper Brock © 13 W Pace Berore AD: YUSTING CONTACTS. WITH THe. .040" Pav GAGE in PLACE, DepRESS THE ARMATURE ANDTHE LcHT Srout Go OUT. Wi THE.O8R"PIN GAGE INPLACE , DEPRESS THE. ARMATURE; The LiguT Spout Star lir. Use Two Fingers In DEPRESSING THE ARMATURE , One On EitHeR Sive OF THe Conracr Speme So Thar Tie Conract Spee 15 Nor Toucen. To Abuusr Tie Pownr Ar Whice Te COnAcTs OPEN, Loosen THe Sceews © Ano RAISE Oe Lower THE AgmaruReE Srop @. Gueck THe CONTACT GAP With THE ARMATURE Fully DEPRESSED AGAINST The Stop Pav In The Cope. THE Mavens Conract GAP PERMISSIBLE IS .10% THe Cowracts /usr Bear On 90% OF Their Woenine SurFACE. BeBASE SHOP DATA: Issu Or /0-2b-4.5 ERLE aire Samael sae MaAl \F CER Ab eeoiroe, Flas ZLECIECAL Sarae accessoves | WOT AP yaa ore. CURRENT LIMITATOR Quen Cou for Covtinurry. Test To Mare Suee Cou Is Nor Suoerep To Feawe OF Unt. CLean Contact Poinrs Wav A VeerFine Fie. wipe Conracts Wirt A GLEAN Rec. DIPPED In CAREON TETRACHLORIDE. SET ARMATURE CORE GAP WITH PolTS Just BREAKING. IWseer Pi Gace @ On Cavracr Sine Ano Next To The Beass Aematuee Svop Pays AnD Conmecr A 3CP Test Ligut Across Te Conracts AS SHOWN. Vhne Suet FiBeR Bunce Buock® [5 in Peace BEFORE ADuusting CONTACTS. © Wire THe O87 Pi Gast In Peace, DEPRESS THE ARMATUREAND THe LIGHT SHOULD GOOUT With THE .049° Pin GAGE IN PLACE, PRESS IH ARMATURE AND Whe Ligut Stomp Stay Lit. Use Two nGeeS iW DEPRESSING THE ARMATURE, QNE Ov ETHER Side OF Te Comracr Speing So Tat The CONTACT SPaing IS Nor TOUCHED. Tb Abwust The Powr Ar Waicn Tue Conmacrs Oren, Loosen THE Scezws © ‘AnD RAISE Ok Lower Tne AerwTuke SToP®). CHeck THE CONTACT GAP WITH Tie ARMATURE FULLY DEPRESSED AGAINST Tar SroP Pin IN Coke. THe Minute Conract Gap Peernss/ace (5.010. THe Con- nTs (ust Bear Ov 90% OF Thee Woexine SURFACE. 37BASE SHOP DATA-Issue Of 10-76-42 5 VEHICLE UNIT OVE FHA | (DUB ASSEMBLY SHEET MBAL |F aeracne VERE. FIA | 6 [Scar Ge 7 FRCESSORIES _|pysrousire Wann ore O ©) (0) eS O} (6) 5 t ASSEMBLE THE THREE UNITS; ‘ °| Reverse Cuerenr Corour @, Vaurace © O ResucaTor ©), AND Cukeent LiniTaToR ©) - Ow Te Mounting Panet. Connect AL O wees As SHown In Fig.l. DO WY oY YO S 6) Fig. / dvsTale THe One Que Cagson Resistor © | BYU Between The Reverse. Cueeent Grour © Ano ine. CuerENT LinTaTor © — SEE FIG.2. dowerT THe PANEL Ano INSTALL The Tree. CARBON RESISTORS AS SHomv Ww fig.3. Mount Pane OwBAse Ano Se CORE Wir Six Screws © — See LiG!. stat. CoRK GASKET QV BASE. SET JHE Cover On THe Unit. Do Nor Fasrew Cover Or Assempre Juncrion Box Unri. ReGuiaror HAs Been TESTED. FIG - ISCBH-F/4-6 (8) 318BASE SHOP DATA ~/ssue OF /0-26-42$ VEWICLE UNIT OVE ‘RHA UL “SuB-ASSEMBLY (SHEET WAL | Frere | tae” Fig [7 Scare Acc ssons WRTACE won oe (O)eomecr THE VOLTAGE RecunaTor To ANY Conmecat Generator Test BeNcH, Mount Ale Votr GENERATOR ON THE tes7 Bencn (The GENERATOR SHOULD Be Tit Same TrPE AS UsED ON THE N3AI ScouT Can) OperATE The Tester /5 MINUTES Wit The GENERATOR CHARGING 10 AMPERES To HEAT The Recut ator. Cover Must Be On The REGULATOR WHEN Unir Is Being HeaTeD Ano Yay When Reapines ARE BEING P® innen. Ose THe REVERSE CuRRENT Cutout To Cuose Te ConTACTS AT (3 To 125 Vours. Vary ae Cosine VouTaGe, AowusT The ARMATURE SPrins Tewsiow By ADJUSTING THE Ni ‘Se7 Tie Tester To Operate Ow OPEN CiRcurr. SET THE VOLTAGE REGULATOR To MAIN TAIN THE GENERATOR VOLTAGE AT 14.5 VoLTS, To ADWST [tS OPERATION, INCREASE OR DECREASE THE ARMATURE Spec Tension INCREASING THE SPRING TENSION CREASES THE Vactace At Whicn The Unit Wut Onerare, Wane DECREASING THE Tension Decreases IPS OrenaTING VotTase. Thus 15 Done Br AnsuStinG Nur@) Wiicn Hows Te Lower Exp OF THe ARMATURE TENSION SpRINGO. MAKE THe NECESSARY ADJUSTMENTS Ov THE TESTER (SEE THE MANUPACTORER'S INSTRUCTIONS To lest Te Current LimiTator For Maxiura CURRENT. SET THE CURRENT LIMITATOR to Pass 55 Ampents. THE GENERATOR OUTPUT May BE Yarieo By CHanGine THe ARMATURE Serine Tension. Tus /s Done By Turwins Nur ®) REPEAT Alt ADJUSTMENTS DESCRIBED I OreraTions@Ano@DANO@. REMOVE From Test BENCH. (43aSCBH FET (8D) 319BASE SHOP DAIA- lszur Ge /b-2-42 $ VEHICLE UNIT ee SHEET = ey aes ee @) Fasten THe Cover@)On THe RecusaTor Wity Tours, Ano Lock WasHERs@). Arracn Tue JuncTion Bax © To Tie Recuraror By PLacine THE JuncTion Bor Over THe TeRMina FINGER ©)AND REPLACING THREE SCREWS, WaSHERS, AND Lock Wasners(E) In The THRs Fincers©). Fasren Tue Cover®) Ov Juncrion Box Wire Two SCREWS AND LOCK WASHERS ©. TOOLS REQUIRED over. | Or 7 TO1 320 (MBA SC-BH-Fid- 8)__BASE SHOP DATA-Issue OF sefrfyr © VEHICLE UN al HAL Sie Assemeny SHEET Wea |C FRM aoe co ‘O TO DISMANTLE ROLLER, REMOVE No.8 -Taperen Pin AT ©. Axe © Is REmoveo By Tapeinc ONE END UNTIL. ROLLER Is FREE AND Tappin Trey Opposite S106 To FREE Power COMPLETELY. IF ROLLER FRAME \ /s Bent, Remove COMPLETE UNIT AT Ravers AS ©. DISMANTLE ENTIRE = ASSEMBLY. STRAIGHTEN OR REPLACE > SeraraTety Any BenT Op BroKen Parts. ® TO STRAIGHTEN DENTS IN ROLLER: — Wetb Ee Hoox @ Direcriy Over DENTED SURFACE. Hook AN OVERHEAD CRANE @ INTO Eve HOOK. HEAT THe DENT WiTH A Torc Unrit-ReD Hor. LIFT WITH CRANE UNTIL ROLLER TAKES ITS ORIGINAL SHAPE. Remove EE HOOK, AND SAND Avy ROUGHNESS REMAINING. To STRAIGHTEN ROLLER AxLE ©. Set Up SupporT BEAM @. PLACE AXLE IN “V" Blocks AS @ AND Appty PRESSURE WITH vack @ AT Pots THAT NeED STRAIGHTENING. TOOLS REQUIRED ase Po to ye 062. (A1B47 SCBH-C2- 107) a Roller... 55 321322BASE SHOP DATA-Issue Or {9-23-42 4 VEWlccE | ASStwayr SHEET M34) ee ASSEMBLY I M3Al SCOUT CAR / OUT CAR WITH HERCULES ENGINE ARrove. XD) OF 35" UNIT OF OPERATION ING: INSTAL TIAL A. ai Al DIFFERENT) EL ATTACH SHOE Ri ATA PIN: D SK Fiz WSBT TANGER Case an PROPELLER SHAFTS ATTACH EXHAUST PIPE UNIT A ¢AKE DRUM SHOE ASSEMBLY 7 ia L (SEM (STALL STEERING GEAR ASSEMBLY WITH DRAG LINK. ;SEMBLE CRAMECASE PROTEC: [ATTACH RADIATOR ARMOR PLATE AND SHUTTER ATTACH RADIATOR. ILE ENGI HASSE INE UB BILOT BEARING, TBs ‘SION NSE! ATTACH TRANSMISSION ASSEMBLE SEMBLE FAN, TANI iT TACH COWL “AND GAS TANK LINES ATTA 'TOR_ SHUTTER CONTROL ASSEN INSTALL INSTI (NEL /L._ AND. SEGRE GATE Wish WIRES i SCOUT CAR FRAME INSTALL ALL COWL UNITS (CHECK SHEET NO. 17 FOR INSTALLATION OF ALL UNITS ONC INSTALL ALL CONNECTIOWS ON RIGHT SIDE OF WO} INSTALL A CT IN ITTACH BATTERY AND ALL CONNECTIONS. VL i: TACH ACH TAC IAT TERY BOX PLATES STALL TALL DUC HEC zi Ht ier. [3AISC-ASSEMBLING-1 (355) Scout Car, Assembly. 323 esa me324BASE SOD DATA~Issuc_Or 10-23-4x4 Hoa) Pa) ASSEMBLING M3Al SCOUT CAR Scour Ge WITH HERCULES ENGINE (MODEL Jx0) ©. HancERS©@Are Bored To THe FRAME WiTH Nurs AS®@. © SPRINGS Age Then Arraciéd To SHACKLES @)AND HanGee © WITH SHACKLE BoiTs@. NOTE: Be Suee Tat THE DISTANCE Flom NuT To BACK OF SPRING (s Geearee Than The Distance Feom Nur To Feonr As SHOWN Iv LLUSTEATION. Gye ZERK FITTINGS © AND IF DamMaGeD REPLACE WiTH NEw ONES. ® © Nore: IN Driving Suackie Bouts @/INTO SPRING SHACKLES USEA qt Swoer PIECE OF PIPE® THAT WiLL. Fir Over Zéex FITTING AS SHOWN IN JLLUSTEATION. THIS AVOIDS UNNECESSARY DAMAGE To FiTTINGS. (4 [BBABC-Assemacine 3 (361) 325BASE SHOP DATA Issue OF i#-23-ar4 Mog F821 ASSEMBLING we 2 M3Al SCOUT CAR Scour Car WiTH HERCULES ENGINE (MODEL JXD) OF 35 @ To Artacn Front AXLE To CHassis: Loop Suins@ Into PosITION AS SHOWN, AND LIFT AXLE INTO PLAGE, SPRINGS ARE ATTACHED TO AXLES WITH “U* BoTs@OvER SPRING BUMPERS ©PASTEN WITH NUT AND Lock WASHERS©). [VBAISC ASSEMBLING-4 659BASE SHOP DATA-Issue Or 10-23-42. 4 a4 Seuene ASSEMBLING toe M3Al 3 MSN SCOUT CAR 5S Scour cae WITH HERCULES MOTOR (MODEL JXD) or 36 © To ATTacH REAR AXxteé To FRAME. INSERT Biock Ano Tacnte Hoox @ INTO ,7081TION SHOWN AND LIFT UNTIL REAR AXLE CAN BE ROLLED BENEATH FRAME. ATTACH REAR SHACKLES AT@) WiTH NUTS AND Lock WasHers ©. ATTACH SpRinNG ©) To’ Fixeo HANGER ©) Witn NuTAND Lace WasHEns ©. Artacn WHeeLs To REAR AxLeé ANO Rot. Unber Frame ¢ OVER EAR OF SPRING. Wine THE UNiVERSAL JOINT CONNECTION To CENTER Og Frame AT ©. Tuts Hotos Axe Iw Posirion Wuité CONNECTING. (©) Artace REAR OF Spring Ta SHacne @) With Pin @)AND TisHTEN Loc Be: @Artacu Spring To Axe WH U” Bours ‘p SPRING SUPPORT Ano SECURE WiTH Lock WASHERS AND NuT @. 327BASE SHOP DATA~Issve_Or /623-424 Venice PSS ASSEM gd MBAl 45 M3Al EMBL ING Scour Ge WITH HERCULES ENGINE (MODEL JxO) OF 2S Fig.t © Note: Be Supe THAT THE SHOCK ABSORBERS Wir The SHoeTeR AemMs@)GOES To THE PEAB OF Flame Ano Tht LONGER AemS Towaeo Thé Font, IF THe UNiT> Have Nor ALREADY BEEN MARKED LF, RF, LP, AND BB In DISMANTLING. © To Arracht HE SHOCK ABSORBERS To The Frame, INSERT BotTs(@)THEOUGH PLATEQ@ ON THEOUTSIDE OF FRAME. PLACE SHOCK ABSORBERSIN POSITION: AS SHOWNAND SECURE WITH NuT AND lock WASHERS AS©, INSEETAEM@ TaeouGH Hote AT© Ano Secues Wit CasTELLATED NuT ANo Ftar WwasHEe®). @ To Insrate PINTLE Hoor To FRAME, ATTACH Ceoss-MemBEe @ WiTH Fave Bars, Lock WASHERSAND NUTS AT @,AT THE SAME TIME INSERTING SPRING @)AND FLANGE® AS INDICATED By THe DOTTED LINE. PLACE PINTLE SHAFT THROUGH FLANGES AND ASSEMBLE Wit CASTELLATED Nur AND WasHER ©. j 328BASE Shop DATA~/ssue Or /o-23-42 6 VEnIcLE —~Tasseneiy ASSEMBLING M3Al SCOUT CAR 7 WITH HERCULES ENGINE (soDEL uxD) Oras Sequence CAUTION: Take CARE IN TIGHTENING NUTS ON COPPER TUBING AS THREADS Can BE VERY EASILY CROSSED Scour Ge 7o ATTACH HroRAULIC BRAKE SYSTEM To FRAME @ ATTACH MasTER CrLINDER@ WITH THREE NuTS AND Lock Wasuers AT @). @® Connect Copper Tusie To MASTER CYLINDER AT©AND©. Tusins CONNECTED AT@)/s RUN ALONG INSIDE OF FRAME AS SHowN To Junctioy©) AnD CONNECTED. TuBING CONNECTED TO ©ls Run To FRONT OF FRAME AND CONNECTED To JuncTion©. PLACE RUBBER GROMMETS IN PosiTION AT@). @® ree fs Cuppen To Frame ATG) AND CONNECTED AT JUNCTION. Toss @ Ano© ARE ConnecTeD To Uuncriov@). RuBBER Tusine @) ATTACHED To WHEEL /s CONNECTED To CopPER TuBinss@AND@AT®. © Front weet Connections® ARE ATTACHED To COPPER Tusins @ Ano ®). 324BASE Shop DATA-/ssue_Or 19-23-40 4 a ASSEMBLING SHEEF a VEnicle M3Al SCOUT CAR WITH HERCULES ENGINE (MODEL JxO) [Scour Cue NOTE: INSPECT HOLES AT @Aw CHECK RUBBER BUSHINGS. IF WORN, REPLACE. CE ATTACH TRANSFER CASE AND PROPELLER SHAFTS. QDhace One Reeser (ou7ne InswaTaR® Ov Lacy OF Four Sruns Ar @ BErORE HOSTING Trawcrer Case iro Pas/Tion AS Show WiTH Sunc OQ Qunseer Avornee InsuiaTor® Over Exc Sruo AT © AFTER TRANSFER CASE HAS BEEN PLACED In PasiTION. PLACE FLAT WASHERS CASTELLATED NUTS An COTTER PINS ®© Ano Ticurew So Thar THE INSULATORS ARE COMPRESSED SLGHTLIC @Arracy Teansree Case Provector Puate® wit Faur BOLTS, Lock WASHERS Ano Nurs AT@. @w Arracume Rear Proveiuee Shar? @), ConnecT 70 Rear Axe fess ATO. THEN JACK Up REAR WHEEL AND Line Up Suarr So Thar I7 Comciass Witt TRANSFER Case 27 @. D0 Nor TouTen Nurs, UT. AL ExcHir ARE In Posirion. @Connecr Fronr Proveieer Suarr DO Frovr DeeeeenTian AT @. Line Ue Swarr Wity Teansrer Cast ATR) AnD COWNECT (M3AISC-Assemaciwe- 8 (351) 330BASE SHOP DATA-Issue OF 4-23-41.5 Moa) S| ASSEMBLING “o 6.9 M3Al SCOUT CAR i, Scour Ge | V2 Wir HERCULES ENGINE (MODEL Jx0) or 36 Taut Pree @ Ano Murriee B Suoutn Be ATTACHED ToseTHeR. BEFORE FASTENING TO Tie FRAME AT BRACKETS{©) AND FASTEN Pipe © To MUFFLER @)AND ATTACH AT BRacKeT ©) @D To Artace Hano Beas DRUM SHOE Assématy To TRANSFER CASE, INSERT CAP SCREWS AND Lock WASHERS @ Ano TigH7EN. Han Beake Roo @), 5 ATTACHED To Braxe Way CLEVIS Pin AN COTTER PN@ATO. IZAISC-Assemaring-9 3B3lBASE Stop DATA- Issue ‘Or 10-23-42-4 Tyan) [eae ASSEMBLING 10 10 I M3Al SCOUT CAR [Scour Ce 2 With HERCULES ENGINE (MODEL JxD) OF 326 TO ATTACH BOOSTER BRAKE To THE PeDAL ASSEMBLY, seer INTO PostTiON AS SHown. WooneuF Ker@Is INSERTED IN SHAFT(G), INSTALL Beare AnoCiutcn Pe pat Io SHAFT ®)AND ATTACH WiTH AAT WASHER, CASTELLATED NUTAND Corer KEY ©). Connect Boo MASTER Cyunoer AT Posmion © WITH PINAND COTTER KEY. TIGHTEN Lock ken Pepals TO SHAFT ®. © TO ATTACH STEERING GEAR ASSEMBLY IXCHASSIS, CONNECT. Two BotTs AT FOSITIONG). ALSO Two Nurs AT PosmON@.ATTACH ARM@ TO HANGER AS SHOWN, WiTH PNAND: Corree PIN @).STEERING DEX Ln ®) - IS Figs ATTACHED To WHEEL ATO) Arter Te Prorective Boor Has BEEN REMOVED, INSERT BaLJonT OF ARM @) INTO OPENING ON ENDOF Dea UNK ©, AND Sceew CaP @QInTO PLACE, INSEETING COTTER PIN. Place LeaTererTe Boor ®) med Over Each END OF Deac Link SPRING@© /S THENATTAGHED To looP@. [GABE Assemarne-0725) 332BASE SHOP DaTA~ Issue Or 10-L3-404 Ty FE sseneLe [ar ScourGe | "214! win Mencuies Crowe mover x0) oF 35 @ To ASSEMBLE CRANKCASE PRoTecTaR PLATE: ATTACH ARMOR PLATE @ Ar Posrrion(®). CONNECT CRANKCASE ARMoR PLATE ©wm Foug BaTsO. B ASSEMBLE RADIATOR ARMOR PLATE ‘Ano SHUTTERS: INSERT BoLTs AT Posirion@) Ano TiéHTew. In ATTACHING ARNOR: Prate Use Ovat Heaven Borrs@Wrn* \ SAFETY Nurs AND FLAT WASHERS. THe FLAT WasHers ARE PLAceD BETWEEN THE PLATE AND CHASSIS. ©» Assemace Rapiaror: Place Raptor In ‘PosiTion So Tie Two Borray Sruos@ FALL Into PosiTi0n ON CROSS- MEMBER. PLACE Raoiaror Suocn SprincsQ)OvER Stubs. AND Screw With CASTELLATED Nut. ATTACH FaoiaTor Support AS®). (SAISC Assemax wet 35) 333BASE SHop DATA- Issue Or /0-23-84 VEMIGLE —[pasenaiy a M3A/ ae ASSEMBLING i M3Al SCOUT CAR WITH HERCULES ENGINE (MODEL Jx0) [Scour Cue (Dessert oss S- Dose Sume®, warce 5 Cowvecteo To Moror Buock AT Fourtn Hean Bo. Ov Rica Front Ar (@) AnD Sécono Heao Bact Ow LeFT Rear Ar (C). @ Swine Engine Inro Position AS SHown So Thar Ir Rests On Havser (D) Ano ©). @Enaine Surrorr® is ArTaceD To Frat Haneers wird Ba7s©@. @Rieur Rear OF Eneive Is Arracen To Rear Haneer ©) With Botr, Flat WASHERS, ONE SHOCK SPRING GP) ON Tor OF Hancer AS SHOWN. Lert Rear OF Enaine:s Artactien To Rear Hancer@) WITH Bocr, FLAT WASHERS ‘Ano Suock Series Ow Tor Avo Gorton OF HANGER. USE CasTentaTED Nurs ANO Correr PINs. (ZAISC-As seme in6-/2 (36) 334BASE SHOP DATA- Issue OF /0-23-428 ERE er MGA Tigti| pare EGING /3 [Scour Cae WiTH HERCULES ENGINE (MODEL JxD) OF 36 Oe Osriu Too @) /s INSERTED INTO SPLINED Hue O Cusrc Ano Tuenen So Tat Furwnee. a Pu.or BEARING @IS AT PosiTION As SHOWN. Tats OPERATION WILL LINE UP TRANSMISSION SPLINE WITH SPLINED Hus Iw Cuvee, As inoicaréD By Dorren LINE. NOTE: BEFORE LIFTING TRANSMISSION INTO POSITION, Ghee Oh. Line ©, MAKING Sure Tuar Ir Lines WoTn Out Cur Ov Insibe, As InpicareD By DorreD LINE. Qrse TRANSMISSION SPLINE INTO SPuinen the OF Clurce Ano Artacn a Screws AsO) Dawe SHAFT IS THem AT- TACHED ToTRANSFER CASE AND Teaws — mission Wits Lock WasHERS AND NUTS: Transmission Ar @ Ano o Teansrer, Ose At @. BRAKE Lever(Ds ATTAGED With CaP ScREWS AT®. Cuutcw Conrrot Roo /s ATTACHED To ENGINE ATO. Cowneécr Cure Peoat Suart ® To Aru ® Hite Clews PinAr ©. ATTACH ner @ To Line ©. (WABC Aesema wea Gs) 335BASE_SHOP DATA Issue Of 1023-914 war _ MA \ibia| on, Beane 4 [Scour Cae > WITH HERCULES ENGINE (MODEL JxO) OF 36° NOTE: BEForE SETTING 6s TANKS INTO POSITION AS SHOWN, INSERT THREE CANVAS PADS @)AS INDICATED By Tue Dotreo LINES. @ In ASSEMBLING RIGHT AND LEFT GAS TANK, Attach AT @). CHECK ALL Screws Ar© To MAKE CERTAIN THEy ARE TIGHT. Fig. 1 @ To ASSEMBLE FAN AND Putte, ATTACH BrackeT (D) To Boss ON FRowr OF ENeine AT ©. Two Fan Bects © ARE PLacéo OVER FAN PULLEYS. Hue SpinoLE © Is THEN INSERTED IN BrackET QD AND Arracuen WiTH NuT AND WASHERS @). Use AnuusTiNe Screw @) To Ger A PROPER SET FOR THE FAN BLADES IN RADIATOR SHROUD. LOCK NuT &) US TIGHTENED 70 SECURE ADJUSTING SCREW. [BAST-Assemonne-14.235) 3BASE Shop DATA - Issue OF 1-23-4045 347 Peel ASSEMBLING ace ON OI BREE om | Se @ To ATTACH Cowt To CHASSIS: CONNECT AT @; @Ano© Wit NUTS AND LOCK WASHERS. Connect Feoor Prate©) To Cowt Witt CAP Screws. ATTACH Cuamps(€)AROUND PEDALS AS INDICATED BY THe DoTTEDLINES. ATTACH LEFT Ano RIGHT GAs TANK Lines AT ®. Aso CuiP To FRAME AS SHOWN. To ASSEMBLE RADIATOR SHUTTER CONTROL! Artacn Lever @ AT@ WITH LocaWasHer ANDNut INSERT ConTRoL Ron) THRousH HOLE AT BASE OF Com. AND Connect To Lever © Wit PIN ANO COTTER Pin AT ®. INSERT CONTROL Ro In Hore © AT BASE OF RADIATOR SHUTTER. TEST OPERATION BEFORE PROCEEDING FURTHER. 337BASE SHOP DATA~Issue_OF 10-23-44 VEnIcLE [essa ASSEMBLING EFF MIA/ MAI SCOUT CAR 16 Scour Cae, With HeRcuLes EneiNe (MODEL 1x0) Or 36° OX & O xR o— O—, ao A e—H re ars Beret Arracane Pane @ To Srezene Covurw Win V BoxsB) Sree ALL wares Troucr Hae OQ. Wikes ARE STRETCHED QUT AND SEGREGATED InTo FasiTIaNs SHomn. Groups) Ano Are Curren 1b Te Cowl, NAKING DURE WIRES ARE WELL. InsyaTeD AT Att Fowrs OF Caviacr With Neva. SWELD Wikes WHEREVER NEcESSARE. iE FoLiowinc ARE TREN IseRTED ToroucH THe Cow: Steeooreer Cue ©) Foor. Conzen.©, Chore Conrrar@) Winosueto Wiper Vacunn Line Q) Oe Presume Line ®. ‘Russe Grorners Must BE PLACED AT Aut-Pawrs OF Enrer Fran Pane. Tieace Cove. Nore: REFER To Ker SueeT 17 For Sunnary OF Cowl ASSENBLK. 338BASE SHOP DATA- Issue Or | 1-23-41 4 3A) beeen ASSEMB oo ee MAl 33 M3Al SCOUT BLING 17 [Scour Cue WiTH HERCULES ENGINE (MoDEL Jx0) OF 36 Dsus tuusTeaTion Sows The RevaTive Posrrions OF THe WiRES Leanne TowaeD ROnT Ano Back OF Scour Car Fane. Heao LIGHT WIRES ARE CLAMPED To Fane Ar. @ Ano B). The Wres Leanwe TowARo The Stop Loar SwrTcw Aro Bue Licats Are-CLanweb ALONG THE INSIDE OF Fane AT Posmins ©, © Ano ©. InporTANT: BE Suee ADDTiONAL INSULATION 1S USED WHEREVER WES Cane In Can TACT WiTH Frane. TAPE Whees ToceTHER WHERE NECESSARY AND CoAT WT SHELLAC, 339BASE SHOP DATA-/ssue Or /$-23-424 VeRIeLE —Tassereuy| leeevene ASSEMBLIM MAL 24 3Al SCOUT on 7 18 Scour Cue wir HERCULES ENOINE (MODEL x0) or 36 NOTE: For A.Suner OF Unrs OH Te Cou, Rerer i Ker SHEET 12, @ ThE FowLowine UNITS ARE INSTALLED. @Hearee Hoses Are Comectta 10 QAP Cueaner Is Arracned Wirt Four Borrs Ar®. Heater AT. Que Duar Horns Are Cowecren 1 Cow. AT@. G@Ariacw Vewrwaror Pe Ar @ Qvacun Cueck vave is AracueD ATO. @Arrararer &s Cowecreo 1 Cows Wim Bours ATO. Qik Acceveraror Assensiy Is Arracnen To Cau. Ar ®ANO®. @B01TS © Ow HEATER ARE INSERTED TuROUGH COW. AND ATTACHED @oosrée Beane Ate Cucaner ks Artacuéo At @). Hose@) is Claneeo 1 BoasTer Beate. @rano furee Ov Orer Sine OF Cows Is Arracuen AT ®. Qvoctace ReanaTar©Is AriacueD AT Quins Sure Tar SworteR Bais Ake Usep In Feow- Ano Lovcer AT Tt Rear Q@sueiveo Kurion Pema @ss Comecreo Ar Posirioen QOsSwrrer Caste Ols Carved AT@: @asreevror Smex Covrran@ Hear iworcaTar Case D Ano Ro Firce wie Q ARE InseRTeD Trove Sane Hace In Cow. Wire DIS The ATiacHeD To Vowiase REGULATOR OAS SHOWN. uOBASE SHOP DATA~Issue Or /0-23-4.4 oad = Toa PEE! ASSEMBLING OEE 28 aay BEEOL ET on say |! DoseBASE SHOP DATA- Issue OF 10-23-24 ad) Fe| ASSEMBLING M3Al SCOUT CAR Saour Cae 26 Wit HERCULES ENGINE (moDEL JXD) OF 36. 29, i> ISAISC-Assematin 6-20(35)) 342BASE SHOP DATA-sssue Oe (0-23-4214 od) P| ASSEMBLING CC 20 | warn Meee oA woe, a) EET Zi 06 36 Scoor Cra. @® THE RIGHT SIDE Moror Conwecriows ARE Assemalep AS FOLLOWS: QAR Cueaner Hose Is CONNECTED To CarBureroR Ar®@Awo To AIR CLEANER ATO. @ Aan Chore Covreos Is ArracHeo To Cows Ar © Ano Were Inseereo i Hote Ar ®. Mano Tuporree ConTrot Caste Is Arracuen Jo Cow. Ar @ AnD CowwecreD To CakBuRETOR AT@). TicHTEN WiTH Screw On NuT@. ACCELERATOR ConTRoL AND SPRING ARE ATTACHED.TO CARBURETOR A TO. © Fuet Powe Line Is Arracuep To Fuee Tank Transrer Vawve AT @Ao Fuet Pump Ar ®. Hose © /s Connecren To Fuet Pump AT @ AND Intake Mawiro.o AT@. © fves Live® 15 Connecren To Fue Pump Ar@® Ano To Cargureror AT ©. Qu Live @ 's ConwecteD To Borrom OF PuroLaroR Ar@ ANE To Ceanncase ATD. Vacuum CHECK VALE Live @ Is ATTACHED To Vacuum CueeK Valve Ar @ Ano To In7ake Manuroto Ar ®. @barrerr CaBce Is ArracneD To Stagrer Ar @. @Lerr Gas Tank Line Ano Pict GAS Tank Live © ARE ATTACHED To Fuet TANK TRANSFER Valve As SHOWN. WinosHiELD Wiper Hose 1s ConnécreD To Fuet Pump Ar @. Conwecr Exwausr Pipe To Eneie ExwausT AT@. WMLORTANT: CHECK Att Moror Cownections, NUTS Awo BoLTS. MAKE SURE THEY ARE ALL SECURELY TIGHTENED BEFORE PROCEEDING FURTHER. Also spect ALL RUBBER HOSE Commecrions, IF DETERIORATED OR WORN, REPLACE. (A3AISC-Assemeiin6-2/G9) 343BASE SHOP DATA-1s8ué Or [0-23-42 5 Toa) | _ ASSEMBLING M3Al SCOUT CA Scour Gx wu HE Ee eS fave. x0) OF 35° MBAIS. — ASSEMBLY 22. (36) 344BASE SHOR _DATA- Issue OF /6-13-424 aa) eee ASSEMBLING Oe MAL 27 M3Al SCOUT CAR 23 Scour Ge | WiTH HERCULES ENGINE (MODEL JXD) OF 3 CD) Tie LEFT Sioe Moron Conwecrions ARE Assenareo As FaLLows: Qvbtarer Hose Connections Ane Arracuen AT @ AnD. Qvacuum Boosrer® 13 ArTacen To Eweine wrH Pin ATO. Hose © 5 Connected To THE BREATHER WiTH CLAMPS. Hose ®@Is ATTACHED. To@AT@ Ano To Vacuurs Cueck Vauve Ar ©. Compensaror Lever @ Js CownecreD To Vacuum BoosTer Wit Pin AND CorTerR Hey AT@. ATTACH SPRING®) AS SHOWN. @ower Raviaror Hose Waicw LEADS INTO WATER Pump /s CONNECTED AT @ WiTH Hose CLAMP As_SHowN. TOP RADIATOR Hose /s SUBSEQUENTLY ArracueD 7 Encine AT@. OpposiTE ENDS OF Hose ARE ATTACHED To RADIATOR WITH SIM/LAR HOSE CONNECTIONS. @\wines From Te Gevenaror TERMINAL ARE ATTACHED To VOLTAGE RE6- uaTor AT@AND@AS SHown. Ocenrer DISTRIBUTOR wire © AnD CONDENSER WiRE (©) ARE ATTACHED 7 IewTion Con®. Oi LINE FROM TOPCONNECTIONS ON Oil. FILTER (PUROLATOR) Is Connected To Encine Ar@. @ Ou Pressure GAUGE LINE Is ATTACHED To ENGINE ATO). @bdear Invicaror Lune Is ATTACHED To ENGINE HEAD AT@. @©Sparn ContRoL |S ConnecTED To DisTRIBUTOR AT @). IMPORTANT: Cuecr Aut MoTor CONNECTIONS ON THIS SIDE OF ENGINE MAKING SURE THEY ARE SECURELY TIGHTENED AND NO THREADS ARE STRIPPED. 345BASE SHOP DATA~ Issue OF /6-23- 424 Sa) ee] ASSEMBLING MOAT \2829) ny AMEE Rie wy | “bese Attach Battery To Boby ON RigHT HAND RUNNING BOARD WITH ‘Hook Batts AT @AND PLATE WITH Nur AT@).Aamor Aste QIS ATTACHED ON RUNNING BoaRD AT (© @. IMPORTANT: Mane A “THOROUGH INSPECTION OF ALL WIRING AND CONNECTIONS BEFORE CONNECTING POSITIVE CABLE To PosT(Q)ANb GROUND CABLE TO PosT@).CannecT RADIO CABLE () CONNECTIONS AT®).THE OTHER Two CONNECTIONS © SHOWN ON CABLE ARE TAPED WITH FRICTION TAPE, AND ARE NoT CONNECTED. UNLESS AN OLDER TYPE Rapio ISUSED IN THE CAR. IN BLEEDING THE HrDRAULIC BRAKES AT EACH OF THE FOURWHEEL CYLINDERS, FIL MASTER Cytiner TANK WITH LOCKHEEDNO. 21 BRAKE FLUIDOR Equat Ano Cap. UNSCREW PLUG) FROM THE BLEEDER Valve ®). INSERT THREADED END OF REGULAR BLEEDER HOSE INTO BLEEDER VALVE. PLACE FREE END OF TUBE INTO GLASS PITCHER@). OPENVALVER) AND DEPRESS BRAKE PEDAL. BE FORE RELEASING, Coose Valve®. REPEAT OPERATION UNTIL FLUID RUNNING INTO Tne PITCHER GS Vo1b OF BUBBLES ;THEY LINES ARE FREE FROMAIR, As EACHWHEEL CYLINDER |SBLED, THE BueeperVatve Is Shur OFFTicHTLy With WRENcH®) @®) ANb PLucQ)Is INSERTED. KEEP MASTERCYUNDER FitteDATALt TIMES. SHEBASE SHOP DATA-tssue OF / 0-23-4144 Maal PES) ASSEMBLING 30 M3Al SCOUT CAR With HERCULES ENGIME (moDEt Jxd) Seer on 3s [Scour Coa CAUTION: BEFORE STARTING ENGINE Ftc hur Gas, O1L, AND WATER AFTER Morr IS STARTED, CHECK On Pressure GauGe IMMEDIATELY AND IF THE Gauek Does Nor Risé Sreaoity To 30 Pouvos WITHIN A MiwuTe, Swur Ore THe Enaiwe Ano LOCATE Trovete.. ® NEON Timine LicHT @ 1s Useo For Final CxEew IN TWINGE: O Make A Mure CHALK MARK [olen Whoe On Tae Firwneee So As To Comcnwe Wary DC Tar Dean Center Mark ®. @ Remove (4a. From No.4 Spar Pie ANd Connect Neon Lisxr@ To PiuG © AWD Puve CaP@. @ Smer Eweiwe Awo Ler Ir RUN AT loLiNe SPEED, DRECTIVG The LIGHT FLASH Oy Tie Opewive IN Furwneel Housine @ 70 CHECK PosiTion OF Cuatk Line in RELATION To CENTER OF Hole, Waicn SHoutn Be Dreerir In Tue Center, See Evtarced View, /F Nor, LOOSEN ADVANCE Akm SCREW © OW DISTRIBUTOR AN ADVANCE Ok RETARD AS THE CASE MAY BE. Nove: WHEN LIGHT FLASHES APPEAR To STOP WriTEMBRK, TIMING 15 CORRECT. 347 (3AISC-Assemacin 62505)BASE SHOP DATA-ISSUEOF /0-13- 924 VEHICLE Bere ASSEMBLY SHEET MBAl 3 \ worm set or ar 26 | T CAR ITH HERCULES ENGINE (MODEL JO) OF 3S aia THE HAND BRAKE ASSEMBLY. © Auace The Hano Brake Lever @ Forwaro Iv THE Fuuty RELEASED POSITION 6 PRoviCe Maximum CLEARANCE BETWEEN ThE SHOES AND DISKS. @ Wsert Two 142" Sums ® BETWEEN THE FRONT SHOE LINING Aso Disk AS SHOWN AND ADJUST Put Roo Ar ©. @ Trorren Ansustine Not © So Thar Disk Firs Sway AGAINST Stim, ALSO TisHTEN AnsusTING Screws ©) So ThaT Disk is PARALLEL WITH LINING. @ Remove Suns ano Test Lever @. whew Brave Lever @ & Puuted Gack TB THE HALF Way MARK AND BRAKES ARE SUFFICIENTLY TiGHT, THEN ADJUSTING PROCESS Is ADEQUATE. 34s MIA ISCASSEMALY 26 teBASE SHOP DATA~ Issue Of /0-23- 424 Higa) 88) ASSEMBLING Ok 3233 MBAI SCOUT CAR Scour Oe Witt HERCULES ENGINE (woveL XD) one j \ @ ATTACH 80TH SIDE ENGINE aN Ptares Ta Coe AND y RaviaTor With Ovat_HEADED Dy Bours As@ Ano ®. Jy ATTACHING FENDER To Bor OF Scour Car, INCLUDE Fenver Piping ©. Tus Prine is WeoceD BETWEEN Fewer AnD Bopy Ar Poinr OF Coviact. FewoeR /S Arracueo To Boor Ar Hotes Atone ©. HEADLIGHT WIRES © Are Cuiped To FENDER SupporT Ar ©. BLACKOUT Ligut Wire © /s CipeeD AT ®. (WBAB5C-Assemacine: 27085) BNFBASE SHOP DATA - Issue Of /b-23-44 Mad) Fe@| ASSEMBLING “OE 34, MBAl SCOUT CAR Scour Cae Wir HERCULES ENGINE (ODEL XD) OF 3S To Conwecr Heaotisut @ B FenveR, Arrach AT®. BE SURE To INCLIDE Taperep Ano Lock WasHER Wir THE Nor As SHown, Bacxour Lint © Is Arracneb To HeapticuT Guaro AT ©. ThE PLATE ON Blackour LighT Firs UNDER The Guarb As SHOWN IN ILLUSTRATION. HEADLIGHT WIRES ARE CLIPPED To FenoeR SueporT AT© ANG INSERTED THROUGH FENDER. RUBBER GROMMET 1s Puaceo In Hore AT ©. Pte © Is ATTACHED To WiRES AND INSERTED IN HEADLIGHT. WiRE® 15 CLIPPED To FenpeR SupporT AT@) AND INSERTED THROUGH FENDER JUST BELOW Biackour LIGHT. OTE: Tape Heabucnr Wikes ToeETHER ANo APPLY SHELLAC, Hooo@/s ATTACHED To RaviaTor Ano Cowt Br LOWERING Hoop IN70 POSITION Win Two 2%4's AS SHOWN, Ano Screwed Down WITH Ovat Heaveb Botts AvD Sarerr Nurs As©. fig.2 (BAB ASSEMBLING: 2800) 350Gast SHop DATA-IssueOr 10-24-4145 VERILE Tass aur SHEET Sequence ASSEMBLIN Wl 3G HAL EMBL | G 29 Scour Can WITH HERCULES ENGINE (MODEL Jxo) OF 36 TO PLACE THE Boy OF THE ScouT CAR INTO PosiTION ON THE FRAME, ATTACH SPECIAL SLING ASSEMBLY AS SHown AT Powrs@), ©, Ano©®. Lower In7o PosiTion VeRY SLowLy As Cowe Ano InsTRUMENT PaNnet CaN Be Benr Very Easity IN THe OPERATION. (JATSC-ASSEMBLING-29035)] 351a SHOP _DATA~ tssue OF 10-1 ?-4u8 Mad (Sr ASSEMBLING M3Al SCOUT CAR Scour Con With Heecuces EnGive (mope xD). ‘SwEEr OEE @ To Arracn Boby: @® tseer Ovat Heaven Bowts Wire Sarery Nurs Atove Tae FRONT CowLine. T ® /wseer Two Botrs Aone UNvER- sive OF Car Direcrty BewinD Boru Gas TANKS. © Mnster Exeut Bois WiTk Lock 8 WASHERS ON REAR Floor As SHOWN, | % @OArracn Ravio MasT WiTH Lock WASHERS AND BoLTs, Nore: IF THe Booy Hotes Do Nor Line UP inserr A DRIFT PuwcH. Tuts Wie Teno To Live UP OTHER Booby Hotes. Do Nor TigHTEN Any Bairs UNTH ALL Have BEEN PLACED In PasiriOu, IBAISC-ASSEMBLING. 3) 382BASE SHOP DATA Issue QF /)->3-454 es eee 31, | [Scour Gua WITH HERCULES ENGINE (MODEL J) (42) Assemaly OF Toot Box, SEAT AND FLOOR PLATES: © Dawer’ Seat @An_Occuanrs Sear® Are ATTACHED To FLoor Prates AT©ANDO. Floor PraTes®© ANn®) Are AtTacned To Floor AT@. @Accessory Box@/s ATTACHED To FLooR WITH ScrEWS@.- @ lou Box@ls Arracnéo In Back OF Occupants SeaT As©. @fioor Prates@@ AND® ARE ATTACHED WITH METAL SCREWS. © Ace GASOLINE CaPS@) To Bor Tans UNDER PLaTes® Ano®. 353BASE Stop DATA- Issue OF 1e-¥¥-4y 5 VEHICLE | ASSEMBLY 7 ‘SHEET M3A| ees ASSEMBLY 2 39.40 M3Al SCOUT CAR Scour Cae a WITH HERCULES ENGINE (MODEL JX) To ASSEMBLE THE DOORS, ATTACH WITH Oval Kean Botrs Ano Sarerr Nurs AS @Ano®. Rovs@ Ano DAre User Onv WHEN Door CURTAIN 13 ATTACHED. CURTAIN Ro0O/s REMOVABLE. MOTE : Berore Arracnine Tau lien7s, BE SURE THe PiGHT REAR LisHT © ConsisTs OF Bacxour Tait ANO BtackouT Srop LicHT, The Lert Pear Lis © (8 THE BuacKour Sror Ano Service Tat Ligut, Ust Test Licur For Testing WIRES To. DETERMINE WHICH ARE BLACKOUT WIRES Ano Wuren Are Tait LignT WIRES, Arracn Tan LiuTs With Two Wors Ano lock WASHERS AS®,. THE wires Are Cue D To Baby BOLTS @ AND Taéw Passep Turouen Hote Ano RUBBER GROMMET @). WIRES ARE ATTACHED To Pive @As SHown, MAKING SuRE THE Sineté Ptues Are for le Biackour Lignrs Ano Lovele Pie FoR THE Service Tait LienTs,lvsERT Booy Botts AT Position ©. 354BASE SHOP DATA- Issue Of /0-23-43 4 Maa BE! ASSEMBLING "33 Scour | 8243] warn Meseuits Punt Crooet w10) eas G5) THE WINDSHIELD WIPER LINE ‘ENTERS Cowl Ar JuncTion@, WINDSHIELD WIPER ASSEMBLY @)IS inserTeD InTo©) AND ATTACHED witw Nur @.RuBBER WIPER BLADE AssemaLy ©)/3 CONNECTED TO FiG./ WIPER WITH Hook ®ywro HoLe®), AS SHOWN In ENLARGED VIEW. 46) ‘Rueser Hose @)!s ATTACHED To RIGHT WINDSHIELD WIPER As SHOWN, ‘RUBBER Hose Q)IS ATTACHED To LEFT WINDSHIELD WIPER. @Apen Sive OF Booy Is ArracHeD WITH OVAL ‘HEADED BOLTS AND SAFETY NUTS AT@ANO]. For FurTWER INFORMATION ON FASTENING THE BODY 70 THE CHASSIS REFER To PAGE 29. OPERATION Ai. @enreer Box Armor PLaTes@) AND@) ARE ‘ATTACHED AS SHOWN WITH CAP ScREWS Ano Lock Washers AT®. [PESAISC AsseveunG- 3305) 355BASE SHO DATA- Issue OF /0:23-4¥ £ vencie” TSSEuBRY ASSEMBLIN SHEET MAI 4445 M3Al SCOUT CAR c Oa Scour Can wir HERCULES ENGINE (MODEL. JxD) 35. Parts ASQAND hac ARE Con- NECTED. SLIDE SupporTs THROUGH SrRaps ARE Pace OVER SupPoRTS AS SHOWN, Bucne Down Securely To Strap Loops) AND®). Duce eis P.aceo Over Scour Can As SHoww Ano BucKLe DOWN SECURELY 7 Loops As@) Tare Ue As Mucu Stack In Oawvas As PossiBlé By TIGHTENING STRAPS. Swe Door CurTAN@)/s SiuIPPED Over Roo@As InorcareD By The DoTTED Une Ano CuppED To Door Ar ©. Removaste fap @Is CLIPPED To TARPAULIN Ar @. REPLACE ALL CANVAS CUSHIONS To SEATS AND AT THiS TIME REPLACE ALL. LOOSE ARTICLES TO THE ScouT CAR. 356BASE SHOP DATA-Issue OF 10-75-04 ASSENEIY SHEET bio | | Seauence ASSEMBLY 35 AL M3Al SCOUT Cap [Scour CAR. WITH HERCULES ENGINE (MODEL JXD) OF 35" Tool Dwe Ne 455070 WOTE? Speciae /mproviseD Too @ IS Useb For CHecKine ToE-N OF Two FRONT WHEELS, @& JacK-uP THe Two Frovr WHEELS Avo Caate The CenreR OF TiRE, ToE-N Toon Is PtacéD Ar Positiow® Awo® So Thar Powrs dee Diceny Ar Cewrer OF Tike AND TOUCHING, ROTATE EXCH Whee. So Tuar Line 13 Deawn Arouno CENTER OF Tire, aportanT: THE Jack Must Be RevovED Berore AavusTine Toe-In @ OF WHEELS ToE-IN Toot. @ 1/5 THEN PLACED AT Rear OF FRONT WHEELSAT ‘Posimow®, lk The Distance Fram Posirioy © 10 Dorren Line © 18 Ye" To 16" Te T0E-IN /s ADEQUATE. If Nor The TuREE Mors As @ Ake Removep From Srecewe Choss-TuBe ASSEMBLY. THe Cross-TvBeE Evo 13 Ti6HTENED For More ToE-IN AND UWSCREWED FoR LESS, AS THe CASE Mar Be. TOOLS REQUIRED Te baie] Sere DOF aosvaz [ig [7 Ta sos9s7 [13 [eA 433048 | 29 | «0 | D 433070 | a5 | si TA M3AI SC-ASSEMBLY— 35136) 357358BASE SHOP DATA~ Issue Or s9 fin wir Cees BAI |psatrse DISMAVTLING / SEQUENCE /I3Al SCOUT CAR Scouréar | cwaer | witm Hercuies ENGINE (maDeL JK) or 25 TE NECESSARY 70 DSPANTLE UT] UNIT. OR OPERATION ance Be aloe ore] T__ [REMOVE DEK TOP. ANYTIME ZIT Z| REMOVE- DUCK-TOR STRAPS f 242 S| REMOVE DUCK TOP SUPPORTS. z 4] REMOVE BATTERY. BYTE 34 Tal ‘ANYTIME ‘© | REMOVE ‘BOGY ANYTINE sé 7 | RERQVE FLOOR“PLATES SHOWN ‘ANYTIME 4217 | REMOVE a0Dy-Hox TS ANYTIME (REFER TO Oe) TS. ‘S| REMOVE DOQRS-AND SIDE CURTAINS. ANYTIME: S19 70. DY. 110.9 INCLUSIVE 7 TI} REMOVE” O00 ANYTIFE awn /E_FRONT PROTECTOR PLATE ANYTIME 712 REMOVE. "ANDO. LIGHTS | ANYTIRE a3 TP REMOVE FRONT FENDERS 1s Str y ENGINE SIDE PROTECTOR PLATES | 14 RADIATOR SHI ANYTIME oT (REMOVE CRANKCASE PROTECTOR PLATES | ANYTIME 1 SOUINE TANKS. £ y 170. rE CONNECTIONS: ‘ANYTIME [-72)8-20 MOVE i= 18 =30 i REMOVE UNITS AND WIRING ON COWL | ANYTIME (AFTER REMOVAL (INSTRUMENT PANEL) ‘CONNECTIONS OW OTHER END) ‘SEE OPERATION 19 AND 20_| 14.| 22 i 1O=U1=15 =22 L REMOVE -TRANSPISSION, TF 16. XHAUST PIPES & MUFFLER. ANYTIME 17 {25 “PARKING BRAKE ASS ZMBLY ANYTIME 17126 cR CASE CANYTIME iE. REMOVE BRAKE & CLUTCH PEDAL LINKAGE —|-7_ (TOE PLATE] 19 [28 i BRAKE 3 ASS i /E HYDRAULIC BRAKE LINES 20 ORBERS. 21 INTLE HOOK iT WHEELS HOVE REAR DIFFERENTIAL & SPRING. IME EMOVE JFFERENTIAL, ANYTIME [ISASCDSAANTLING-T cz sn Me Scout Car, Dismantling... _5¢ 357a SUSE. wor DATA- Issve_ oF ial? 134) Pree] == DISMANTLING i LEAT IPS wn AB SEO Elie < Disconnect Bucxies As AT@. Foto Canvas Jo. Dorred dines In THe CentER From Att Four Sues Ano REMOVE. O Nore: Foubing AS Descristo Above Witt Keep ALL BUCKLES To Tue Inswe, Free From DAMAGE. Disconnect Straps Ar @) AnD @ AND REMOVE. Dance Roos ©) ARE REnoveD Iw Two Secrions AS SHOWN. (RASC DISMANTLING-2¢2 360BASE Swop DATA- lsoue Or Wheel ee — mer 34 a DISHANTLING ee ee 4) Renove Pares @ Ano ®. REMOVE ALL. CONNECTIONS FROM Tue Barvery, Starting WiTH THE Positive CONNECTION. Disconnect Nuts © Avo @) Ano Renove Barrery From THE CASE. - Putt BATTERY CABLE UNDER Cuassis. CROSS-nENBER, AND PLACE Ww Position Suown Wirn DorTeD Line AT@. Remove GROUND CABLE FROM The CHASSIS. Disconnect Sioe PLare ©. Putt Baroners From Tait LIGHTS, BLACKOUT LIGHTS AND STOPLIGHT ASSEMBLIES, Unscrew CaP @ Ano Renove Wires Fron THe Plue AS SHOWN AT @. Remove RuBpeR Gromer @ Ano Putt Wires TuRoush Boor OF Car. Renove Boor Bo.T GQ), RELEASING CuiP ©. REPEAT Process On THE OTHER SWE. Renova OF Tan Lugar UNITS ARE PERFORMED BY Removing Two Nuts Fron Tue Back AT Position ©. Remove -Booy Bots AT @ From Born Rear CORNERS OF The CAR. 361Base Snor DATA Issue ae tof? Hal [9] SSPANTLING: 4s [Scour Cag WITH HERCULES ENGINE (MODEL yxb) OQ, voor SSS eenove 10s) Daree Tanine THE Seven SEAT CusHions @ AND OTHER LOOSE Arricies Frot Tie Car, Remove THe FotLowine, IN ORDER: Dewers Seat AND BOTTOM PLATE ATTACHED. EQUIPMENT, Box. RicuT FRonT Sear. Toot Box. PLare UNDER RicHT FRONT SEAT. Risur Floor PLATE. -LefT Floor PLATE. CENTER FLOOR PLATE. ©909O900 362Base_sHop DATA Issue or fan ® a) Peal DISMANTLING “E SOM NBS | mp ABLES cy | Pv, Lirt Swe CURTAINS From THe Doors.. Dis- Connect Bats Ar ©, © AND @; THEN Remove Sie Door. Remove BoTH Doors In SAME MANNER. ©) Remove THE FoLowine ‘Boor Bours. @ Ate Gorrs SHOWN ALONG FRONT OF COWLING, @Two Bars Ov Uwersg OF Car, DirECTLY BEHIND Boru Gas Tanks. ©£iewr Bouts On REAR Froor As SHOWN. QPemove AERIAL BRACKET 1ZAISC- DISMANTLING:Base Suop DAra- Issue or Miaae wenicLE M3Al [Scour Can naming ‘Heetente /0 DISIANTLING 713Al SCOUT CAR with HERCULES ENGINE (MODEL JxD) eal or 23 Ou Booy From THe CHASSIS Wity OvERHEAD CRANE AS SHOWN. 364BASE SHOP DATA-Issue Or wha? i Lee Pe WITH HERCULES ENGINE (00EL Jxo) Decnove Sie OVA. Heaved Botts @) from Hoon. LieT Hoop From Scour Car Br INSERTING Two 2'x4"s As SHOWN. Qrenoe Fron? PROTECTOR NOTE: Wasuers © Pare © By Removat OF Are Found BETWEEN THE Six Oval HEADED Bours FRONT PROTECTOR PLATE AT’ AND CHASSIS. 13A | SCDISMANTLING-T(23) 365XN BASE SHOP DATA- Issue Or _polafasl maa) bese] DISMANTLING LOA ETA son RCE” wy | Ea] ®pscovecr Phuss Fea HEADLIGHTS And Biaceour Lists AT @) Ano @ 2e- SPECTIVELY. 2enove Buacrour Lists Ar ©, HeAb- LGHTS Ar Dismwme AL CUPS Ube FENDERS AsAr®, Beret Puucs® Aw @, PUL Wes THROUGH THE FENDERS Ano EEPLACE RUGS. Slane Feoceauee OF REMOVAL USED Om Oprosire Site. oenone FeonT Fenoges By Troan Our Batrs Ar ©\@Ano @. 366BASE SHOP DATA-Issue OF folate aA) ee DISMANTLING SHEET (Al SCOU. CAR WITH HERCULES ENGINE (MODEL JxD) oF 23 @® Remove ENGINE SIDE PROTECTOR PLATES © AND ALL LOOSE BRACKETS ATTACHED. Remove Pirate ® ON EACH SIDE _OF RADIATOR. Put Roo © From FRONT SHIELD AT ©. DISCONNECT Bows ON Eacu Sie OF SHiELD At ©, Ano REMovE THe SHIELD ©, Remove RADIATOR HoLoins Roos © ON EACH SIDE, (WBA7SC-DISWANTIING - 9 (23)] 367Base Suor Dara - [ssue Or liter vance este DISMANTLING oa SA AIO vigor eteoe poll args thou Op REfOVE THE Two CRANKCASE PromecTor Prarés, Remove Bowrs @) Fron Hotes AT ® Ano ©. o. Gas Tank Comnections Ar @Ano®. Renove Nurs AT@ FROM GAS TANK BRACKETS. USE SAME ProCEDURE ON REMAINING CAS TANK, Nore: Draw Gasoune AFTER Finks Have BEEN REMOVED [BASGDeranreING-10 @ 368BASE Shop DATA- Issue_or sits/4a€ carpal ep te er YN FID | a Oe ZL ((g)uon Renoir. OF 19 Paws OF ENGINE INTERFERENCE IN ThE SEQUENCE ABOVE. Key To ABovE SEQUENCE GivEN On ThE FOLLOWING HAGE. AIS C-DISAANTL ING! C3) 369BASE SHOP DATA-Issue Or soliylaa © POA FS | cee | le SHEET. Key To The NINETEEN PONTS OF ENGINE INTERFERENCE SHOWN ON Tite PRECEDING PAGE. (Odarree Draining RADIATOR AND BLock AT Two Powrs Maren @, Remove THE FOLLOWING: G8 G QPOOBOGHO OOOO OOOOOO UPPER HOSE. Fan Ano Fan Bects (Remove Unirs @). RaoiaToR BOLTS. LOWER Hose ANDRADIATOR, FronT Motor HancéR (BorH SIDES). DistrieuTor (ALL WIRES LEADING 70 PLUGS. REMOVE WIRES To Cou Ano Atso The Cou). INLET AND OUTLET HEATER HOSE. Remove Booster BRAKE CYLINDER. AT PownTs MarKED ©. VewTiaTor Tose On BoTH SIDES. Morar Mounrine Bott (Born Sives)(Two Bouts ON LEFT HANGER SHOWN IN ILLUSTRATION). Alt CLUTCH HousinG Bows (12). CaBie FROM STARTER. CONNECTIONS FROM FUEL PUMP. HEAT INDICATOR UNIT. ALL CONNECTIONS FROM GENERATOR TO.VOLTAGE REGULATOR. On. Pressure Live To GAUGE, INLET AND OuTLeT Qu. LINE BFE. VACUUM BRAKE RELIEF Vauve’ (REMOVE ALL CONNECTIONS Anp Um Proper) BaHAUST FLANGE CONNECTION (3 Bours) Remove Air CLEANER CONNECTION, CARBURETOR FUEL LINE To Pump. Foor TarorTLe ConTRoL, HAND THROTTLE AND Coke ConTROL 70 CARBURETOR. 370ae SHOP DATA-Issuc_OF (ates Ke w (3A | eo DISMANTLING 3 ScouT CAR SCOUT CAR Wit hecaes Engine (Mopet JXD) OF 23 Toot Dwe/va 908792 use HiTcH @)ConnecTeD To Motor Block At FourTH Hab BoLT On Rist Front _AT(®) Ano THE SECOND HEAD BoLT ON THE LerT REAR AT©®. Remove THE ENGINE. M3A1SC DISMANTLNG~S_(23)) 37hBase Suop Dara- Issue Or wltlen® ee pe DISMANTLING a MEAT |O0 | sun itine ves rac |! ve & @ Remove THE FOLLOWING ITEMS: DAR Cueaner Wirt Four Bours @) Tae Orr Borrom OF Air CLEANER AND DRAIN THE OlL. Tue Two Horns AND HoRW RELAY. PUROLATOR Oil FILTER AS SHOWN. @Discowecr Ammerer Wire @) AND Remove VoLTAGE REGULATOR. ®Dscowect SHurrer Caste AT © Ano Remove Bracket AND BoosTER BRAKE BREATHER. @Remove ALL CLIPS AND GROMMETS. REPLACE ALL PLuGs ON LINES AFTER Punuine THROUGH THEIR CHANNELS. @kemove “U’ Bot On STEERING COLUMN. ©insrrumenr Pane 15s REMOVED WITH ALL CONNECTING WIRES ATTACHED. @foor THROTTLE ASSEMBLY. QDSTARTER SwiTcH AND CABLES ATTACHED. (@ WinosHIELD WIPER LINES . @ DISCONNECT HEATER. (51 SG DsweorTnG 140 372Base SwopDara- Issue OF telntfane GAL PAEe| — OSMANTLING “Ser | MRA gente | 22 wrw Hescuces Exone (MaceeTx0) [3 ora REMOVE COWL. REMOVE CLAMPS DO NOT REMOVE FIRE EXTINGUISHER AROUND PEDAL. BRACKET 'S! SBOLTS AND REMOVE CLIPS AND DISMANTLE LINES AT SHUT-OFFS. SHUT-OFFS REMAIN ON THE COWL. 373BASE SHOP DATA-Issue Or_tbalea™ VEHICLE, | BeeaEae| DISMANTLING SHEET, MOAI \ 95 | amt BHR newavo» | 9, Onee@ !s Remove AT ©. Unscrew Ol. Reranee ©. DISCONNECT “i-Lo’ Levee At © Ano ©. Pur CLevis An AT ©.Lemove Beane Lever AT @. MOVE TRANSMISSION FORWAED AND LOWER TO THe FLOOR. Nore: IFENGiwe Has NOT BEEN REMOVED PREVIOUSLY, REMOVE THE Two UNIVERSALS@ AND. 374BASE SHOP DATA- Issue Or (elrifan VERCLE Taser SHEET 34) S| DISMANTLING aad 265 wirn Heo iS roost 1x0) / Z 23 Disconnect Extaust Pipe ial ‘AnD MureLeR Br REMOVING EeacneTs Ar @, ® Ano ©. SpLit THe AssemaLy AT ©. Remove Ture Bors © Ano Pw © To Dis- Connect Brake Drum SHOE ASSEMBLY. PBASCDisnAn Tune rea] 375BASE SHOP DATA -Issue Or wirgant sae pg A 0 _ MOAT [26 | waite ROC oe uy a @ To Remove ThE TEANSFER AND TRANSFER UNIT: © Bemove EiaHT NuTs As @ON EACH SIDE OF PAN. @ Bemove Four Nurs As @) ON UNIVERSAL JOT. @Arracy Crane bitc As Suawn Remove Nurs©Avo®. @Pemove FOUeNUTS ON Universal Jnr AT Rosirion®). © Remove Deive SHarts ON FRONT AND BEAR DIFFERENTIAL UniT AT ®AND © RESPECTIVELY. 396 (ASC Dsmmne 8 &)Base SHOP DATA-Issue OF elise VEHICLE [DISMANTLING (SHEET_ Maa) ee DISMANTLING 19 : dl Wy, © SCOUT SCOUT CR, ho] WT HercuLes ENGINE (Macex TxD) To REMOVE CLUTCH AND BRAKE Pepars: Remove Pn@ ® AND DISCONNECT ARM AND SPRING @). PEMovE NuT AND Correr Key From SHarT ©). Cuurcn Ano Brace Pears ARE TaKEN Orr Sart © By LOoseN- ING Set Screws AT. Woon- Rure Key © (5 REMOVED. ey ‘Booster BRAKE IS TAKEN a | OFF By Removing Pin@). fig a Remove Pin@ AND SLIDE %) SHAFT ©) From CHASSIS. To REMOVE STEERING Gear-AssemaLy @), REMOVE COTTER Key AnD Drag Link AbsusTING NuT D. Remove Nut(®) Ano Two Nurs AT ©. To Remove DRAG LINK@) From LEET FRONT WHEEL @®, UN- SCREW THE Four Nurs AT ATTACH TIN PLATE OVER Orenine To PREVENT Dirr From ENTERING WHEEL. [RASC Dsranrins-19 63) 317Bas£ SHOP DATA- Issue Or toltslar® MOAI [BQ| , GRMANTENC 20 Wit HERCULES ENGINE (MODEL JxO) [Scour an asconnecr Lunes AT @ Ano @. Renove Tunee Burs AT ©, To Remove MASTER CYLINDER. Disconnect Lines AT Q)ANo Ar Juncrion © Removing Aue Cups AS Lines ArE DISMANTLED. REMOVE CONNECTIONS FROM WHEELS AS SHOWN AND DISMANTLE THE REMAINING HYDRAULIC LINES. Remove BeackeT From The Cuassis ATO). [ZAI C-DISMANTLING-20- (2) 38BASE SHOD DATA- Issue OF sel} pre WAI |B eee oe cee Wit HERCULES ENGINE (MODEL JxO) [Scour Ge @ To Remove Tie Two Frowr Ano Two Back SHock. Ansoesers: Remove CASTELLATED Nut @ Ano Two Nuts Ar®. Pi Avo Rema Nut ©. Dewe Pw O) Fran Toe Cap. Remove Four Bos OwEacn SDE OF Benceer As Ar®.. Remove Serine ©: Dace Up Enns Cuassis Ano Ser ON Horses. REMOE THE Fou WHEELS. Tee Hue Nurs OF Ris Hano WieeLs ARE ‘Rie Hano Tareaos. THe Lert Hano WHEELS FI6.3. Are LEFT Hand THREADS. (WBAISC-Disrmmruns-21 (23)) 379BASE Snore DATA-Issue_o fitea™ M3Al ‘34 eS 22. Scour oR WITH HERCULES ENGINE (MODEL JXD) SHEET, NOTE:Zeem Firnnes Ave Ensuy Daansea Use Cage Wen Remouins Pins Fear SHACKLES. CRANE HITCHEDAS SHOWN, Disconnect Unit By Removing BoursAT @ And ®. Tap Pins Fro SHacnies Awd LowEe Unir To Foor. DISCONNECT SPRINGS On Each Site By Remove ‘U” BaxTsAs SHowvAT ©). Birsceew Bott® Anp Revove REAR SHACKLE From CHASSIS. [BASCDISMANTL 76-00) 380BASE SHOP DATA -Issue Or softly” Ee eee Th men revere TENSION ON FRONT AXLE ASSEMBLY By LIFTING SLIGHTLY WiTH AN OVERHEAD CRANE Suown Asove AT @). Remove “U" Botts @ AND Lower UNIT 76 THE Fioor. ISMAN’ Br REmovinG 1D Ano ©. Dismanrie THe Series Br Removins PIS Ar ©O an®. [Fook Dw. wo | SHEET ore | DET. 459078 6 yatta 30872% 73 [ara _t [MGATSC Dsnanrinszaes) Bal382| Base SHOP DATA - /ssue Ox yaa VEHICLE: WIT ‘Sus- ASSEMBLY SHEET MAI |D) ERIE STERN D3 | || Scour CAR a4 Nore: NUMBERS IN CIRCLES DENOTE OPERATION. FOLLOW IN ORDER. THE FOLLOWING DISMANTLING ProceouRE OF THe THREE DRIVE SHAFTS |S REPEATED ON Aut Six UNiveRsat JOINTS, AND ON ©, ALL Four SIDES OF EACH JOINT. CO) © Remove Swap Ring @ With A Pair OF Piers. DRIVE OUT NeEOLE BEARING ® wg) Punch AND HAMMER By HITTING IN FRONT OF RETAINER Ring ©). WHEN ALL Four NBEDLE BEARINGS ARE REMOVED, SLIP @y Qur Uournal(D) From Bore Yores ©) AND ©. =e \ 2 Pry OFF RETAINER Rinc© Ano Cork WASHER G) From JourNAL ©). REPEAT SAME PROCEDURE Fig.2 On OTHER Three Enos OF Jourwat ©.” DiscaRO RETAINER RINGS AND WASHERS. MBAISC-EH-D3 ~/ a BSD. He, Shafts (Drive & Universals)......... 56 383BaSéE SHOP DATA -Issue Gr 1ofs/42€ VEHICLE UNIT OVERHAUL | 32 Assenacy SHEET. MSA. |D. Pence tom| SAFLORVE D3) 2, © © To Rewove Steeve Yore Assemacy @ From SPLINE ©) Screw Orr Dus Curp©, AND FULL APART. Corn WasHer ©), Lock WasHer ©, Ano DusT Cue © CAN THEN BE REMOVED FROM SPLINE. Tane Our Grease Firmins ©. (: Pry Orr Necoce Retainer CaP@ From Neeote BEARING GuP @ Ano Remove Nezoe Bearincs D. | WASH Att PARTS IN GASOLINE AND CHECK POINTS Or NEEDLE BEARINGS. Nove: NEEDLE Bearins © Caw Be Usen AGAIN, BUT Bearings © Ano @ CAN NOT, BECAUSE_ONE HAS A BURRED Pont AND THE OTHER /s 700 POINTED, AND SHOULD BE REPLACED WiTH New One. INSPECT INSIDE OF NEEDLE BE* RING Cup @) For Grooves. IF THERE ARE GROOVES, NEEDLE BEARING CuP Is REPLACED. NeEDLe Bearinc Gup@ SHOULD BE LINED Wit No.3 JounT Grease Berore REPLACING NeEoLE Bearincs DIN CUR THERE ARE 27 BEARINGS To A NEEDLE BEARING Cup, SHOULD THE NEEDLE RETAINER Cae © Fir LooseLy Wren REPLACING [TON Bearinc Cup@, Use A New ONE. [assisc-a8 85-2) 384BaSE SHOP DATA -/ssve_OF 12/3far€ VEHICLE UNIT OVEPHAUL ‘Sue- ASSEMeLY ‘SHEET. M3Al Aaiee Tein] SHAFT DRIVE Scour Cae D POWER TRAN| > D3 a Nore: Yores Ano Swarts To Be Macnariured For Cras Ano InspecTeD To Make SURE THer ARE NoT SPRUNG. Dusr P@, Loox WaseR®, Ao A New Cone Wasner ©) ARE SuirreD On Te Sune ©. Lock WasteR® Has To BE TwasteD Our OF Suape Iv Oroér To Be Pur On, AND LATER Ir ts Bent Back To SHAPE. (Q) fu Grooves On The ExTERNA. Seine Q) AiO COAT THE INTERNAL Spun OF SuEEVE You Asseieny ©, Licnmur WiTH No.3 GREASE, Whew Purrine SLEeVE Yore © Ov Exrerna. Spe ©. MaKe Sure Tnar Arrows © ARE IN LINE. Ox» duit Cue@ Ow To Eno OF Srecve Yore ©. (pre Grease Firtine © If NECESSARY. MAIS -BH-LB- 3) 385BASE _SHOP DATA - Issue Or 1o/3/4n€ VERGE Twit VEL} Sie-ABseneLy Maa |p SRR siaer Lene 3 SHEET a4 Repiace Retainer Ring @ Ano Cook Wasnee ©. ‘SUP THE To OVER ONE EXD OF Journal ©. Do THE Same Wit The Orne THRee ENDS. [LuapicaTe Join Cross © THRousH ALEMITE QOWirn Stared GREASE Gun, UNTIL GREASE Snows Ar THE Enos OF JOURNAL. mer 0 20209 © rene tomee Dene Necoue Bearing © e® = Down To iB SURFACE. Drive NeEDLE BEARING Ov Ornee Sie Dom Pasr Swap Pins Geone ©. @ Cj-© (ser sue tre ® we Wirt PuERS. ‘Swap RING IS DRIVEN INTO GROOVE WITH Hanmer Ato A Brass Derr. Turn OVER Ano Deve The OTHER Bearins Down The Same Way. This Peocess 1s Dave On The Omer Two Enos OF JOURNAL. Nore: The OmHER Two Drive SHAFTS A&E OverHAULED IN THE Same MANNER.BASE SHOP DATA-Issue Or 10-20-42 5 VEHICLE UNIT Vi Pee PUG i LGA \BH a tien a NOTE: NUMBERS IN CIRCLES DENOTE OPERATIONS. FOLLOW IN OroeR. USE NeW GASKET WHEN ASSEMBLING. 16 CLEAN Spark Phuc @ wire Orr Dirt Ao GREASE AND BUFF ON Wire BUFFING WHEEL. WASH Iv PeTROLEWm NapHTHA Ano Dry WiTH COMPRESSED AR. SanDBLAST WiTH SPECIAL EQuiPMENT. BLow OUT Wits Air Hose AFTER SANDBLASTING AND INSPECT THe PLuG For DEFECTS, The Porcetaw@) Srou.D Nor SHow Burns Or Cracks. Ir IT Does, Orscaro Phuc. The ExecTRape ©) Suouto Aso BE INSPECTED For BURNS Awo Execrrane InsucaTor(D) INSPECTED FoR Cracks. IF EITHER Conorrion Is PRESENT, Discard THE PLUG. TEST CLEARANCE BETWEEN Etectrooe ©, Ano Por ©) Wir A Feever Gause (©). CLEARANCE BETWEEN POINT Awo EvecTrooe Siowo Be .025° IF CLEARANCE_IS NoT Correct, ApjusT The Powr © wirn A Pap Or Scencer- Nose Puers UNTIL CLEARANCE [S CORRECT. QDroece Tureans © ANp RETHREAD Wita 4 MM Dre. IF Necessary, To CHeck Tue Fire OF THE SPARK PLUG, INSERT PLUG In Spark PLUG TESTER AND 5€T At 90 Pounds Pressure. (Ff Fire OF Pluc is Weak, Discard Plus, Gyan 15 10 BE STORED, PROTECT Ture aps @) By PLACING CARDBOARD ProrecTor QD) Over Tit THREADS. PBABCBHBT TT | nam Spark Plug... 57 387388BASE SHO DATA - ./ssue OF shpat VEHICLE ee ar a iG WERHAUL CHASSIS Sus-ASSEMELY SPRINGS C6 SHEET Pe 4 fs TO OVERHAL SCOUT Dacaren SPRING WTA CCAP) renove Four Bars As® Fran SPRING CLIPS. REMOVE CENTER Tie Bow ©. onsEN'C™ Crane ) AND SEGREGATE LEAVES. Nore: BE Sure Pan Lear (Q)IS ASSEP® “BLED AS SHOWN WITH SH®, (Fi 2) fig.) SPRINGS ‘CLEAY AND INSPECT ALL LEAVES FoR Cracks Ano BREAKAGE. (STRIKING face LEAF Centar WITH A KAMER, WiLL, EMPHASIZE Ar Cracks Or Dérec “PLE DEFECTIVE LEAVES AND APPLY FINE GRAPHITE GREASE. ASSEMBLE. By INSERTING ¥8"DRILL Roo Turouse The Bout More. APPLY “C’ Cramp Remove Dent Roo Ano Insert Bowr(©)Ano Bours). MSAISC -BH-C6-7(1) SB he, 5E Springs (Front & Rear)... 389390BASE Shop DATA — /ssue OF Wa VEHICLE aw ~Saeer— OVERHAUL) “2 Asserevy Sueer ae SPRING MBAl C CHASSIS. |- SHACKLES CF / os [ ot Dasecr Frovr Sremc Beacker @) For DEFECTS AND CRACKS. QHECK SHACKLE Bars ® Avo Nuns © for Sri TiReAs Fig] AND WEAR, REPLACE IF NECESSARY Qyrer FRONT SPRING SHACKLE foe DEFECTS AND CRACKS. CHECK Snaceie Barts ® Ao Nurs © For STRIPPED THREADS AND WEAR. REPLAE UF NECESSARK o Rear SPrine Suacnie @Fae DEFECTS: AND CRACKS. CHECK SHACKLE Bar Brno Busane D For Stans OF eae iF Baoty WORN, REPLACE. Remove AnD CLEAN Au ALEAITE CREASE Fittings ON SHACKLE BOLTS. Nore: IF Magnarcux Epinmewr 1s AYALABLE, Use WHEN Ever NECESSARY ON THE ABOVE CMTS. [3A 1SC-BH-CS- 1 (1) SD. Me. Spring Shackles—___..... 5 391Base SHoe_DATA ~ Issue OF fefys - VERICLE UNIT UB ASSEMBLY Seema y OVERHAUL [ae ne SAI \E sear ioe E 7) Remove Plus @ AND DRAIN STEERING GEAR LUBRICANT. REPLACE PLuG@). Q Remove NuTAND Lock WASHER@)- NOTE: Before RemovincARM AND BALL AssEmBLY©, Make PUNCH Maexs Ar ©) Ov Smarr Ano Lever ASSEMBLY @)AND ON Bat AND ARM ASSEMBLY©). THis FACILITATES CORRECT LocaTION OF ARM WHEN ASSEMBLING. With Te AD OFA SuiraBLe Putter © f16.2 , Remove Aem AND BALL ASSEMBLY ©), WiTH Drac Link @)Arracne, Fig. |. Foo pus wi mse FIG 2. (sar SC-BW-ET— 1 Ga) 250. ma Steering Control & Drag Link fe 333BASE Suop Data ~ ssut OF “*/e/pe Tal |e ERHALL Jetwmas seme F 7] 2 zi ; [Scour Caz Means Avo DRas Linn or 2 3 To Remove BALL Ano Arm Assemacy @ From Drag Linx (€), REMOVE COTTER PNG, Screw Pus, Batt Seat © Ano Lier Ou Bau Ano ARM Assemety®, Remove Ball Seat ®), SPRING © Ano Sprine ScaT @. Fig.l. @ To REMOVE STEERING KnucKLe BrackeT @) FRom DRAG LiNK®, REMOVE Corre Pin ©, Unscrew PLUG @, SPRING SEAT®@, Serine ®, Bau SeaT@ AND LIFT QuT STEERING KNUCKLE BracKeT@). Remove BALL SeaT®). Remove STEERING KNUCKLE ©) FROM BrackeT @). Sénnsab MBATSC-BH-ET~ 2012), 304BASE SroP DATA — SUE OF idofqe VEHICLE Eo QWERHAUL ALESORES ‘SUB ASSEMBLY SHEET caviras, ERM fF 7 Ano DRAG LINK Or 12 (Scour CAR @) oF a Fig. 1 ve Hoan BUTTON @ By PRESSING Down Ano Tuenine To THE RIGHT. REMOVE cae Contac ©, Seec ©, AnD CaP CONTACT ©. Remove Trees Screws AS© Feom Base PLaTe®©. Putt OUT Base PLATE @ ALONG WITH INSULATING FERRULE @, CONTACT SPRING®, Cowracr Wasner D,AND CaBLE Ano TERminal AssemeLy ®. Remove Nur ©, FiG.|. WITH PULLER®, FIG. 2, REMOVE STEERING WHEEL@. Revove WoopkuFF Kev ® Feov TuBe Q, Fic. |. Nore: Horn Burton ASSEMBLY /5 700 DUE. ‘WO 9068712 Fig. 2 ASSEMBLED TOGETHER AGAIN AT Tus Time Axo A Kwor Is Tied In THe CABLE TO PREVENT oss Or Papers BeroRe BEING OVERHAULED By THE EvectRical DEPARTMENT. [ABATSC 395Base Swop Data — Issue Or 10/o/te © aA | E OVERHAUL (UB ASSEMBLY SHEET E7 (MECHANICAL OUT CAR ACCESSORES Avo DRAG _LINK or i2 D Reno Six CaP Sores Ano Look Wasiers AQ. Remove Sine Cover @), GasKer ©, Ano Swer Ano LevER Assematy (), FROM HoUsine ©. Reeve Not Ano Loox Waster @) Ano Came Baur @. Tare Our STEERING June uacner @. Remove Four Cap Screws Ano Lock wasuers ATD, ‘From Upper Housine Cover @). REMOVE Corer ® Ano Sums ©. [MSAISG-BH-E 7 ~ 4 (2) 396a Base Shop _DaTh — ‘sve OF 1o/ofra — VEHICLE UNIT ‘SUB ASSEMBLY ‘SHEET M3A QUERHAUL | covreass, srezan6 (3Al |E eae [tobe ET) og oe Tue AND Noam Assemary @ Feo Housinc ©. Remove RETANER RING ©, BEARING Cup O)AND Balt Beaines ©. Feom Ornee Eno OF Woem ASSEMBLY, Renove RETAINER Ring ©), Bearinc Cup © Ano Bat BEARines @. [BAT St-BH-ET— sCia) 397BASE Sno Dara — sue OF H/e/oe™ VEHICLE UNIT ‘SUB ASSEMBLY ‘SHEET A QUERHAUL | covrmass, st 9» STEERING, Man CE ree ime foe a Inspect Housins @, IF CRACKED, REPLACE WitH New HOUSING. IF Necessary To REPLACE THE Two Busines As @) In Housine @, Arst Pry Our Oi. SEALOWITH A SMALL Pry Bar ©. Fic.!. @ TURN HOUSING OVER, Fic.2. UsiNG Toot ©, PRESS OUT BUSHING @ TOGETHER, ON A BEARING PRESS. IN SAME MANNER, PRESS NEW BusHine IN ONE AT A Tie. IF BEARING PRESS Is NoT AVAILABLE. OLD BUSHINGS May BE TAPPED QUT WITH A HAMMER ‘Ano Toot © As SHOWN. New BUSHINGS May BE PRESSED IN WiTHA VISE. REAM BUSHINGS TO SIZE, BEFORE INSTALLING SHAFT AND LEVER ASSEMBLY. REPLACE with New Oi SEAL As © Fic. |. Fig 2 (MBATSC-BH-E? - 6(12) 398BASE Sop’ Dara — (sue Or 1o/s/4e VEHICLE UNIT UB ASSEMBLY SHEET OVERHAUL \covvreass, sree MAI |e Soeeee awoe © 7) lg ® INSPECT WORM GEAR @ FoR WeAR OP SCORING. IF Worn Oa SCORED, REPLACE WITH New TuBE ANo Worm ASSEMBLY. If Tus. ® | BenT More Tuan “0” OFF CENTER, REPLACE.WITH New Tupe AND WoRM ASSEMBLY. @ InspEcT Batt BEARINGS AND BEARING Cups © Ano ©. IF SCORED, REPLACE WITH New CUPS AND BALL BEARINGS. LUBRICATE AND INSTALL BAL Bearinos AND Bearinc Cues © AND © On Worm Gear ®. Lock With Revainer Rincs © Ano ©. NOTE! THERE Ane 14 Batt BeARInes in Eau RACE. (3A SC-BHET- 7(12) 399Base SHOP DATA — BsuE OF /0-6-42 4 VERE ad Tie Aasemaly SHEL WERHA sal |e ORRiaL eaeiems £7)" 8 | IT CAR ACCESSORIES Awe Dias LINK or 12 @® usta Tie Axo Worm Asseuary @ Ivo House @). Nore: Remove AsquT THREE Op Four Sums ©, OR EnoucH To Cause A ‘rac On Worw Assemeny @, WHEN UPPER Housinc Cover © Is Ticurenco Down, DRAG SHOULD BE NoricED WHEN Worm ASSEMBLY 1s Turned By Hano, Repcact One Sum Ar A Te, UnTit DRAG IS Peuever: Tieuren Ubeer House Cover ©) As Exon Sum 1s Aboeo Ab TesréD. (6) g seer Tie secret © Is Bent On Bao DEnTED, REPLACE WITH NEW JACKET, INSTAL IT Into Urrer Housinc Cover ©) Ano TictTEn Wire Claw Baar, Loc Wasier, Ano Nur ©. CDi 01 nen asia Oo Wear OR ‘ScoRING Ow Suet B) Ano Cams QD. Repuace Wine NEW “Assenety Worn Oe Score. Wstaue New CAsKeT®. Insta New Sve Corer© If Oty One Is Cracré. FASTEN WiTH SK Lock WASHERS < Ano CAP SCREWS A@. . PBAISC- BHET ~ 812) 400Base_SHop DATA ~ sue OF 10-6424 VEHICLE ONT ‘Sue ASSEMBLY EE QUERHAUL | covmras, sreeens, MoAl|E amen [wn ET) Fo, PLace STEERING ConTRaL@)N'A PosiTion ReLaTivE TO THe NATURAL, PosiTION OF CONTROLS IN THE CAR INSTALL WOODRUFF Key © Into Key Way OF TuBE ©. STEERING WieeLD IS REPLACED IF OLD ONE Is BenT OR CRACKED. PLACE STEERING Weicen ©) Over Tube © Witt One OF ITs = Two Key Was Over WoooruFF Key @). Fel. OQrnev Sreerne Wee. ©) To The Ler As Far As Ir Whee Go, Then Turn WHEEL o The Rg As Fae AS Ir Wit. Go, COUNTING THe REVOLUTIONS. Turn WaeeEL To The LEFT have THe Ameer OF Tora. REVOLUTIONS AND Stor. Tals SETS THE STEERING CONTROLS IA STRAIGHT Ané¢D Position. Whee. © Svouo Have ITs Trae MARKED SPoxe €) WA CENTER DOWNWARD POSITION AS SHOWS IN Fic.2._ IF IT 15 Nor IN This PosiTion, Grange Wreer © To OTHER Key Way PosrTion AND TIGHTEN NuT ©, Fig ore: For Overvaut OF Horn BUTTON, REFER To ELECTRICAL ACCESSORIES-~ SuBASSEMALY FIO. WSTALL BASE PLATE @), ConTacr SprING@, ANO CONTACT Waster @. ON Crete Ano TERMINAL ASSEMBLY @._ INSERT Whee TrRoUGH BOTTOM OF Housing UP Jo Srecring Wreer©). Tie Ir ON THE CABLE AND TERMINAL ASSEMBLY @® Ano Ir THrouGH. FASTEN BASE PLATE @) WiTH TAREE Screws AS @, Insrate CaP Contact @®, Sane ®, CaP ConTacT @ AND HoRN BUTTON ®. — MRATSC-BH-E7- 92) 401ei Base SHoP DATA = fe Or 1b-b-4u.4 LE UNIT 7B ASSEMBLY ‘SHEL Misa |e OGRA Yeas ames 7) 70 | : UT CAR ACCESSORIES @ 7m Aguust Te PLay In STEERING WHEEL ®, FIG), TURN STEERING WHEEL To THe LEFT AS Far As IT Witt Go, THEN TURN IT To The RicHT As Far As IT Wie Go Counting THe Revo.uTIONS. Tuan To THe LEFT AGAIN HALF THE NUMBER OF TOTAL REVOLUTIONS AND STOP. @ Loosen Lock Nut ©) AND TicHTEN ADJUSTING ScREW © FiG.2, UNTIL A SLIGHT DRAG ® /s NOTICED fig.t WHEN WHEEL /s Move Back AND ForTH OvéR CENTER Position AS SHOWN IN Figh Loosen ADJUSTING Screw © UNTIL THe SLIGHT Drag Is FeLT ONLY On AsouT 3° OF TRAVEL WHEN WHEEL IS MOVED Back AND FORTH OVER CENTER POSITION. TigHTEN Lock NuT ®- @ Make A Fina CHECK By TURNING Wheet COMPLETELY. 70 THE LEFT AND Ric. Be Sure THERE Is No DRAG IN TURNING, OTHER THAN THE AppROximaTe 3" DRAG AT THE CENTER PosiTION. M3AISC-BH-E HO (2) 402BASE SHoP DATA — ft (0-6-4245 E WGAL \c OERHAUL \comas seas £ 7) | IScour Car ACCESSORIES Ayo DRAG LINK Or 12 Borers For DeAG UNK, BALL AND AeM ASSEMBLY, AND STEERING PAUCALE AGE RepLacto WITH New Je They ARE BewT, Woen, Beoxen Oe DisTarreD. INSTALL SPRING SEAT@, SpRING ©), AND BALL Sear ©. InsTALL BALL AND ARM ASSEMBLY © Into Deas Link £) © insta Bau ‘ SET ©, SCREW Pus ©, Avo Lack a” GrTER PIN FIG. I @, ASSEMBLE Orne Eno Or Deas Link, FiG.2, INSTALL STEERING Hewucnie Q Ino BoacreT ® Ano Looe Wire CASTELLATED NuT AND Corer PiIn ©. INSTALL BALL SEAT @ AND INSERT STEERING Pauckte D INTO DRAG LINK @,_ INSTALL Bait Sear ®, Seenc® SPRING SEAT ®, SceEW Pius ©, AnD Lock Wir CorTeR PIN ©.Base _Swop Data ~ sul OF 10-6-42 8 aA / a OVERHAUL ‘Sue ASSEMBLY E 7 MECHANICAL 5 WScou7 Car ACCESSORIES, Avo DRac Linn OF 12 SHEET. @ Ip O10 SHAFT AND Lever Assemety@ AND. OLD Bau AND Arid Assemacy ® ARE To BE USED AGAIN AFTER OVERHAUL, PUNCH Marns © MADE Previous To THE DISMANTLING WILL FACILITATE THE SERRATION SETTING OF BALL AND ARM ASSEMBLY WHEN INSTALLING. @ UF EitHER 15 REPLACED, MAKE THE SETTING BY ATTACHING STEERING KivuckLE END OF DRAG Link To Car. SET CAR WHEELS IN STRAIGHT AHEAD PosiTion: . FinD THE CENTER PosiTioN OF STEERING WHEEL AS IW (SHEET S) (QpeRATION 19). INSTALL BALL AND ARrM ASSEMBLY @) AND FASTEN WiTH Lock WASHER Ano NuT ©). TooLS REOWRED TE DE NO | SHEET] OPER] OET 0879 | 1 soaare | 3 | 6 (eee 6 fe @ MAKE A FINAL CHECK, BY Turning WueeLs 70 Lerr AND RIGHT COMPLETELY. MAE Sure THAT _RicuT WHEEL STOP TOUCHES AXLE HOUSING WHEN WHEELS ARE TURNED To THE RIGHT, AND LEFT WHEEL STOP TOUCHES AXLE HOUSING WHEN WHEELS APE TURNED 7 THE LEFT. NOTE WHEN WHEELS ARE IN A STRAIGHT AHEAD POSITION , THE TRADE- MARKED SPOKE ON STEERING WHEEL SHOULD BE INA CenTéER DOWN- WARD POSITION, AS SHOWN In Fic.2 GHEET 9). AFTER FINAL ADJUST MENTS, FILL STEERING GEAR WiTH GOOW. GREASE AT ©. M3AISC-BH-ET ~ 12072)BASE SHOP DATA-Issue OF Wa &. wea I te a Weal |F gee oes Fe [1 ‘SOUT CAR. ACCESSORIES. ort STOP LIGHT SWITCH A mT Aik PRESSURE Pe TEST PRESSURE OPERATED STOP Lieut Swirc By Conectine Test Lame Across Termias @) Avo ©. APPLY Air Pressure To SwitcH By TuRNinG On AiR PRESSURE REGULATOR AT ©. LAMP SHouLd © LIGHT. RELEASE Alp Pressure. LAMP Suauto I Go Oui. REPEAT TEST SEVERAL TIMES. IF LAMP [f FLASHES On EACH TiME Pressure Is ~ APPLIED To SWITCH, IT IS SaTisFacTory, ~-WMET Mount Starting Motor On A TEST BENCH. Measure VOLTAGE Drop ACROSS SwiTcH TERMINALS © Ano © WhEN Starter LOAD Is Apeiiéo. Ie Drop Is Over .1 Volt, SwiTcH SHOULD BE DISMANTLED AND REPAIRED OR REPLACED. Dummer swrtcn(R) €) aa aaG) Test Dinar SwitcH With TesT Lame. Ss Connect ONE Lead OF Lamp To TerminaLs @. Touch Oruer||, | Lean To Terminacs @ Ano @. Lamp SHOULD LIGHT WHEN CONTACT IS MADE WITH ONE TERMINAL AND Nor LiGHT WHEN CONTACT Is MADi ATTHE OTHER TERMINAL. PRESS SwitcH Down AT @Anp Retease. REPEAT TesT AND THE RESULTS When Test Props ARE ToucHeD Ta® AnD D) SHoud BE REVERSED. DiSCARD DEFECTIVe SWITCH. W3A/SC-BH-FE- 1) aan Me Switches_..._.6]$06BASE SHOPDATA-Is sue 10/#/42T VEHICLE ‘Uwir OVERHAUL SueAsseHaLy ‘SHEET / CHASSIS | MMS GIOUNE CT [Scour Car Ort GASOLINE GAGE) /S REMOVED FROM: GASOLINE TANK. REMOVE Dray Puus As@). ® (2) ere un Feetaer Oe One Pr ICLES. IF CLEANING /S NEEDED THE Fowwowine /s Useb: 7.5 GALLONS OF. Warer, #* CAUSTIC SODAAND G*OF OprHosic (OaKiTe). Moc WELL, IMMERSE TANK IN SOLUTION ANOLET ‘STAND For 12 HOUR. RINSE INCLEAR WATER Ano SHOOT LIVE STEAM THROUGH Tank FoR THREE HOURS. —o® oU ToTest Tank For LEAKS, INSTALL WATER TiGHT Covers Over GasoLinE Gace AND GASOLINE TANK OPENINGS. TANK IS THEN IMMERSED IN WATER AND AiR PRESSURE OF Nor More THAN 15 Poun s/s FORCED THROUGH DRAIN PLUG OPENING. ESCAPING AIR INDICATES LOCATION OF LEAK. CAUTION: IN REPAIRING LEAKS, IF TANK HAS NoT BEEN CLEANED, BE SURETO Fite TANK Witt WATER TO Dene Our DANGEROUS Gas Fumes. Dm Wit Warer In Tanx, Pace /7 So Tuar Hote To Be Souperen/s On Tor Then Sowvee Wer 50-50 SounER.(50 Ti AND 5O LEAD). NOTE! Gasotine GAGE FLOAT IS OVERHAULED UNDER ELECTRICAL ACCESSORIES’ AFTER THIS UNIT [9 OVERHAULED, ASSEMBLE /T To THe Tan. ALSO Repiace Pluc @). (M3AISC- BH-C7- 101) esa he, Tanks, Gasoline... 62 407408BASE SHOP DATA-Issus Or 10-10-42 4 VEHICLE SCOUT CAR ‘D OVERHAUL POWER TRAIN ‘Sue-Assemey case transfer D2 SHEET oF 39 DISMANTLING Nore: NumBers In Circies DENOTE OPERATIONS. FOLLOW IN ORDER. O @ REMOVAL OF BRAKE WHEEL REMOVE COTTER PIN@ From Nur ® HoLoine FLANGE© ON REAR INTEGRAL DRIVE SHAFPO) IN TRANSFER Case ©- Prace TooL® Over Fiance ®. Loosen Nur@ With SockeT WRENCH AND Putt FLANGE AND BRAKEWHEEL®@ From SHAFT. Remove Four Nurs @ Frou Bolts QAND PULL BRAKE Weeks FROM FLANGE. 409)BASE SHOP DATA -lssue Or 10-10-42 4 UNIT Sie-AssEMBLY D sitet case, reausrer D2 a] SHEET, 0F39 REMOVAL OF SHIFTING ASSEMBLY Remove Four Cap Screws @) AND LOCK WASHERS Feom SHIFTING Fork HousinG PLATE®). |PEMOVE PLATE AND GASKET @. TAKE OuT SPeING®, PLUNGER®),AND BALL@. Remove COTTER KEY@) AND NUT @ ON Bor ® OF SHIFTING FORK Came ©. UNSCREW AND Put. Our SHIFTER SHAFT@. PULL OUT SHIFTING FORK®. Tip Oe Baise Opposire Eno Feom SHIFTING Box THUS ALLOWING OIL TO OBAIN OUT OF CASE. tioBASE SHOP DATA- Issue OF 1079-425 VEHICLE WT OVER Sue AssemeLy SHEET ie id) D ER HALL. ‘POWER TRAIN CASE, TRANSFER @ Remove Four Cap ScrEWS(@) AND Lock WASHERS (6) Firom Rear INTEGRAL DRIVE ‘Sarr Cap ©) Tap Cap WiTH Brass MALLET To Rexove CAR SHints (D) Ano Gas- @. ar REMOVE Sr CAP ScREWS ®) Ano Lock WASHERS @ From Case Housine OF REAR InTEGRAL Drive SuarT QD. Tap GAGE HOUSING WITH BRASS MALLET To LOOSEN. Pry From Swart Witt BAR. REMOVE GASKET ©). RoLLer BEARING (L) Cones Orr Swarr WiTH Cage HOUSING. GAISC- BH- DE- 303) 41hBASE SHOP DATA-have OF 10-10-42 £ VEHICLE. wT OPE y fh, i AssemaLy SHEET YOAL D renee Tenn |CASE TRANSFER D2 © Denar 16 CAP Icnews ® ANo Lock Wasees ®) Fam Comp Pate ©. ene wo Dower Pris @ANo © cur OF TRANSFER CASE©. PINS Stay N CovER. REMOVE DEAR Cove PLATE © AND GaskeT ©. 412BASE SHOP DATA-lesue Or 19-10-42 4 SUB-ASSEMBEY “Wh / 1D OVERHAUL case rrusree D2 POWER TRAIN ‘SHEET | 908888 (4) Remove Correr Ker@. Ptace Too@) Over FLANGE © AN Remove Nur ©) WiTH SOCKET AiG. 2_ WRENCH. Put FLANGE © From FRONT Drive SHAFT@) Pewove Six CaP Screws(E)AND Wasitens @)From CaP@). Puce be CaP Ano Oeserd ; (6) Pemove Correr Ker). How FLANGE © WiTH Tool) Ano REMOVE Wu @ Mira SocneT WRENCH, PuLt. FLANGE OFF MAIN DRIVE SHAFT). Renove. Four CAP SCREWS(P)AND Lock WAsHERS©@ From Maw DRwvE SHAFT CAPR). Putt Ore Cap Suis) Ano GskeT@. — SS 3BASE SHOP DATA-Issue Or 1010-424 VEHICLE UNIT ‘SuB-ASsEMBLY SHEET OVERHAUL MOAI | D Feree ren |ose teusree D2| 6, REMOVAL OF GEAR ASSEMBLIES Putt Our REAR INTEGRAL Drive SHAFT AND GEAR@) Witn Roller BEARING® AND SPACERS © FROM TRANSFER Case ©). (9) Put MAIN DRIVE SHAFT®), GEAR@), AND Two Bearings @AND@ Our OF Case. Putt Our COuNTERSHAFT OR FROKT AXLE DRIVE SHAFT@ WITH BEARINGS @Ano©. Pu Our loLer SHAFT @) AND GEARS®@) WITH BEARINGS©® Ano©. [W3AISC-BH-02-6(39)| altBASE SHOP DATA-lssue OF 10-10-42 $ : ASSVBLY_OF REAR INTEGRAL DRIVE SHAFT Press Bearinc Race @ Inro Sear OF Drive Cear(®) Usine HrDRALIC Press AnD Too. ©. puce Reuse Bewine ® Over Rear Inrecan. Dawe Suurr@® Avo Fis.3 ‘PRESS INTO PLACE WiTn Hyorauic Press Ano Toa @) ASSEMBLY OF MAIN DRIVE SHAFT Pure Rowuer BEARING © OveR Maw Suart @) AND Press OnTo SHAFT With HyoRauuic Press Ano Toa. ©), OR Dare On Wire Driving Toor Avo Haver. Geiser MansuaeT @ Into Suc GARB. (ee Roxuer Bearing ©) OVER MainsHarT AND Press ON WiTH A ‘Hroranic Press Ano Too. ® Or Davis Too. D. MBAISC -BH-D2-25(39) 433BASE SHOP DATA-Issuz Or (0-10-414 ‘SuB-ASsEMBLY POWER TRAIN: VEHICLE UNIT MBA | D QEREAUL | cee remsece D2 | ‘SHEET 2639. scour car a ASSEMBLY OF IDLER SHAFT ASSEMBLY C8) ness lover Gear @ Ow (nLeR Smarr ®). Rinse @. PRESS BEARING © ON IDLER SHAFT @)AGAINS TT IDLER GEAR @) WITH HYDRAULIC PRESS, OR DRIVE On Hors Hammer Ano Driving Prue ©). COeew On Ano Tignten Nur ©Ano Loci WTA LOCK kins ©. INSERT New WoooRuFF Ker © Iw END OF SHAFT, AND PRESS,ON SPEEDOMETER DRIVE GEAR @AGHINST NuT ©) MTH HYDRAULIC PRESS. Qress Low SPEED GEAR D)Ow/oLer SHAFT®). Qype BEARING@)ON IDLER Sear ®)AGAINST LOW SPEED GEAR QD W7H HYDRAULIC PRESS, OR Deive ON Win Hammer Ano Deine Plus ©). SCREW OV AND TIGHTEN Nut Q)AnbLock Wir Lock 7005, plug. No.BASE SHOP DATA-Issue On /0-0-#24 VEHICLE UNIT Sus-AssEMaLy OVERHAUL MOAI | D SER \se.reusrer D2) CT, @hes Geae @ Ow Frovr Dene Sarr @). (bne Bearins © Ow SurT@Asansr Geae Q Wir Hamaer Ano devine Pus ©. AG. Qveoe Ow Ano Ticeren Nur ©) Lock wire Lock Pine ©. Qe Bespins © Asamsr Skouoer OF SHarr @ Wit Hammer Ano Devine P.we®. So \ £iG. 3 Y CAGE HOUSING @rss Faces @ Ano Dinro CASE ASSEMBLY Housine © Usins Plus (Q Ano Arsor Press. Tool Du. wo. 908896 3-0 tes (MBAISC- BH-D2ZTGA 435BASE SHOP DATA-Issut OF Nt-Ht-42. VEHICLE ‘SHEET UNIT jUB-ASSEMBLY M3A/ | D QUERHAUL | cs eansree D2| 28 scour CAR POWER TRAIN F359 Sele?) A INT OF REAR INTE ING SPREAD GASKET CEMENT Ow CAGE Housing @. PUKE GASKET @IN PLACE AND SECURE ‘Housing To Cover © WITH Six Cap Screws) Awp Loce WasHers ©. (BL SUDE REAR INTEGRAL Drive SuarT © INTO Gace Housine @. Pace Sims © OVER SHAFT. Press ON ROLLER BEARING @. SPREAD GasKeT CEMENT ON Cacé Housive @) AND PLACE GaskeT DAND CaP @ Over ROWER BEARING Ano Secure To Housine Wire Four Cap Screws© Ano Loch WASHERS @. ‘SLIDE FLANGE @ OVER SPLINES OF SHAFT. Screw ON AND TIGHTEN NuT ®. ‘CLAMP Cover © IN Vise AND SPIN SHAFT. IT SHOULD ROTATE FREELY. TRY SHAFT FoR END PLAY. IF LOOSE,REMOVE NUT, FLANGE, CAP AND BEARING. TAKE OUT SEVERAL SHIMS, AND ASSEMBLE BEARING, CAP, FLANGE, AND NUT, AND SPIN SHAFT AGAIN. REPEAT THE ABOVE SEQUENCE OF OPERATIONS UNTIL Att END Play /s REMOVED AND SHAFT SPINS SMOOTHLY. MBKISC- BH- 02-283} 436BASE SHOP DATA -lssue OF 10-10-4124 VEHICLE UNIT ‘Sus-ASsEMBLY M3A/ | D ALE case, reansrer D2 ‘SHEET or 39 Scour CAR ADJUSTING GEARS_ @sxew GASKET CEMENT ON CAP@. PLACE GAsKET® Ov CaP AnD PLACE CAP ON TRANSFER CASE © Tauren Wire Sx CaP SczEWs ©) Ano Lock Wassces®©) » (NOTE: Ths 1s Fhe Statins Rant Foe AnwusTine BEARINGS ON P Suarrs Door Remove CaP @)IN FOLLOWING OPERATIONS. 3 Toe Case Q)Wirn Rese Sie Lb Aro Ser. Ou Wancen Buocrs 50 TnaT TaeRE bs EnousH Space Foe Dene SHarts To Peompuce. pe BEARING RACES INCASE CLEAN. Ou. BeaRINeS OF IDLER Sue @ Ano seer In MocLe het OF Os ra Tae Dove GER@ LP Oe TREO Ose. * ‘On, Beaeanes An insert Four Dane Swart (DIN Case. The Faces OF IDLER AND FRONT DRIVE SHAFT GEARS SOLD BE ‘Ov.SAME PLANE, AiG 2. IF late Sart Dene Gear is Hic, Ake (Our Born laze AnD Front Den SETS. Toe THE CASE OVER. Che parmncenree MEASURE THE DISTANCE Fou TRE Ins Fae OF CoD) Toe Oursune Face OF Te Case. IF THe Distace Feo Face OF Case 15 Less THAN O12“ ADD STEEL SHIMS TAB0UT.OZO' BETWEEN THE FLANGE OF THE Ca @D AND BEARING Bice ®. Pe Measure Tie Dstance BETWEEN Insibe OF Ti CAP Ano QuTsioe OF Case To De TERME NWEER OF Sus NEEDED Toe Pisses BETWEEN CP ND CASE. SPREAD GASKET CEMENT ON SPEEDOMETER CaP@), Pace Gasrer Dro Sams QOn Car Aro REPLACE CP ONTEANSEER CASE, SécuRE WITH FOUR Cap Screws @ Ano Look Wasnees @. @ CASE Over So Thur REAR Swe lst Ame OF \ 1OLER AND FRONT Deve SHAFT INTO CASE, TAP SHAFTS 7 Wit MALLET. GeAe Faces rout B= InThe Save A - FiG. 2 PLANE. IF-NO, REPEAT ABOVE SEQUENCE OF OPERATIONS AND ‘Adb Oe REMOVE SHS UNDER SPEEDOMETER C4? UNTIL. GEAR FACES ARE Te Same PLANE. REMovE loLER Shar Feow CASE. 437BASE SHOP DATA -lssut OF 10-10-42 6 ; “MA / D OVERHAUL ae D2 "3 SCOUT CAR POWER TRAIN: ‘oF39 ADJUSTING FRONT DRINE SHAFT BEARINGS. @®._ Lar Gasxet ® On Cover Ano Place Cover Ow CASE © Over FRONT DRIVE SHAFT @. SECURE IN PLACE Temporariy WITH Six CaP Screws © Avo LOCK WASHERS OW ey ip we. EVENLY AROUND Cover. @ ro @ SPREAD GasKeT CEMENT ON TRANSFER COVER Remove Four Cap Screws © Anb Lock washers @ From Faonr Drive SHAFT Rear CaP QD). Pu. Cae, Shims ®, Ano GasxeT © From Cover ®. Reacu THROUGH. REAR INTEGRAL SHAFT HOLE IN =O © Cover To CHECK END PLAY OF FRONT DRWE SHAFT. IF END ——_—=, Par fs Passe Dre Bests BACE eee FAR >\ ENoucH To Eximinaté END PLAY IN THE SHAFT. ( eS Tap Tue SHAFT LiGHTLy To Sear The Bearinc. It May Be [iftsceot ed Necessary To Drive THe RACE IN ALITTLE FanTHER To Euminare END PLAY. pl fi ! WHEN BEarinas ARE ADJUSTED, PLACE CAP @) IN wg Proper POSITION ON THE CASE WirHouT Sims. MEASURE Tue DISTANCE FROM THE INSIDE FACE OF THE CAP @ To THE Oursing face OF Cover @. IF Tae Distance From Face OF Case Is Less THan 02; Ano Sree. SHims Equat To Asour.020" BETWEEN THE FLANGE OF THe CAP @ AND BEARING RACE @. REMEASURE THE DISTANCE BETWEEN INSIDE OF Tue. CAPAND OUTSIDE OF THE Casé To Deve amine Numaée OF SHMS NEEDED To TAKE UP CLEARANCE BETWEEN CAP Ano COVER. RepLace GasKeT ©,SHims @,Ano Cap DOn Case. Secure WH Four Cap Screws © AND LOCK WASHERS @. INSPECT For END PLAY AND EASE OF ROTATION. IF Tien ISNo ENDPLAY AND SHAFT ROTATES FREELY, THE Fron Dawe Sear BEARINGS ARE ADJUSTED, M3AISC- BH-D2-3039) 438BASE SHOP DATA-Issuz Or 10-/0-4.4 Td |B QR [occ marer D2|" SCOUT CAR POWER TRAIN 7 ‘or 39 ADMISTMENT OF IL “AFT. BEARING: Remove CAP ScREWS @) ANDLOCK WASHERS @ From TRansrer Corer ©. REMOVE COVER. Tare Out Fron Drive SuarT © Ano PLACE IDLER SHAFT © INTO TRANSFERASE ©. REPLACE TRANSFER COVER AND GASKET ©, Ano SéCune With Six CAP ScrEWS ®. TEMPORARILY). REACH THROUGH CAGE HOUSING HOLE IN COVER AND CHECK IDLER SHAFT For Eno PLAY. IF Enb Play Is PRESENT, Remove FouR Cap Screws @ AnD Lock WasHERs QD). Remove REAR IDLER SHAFT CaP ®,SHIMS Q, ‘AND GASKET @ From Cover ©. BEARING Race @ In COVER © SHoud BE Driven In A BIT FARTHER WITH A DRIVE Bar AND MALLET. CHECK SHAFT For END PLAY. WHEN BeAarinss ARE ADJUSTED, PLACE J" CaP ® IN PROPER POSITION ON THE CASE WrtHouT- SHIMS. MEASURE ThE DISTANCE Frond THE INSIDE Face OF Te Cap © To THe Oursibe Face OF THe Cover ©. IF THe DISTANCE From Face OF CASE IS LESS THAN.0I2;" ADD STEEL SHims EQUAL TO ABOUT.020" BETWEEN THE Fiance OF THe Ce © AND BEARING RACE @. _ REMEASURE DISTANCE BETWEEN INSIDE Or Car AND OuTSIDE OF CASE To DETERMINE NUMBER OF SHIMS NEEDED To Take UP CLEARANCE Berween CaP Anb Cover. REPLACE GASKET @,SuMS @,ANO CaP @. SECURE WITH SCREWS @ Ano Wasners QD. inspect SuarT FoR END Pay Ano East OF Rorarion, Wien Eno Aay Is ELIMINATED AND SHAFT ROTATES FREELY, BEARINGS OF /OLERP SHAFT ARE ADJUSTED PROPERLY. [MBAISC-BH-D2- 31039) 439BASE SHOP DATA-Issue Or /0-/'-41.8 VEHICLE UNIT Sue-AsseMaur SHEET OVERHAUL Al | O Force reanr se Tense D2| 32 ,, ING MANN ORME S} Remove Six Cap Screws @ ‘Lock Wasners() From COVER ©. Remove Cover Ano (OER SHAFT From Case €). 3 Remove Front Cap ®)0F A Mamsnarr @) Ano Drive BEARING mp RACE @) IN TRANSFER fase @ 07 Our P’ OR Towaro Front OF CASE ABOUT 025° Witt BAR AND MALLET. PLACE IDLER, FRonT Drive oN MAIN DRIVE @ SHAFTS INTO O DRIVE IN Ps Dowex Pro Déno Ano Secure Cover Wir Ub Cre Screws A Ano Lack Wasers Oo WL HAVE END PLAY. DANE BEARS RACE @) ITO CASE FAR Enovett TO ELIMINATE Au Bur ABour Tao OR Thee Thousmomis Eno Peay. ‘Pace Cap (©) Proper Posiminy Qn Cise Wiriour Stas. Measure Distance From Tre Insioe Pace OF Te Cae © Io Oursoe Fre OF Case ©). Te Distance From Face OF Case Is Less Thaw 02" Aco Sreet SHS Faust To Asour 020" Be Tween The Flawce OF CapE Ano Bearing Race @). 6, ‘Remensure THe Distance BETWEEN INSIDE OF THE Cap/ANo QuTsibe OF THE CASE To DETERMINE Noaer OF Stinas NEEDED To TAKE UP CLEARANCE BETWEEN CaP AND COVER. Place GasKeT G), Stums(D, Ano Cap ©) Ow CASE Ano SECURE Wire Four Screws Q Ano WasHers Y). (M3AISC- BH-D2 GD) 440BASE SHOP DATA-Issue Or 1-0-42.4 VEHICLE UNIT ‘Sue-ASsEMeLy — VBAl | D OVERHAUL ase rnssr D?2\ 33 cece POWER TRAIN (Cerorerae CAP Scius(@)Ano Lock Wasttses@)Feom IAIN Dew SHAFTCAP©) Pu: CAPAND Stuns) Fon Teawsmission CASE. GaseeT®)/1¥ Come OF WitnCap Oe REMAIN ON CASE.BE SwuRE Swims 5) ARE KEPT TOGETHER, © Pace CAPO) UNDER ARBOR PRESSAND PRESS Ott. SEALG@) INTO CaP Wir BEVELEDOR SHARPEDGEOF LEATHER SEAL TOWARD Bacy Or INSIDE OF CASE®). @) Suibe CAR Suns AND GASKET OVER SHAFT AND Secure WiTH Cap SCREWS AND LOCK WASHERS. @ Sue FianeeD Over SPuines OF SHAFT®. @ Sceew OvANo TeHTEn Nur(®). Lock Nur wit Correr Key ©). [MBAISC- BH-D2-331(29) 441BASE SHOP DATA-Issue Or 0-11-42. VEHICLE UNF ‘SuB-FesewBLy Saar OVERHAUL LA D “POWER TRAIN | ASE TRANSFER D2 eS INSTALLATION OF FRONT DRIVE Oy, SEAL AND FLANGE yy REMOVE SIX CAP SCREWS @ AND Loch WASHERS © From Fronr Drive SuarT Cap ©. Put. CapsStims © AND Gasnet © FRoM Transrer Case ©. @ Place Cap © UNDER ArBor PRESS AND PRESS IN A New DOUBLE LEATHER Olt SEAL @. The BEVELED OR SHARP faces OF LEATHER TOWARD THE Insivé OR Pian OF TRANSFER CASE®. @ SLIDE CAP, SHims, AND GASHET OvER FronT DRIVE SHAFT @ AND SECURE IN PLACE Wit Cap Screws @ Ano Lock WasHEeRrs ©. @ SLIDE Flange Q OVER SPLINES OF FRONT DRIVE SHAFT. * irs On AND TIGHTEN NuT @. Lock NuT WitH COTTER PIN M341SC- BH-D2-H939. 442BASE SHOP DATA-Issue OF /0-/1-424 ‘SuB-AssEMBLy ‘SHEET eRiele | nar VER MA | D OVERHAUL osse, awusier D2| FD, INSTALLING PEAR INTERGRAL Dpive Swarr Ot SEAL AND FLANGE @rror Four_Cap Sceews@ Ano Lock Wasxees®)feom Peak INTERGRAL Dewe Suarr CarPQ. n. cap, SumtsQAno Gasxer © Foam Cace Housine®). HEEP Suis Intact WITH CaP. PLACE CAP UNDER AbBa2 PRESS AND Does IN New O1t. SEAL ©. BE Suee BEVEL Oe SHARP EDGE OF LEATHER SEAL 13 PLACED TOWARD THE © Oe Fron Eno OF Teawsrer Case®. PLace CEMENTED GASKET ON Case HOUSING AND PLACE SHIMS AND Cab ‘Oe HOUSING. SECURE CAP WITH FOUR CAP SCREWS AND LOCK WASHERS. SLIDE FLancé D) Over SPLINE OF REAR INTERGRAL DeIVE SHAET ®. Screw ON AND TiGHTEN Nut © WITH Fincees. Nur IsOT TioHTENED BeCROsE 7 Must Be REMOVED AGAIN WHEN ASSEMBLED INTO THE CHASSIS WHEN The BRAKE WHEEL 13 INSTALLED. MSAISC- BH-D23529)| 8BASE SHOP DATA -Issue OF /0-/t-42 9 VERICLE ie Sua-Aasewaly rig LEA Qe case, reanster D2 539 Ra et = INSERT SHIETING Fork © INTO TRANSFER @ BEING SURE FORK JAWS © STRADDLE THE SHIFTING COLLAR OF SLIDING OR CLUTCH GEAR ON MAIN Dawe SHAFT ©. BE Sure Bever OF Fork Faces To REAR. Press IN Ott SEAL ©. SLIDE SHIFTER SHAFT © INTO CASE. screw BowT @ INTO Fok CLAMP @ Ano Screw On Nur @ Bur Do NoT TIGHTEN. <) Screw SHIFTER SHAFT ® InTO CLAMP @ FAR ENouGH THAT By SLIDING SHIFTER SHAFT BACK AND “ORTH, THE CLUTCH GEAR Witt Have Fue MESH WITH THE Rear InreGrac Drive SHAT GEAR. THE Groove ® OF SHIFTER SHAFT SHOULD LINE UP In THE CENTER CF PopPET HOLE ©. TiGHTEN Nut © On Bout G In Clamp @ Ano Lock Wir CorTeR Key @. InseRT BALL @, PLUNGER @® AND SPRING © INTO POPPET HOLE. SPREAD GASKET CEMENT ON SHIFTING Box Cover ® AND PLACE GASKET © ON Cover. PLACE Cover IN PLACE AND SECURE WITH Four CaP Screws © Ano Lock WasHERS ©. W3A 130 -BH-D2-3689) 444BASE SHOP DATA-Issue On /0-/6--42 VEHICLE UNIT ‘Sus-ASSEMBLY ‘SHEET OVERHAUL | ” M3A/ D DOWER TRAIN CASE, TRANSFER D2 ee SCOUT CAP (enn REAR Ot PLUG® Ano Pour Two ai) > Quer OF "60 SAE. Eucine Ou Wo Tae Teansrce S| l) Case®. Sceew IN AND TIGHTEN Oil PiuG. CHECK To ~* * ‘See Thar On PLus©0b Text Fi Fig.3. ssc TESTING FixTURECD)ON TESTING STAND. @ roe Henaep Bors OF Teansree Case, TheoucH Fixtuee®ANp Secuer Wid Nur ©. @ue Universal JonT@ OF DovesrarT @ OF Test Uni D B fiance QOF Main Deive Swarr Wit Two Bos Q Ano Nus@. (DB fern Suinng Levee @ Suerina Shar ® Wir Av, 445BASE SHOP DATA- Issue Or 0-0-4r4 WEMICEE Thi ina = OVERHAUL | scour Al D Power TRAIN | CASE TRANSFER D 2 58, TESTING TRANSFER CASE Starr Test Moror@®, Diseweace Te Clurcw ® Avo Ser Testing Transmission © InTo LOW SPéED. THE Transrer Case (Q) Suou.n BE SHIFTED INTO NEUTRAL. (Qraee uTcH AND ALLOW GEARS To ROTATE SLOowty IN TRANSFER CASE UyTi: THOROUGHLY LUBRICATED. (Quer Lupricared, SuicT Thawsrer Case iro Car Ano Run AT SPEEDS FRow 750 To 1800 R.P.M NOTE: Dawe Swart © SHou.o Not BE TuRWine WHEN SHETING TRANSFER CASE INTO GEARS. Run Test for One Hour. If THERE IS A Norictaate Hom, IT May Be Due To Tica C&ars OR BEARINGS. If Knocks ARE Auotete, A Ben7, OR BuRRED Too, OR CracKtD Or CHireD BEARING Mar BE THE CAUSE. Jp Not Rune Quiétur AT The Eno Or An Hour, DISMANTLE AND CHECK BEARINGS AND GEARS. (MBAISC-BH-D2- 3809) 446VEWICLE, SCOUT CAR BASE SHOP DATA ASSUE OF 1-10-$>3, | % OVERHAUL ‘SUB-ASEMBLY POWER TRAIN case, Transfer D2 ‘SHEET Of 39 447448BASE SHOP DATA —_ Issue OF wh/var VEHICLE Gn OVERHAUL | Sve Assenety SHEET ebO! CASE, TRANSFE} POWER TRAIN| CONTROL AND LINKA @ Remove Correr Pin @) AND Washer ®) From BrackeT SHAFT ©. @ Rewove Suir Tine Lever@©) From BRAcKeT SHarT©). @) UNSCREW SHIFTING BALL ©) FROM SriF TING LEVER ©). @ Loosen Lock Nut @) Ano UNScREW AaJuSTING END@ OF StiFTING RoD. Unscrew Lock NuT(®. * 3) Remove COTTER Pin@Ano Stipe Out Pin D), Thus RELEASING CLEVIS Eno®. [PATSCBDBTS)| SD. Me Transfer Case & Linkage Controls... 64 449BASE SHOP DATA_-__Issut OF w/afva — VERICCE ONiT ‘Sus Assemair ‘SHEET. 77134) |f) QLERHAU case TRansrer 2 | Scour CAR POWER. TRAIN | CONTROL AND LINKAGE OF 3 OVERHAUL specr To See THaT Bracket @ Is Nor Bent Ano THar Start © Is Nor ExcessiveLy Worn OR Qracken. REPLACE BRACKET AND SHAFT IF NECESSARY. os EXAMINE SHIFT BALL) FOR CRACKS AND STRIPPED THREADS. REPLACE IPNECESSARY. See. THAT Swetine Lever © IS Nor BEnTs Thar HOLES ARE NOT Excessivety WoRN; AND THAT THREADS ARE NOT STRIPPED. STRAIGHTEN Lever if BENT. REPLACE IF NECESSARY. Q InsPECT To SEE THaT AdvusTinG ENO) OF SuiF TING Rao IS STRAIGHT Ano THAT THREADS ARE NoT STRIPPED. STRAIGHTEN IF BENT. REPLACE IF THREADS ARE STRIPPED. InsPECT THREADS In Nut ©) AND Levis ENO G OF SniFrine Roo. REPLACE IF NECESSARY. REPLACE Pin IF BADLY WORN. 450Base SHOP DaTA —__ Issue OF 14hefe.” VEHICLE UNIT ‘SupAssemary ‘SHEET. M3A/ OVERHAUL ASE TRAN.3FER] ) 3 POWER TRAIN | CONTROL AND LIHAGE ar 9 Scour CAR ASSEMBLY @ PRESS SHIFTING LEVER @ Ov Bracker SHaFT®). INSTALL WASHER©: ANo Lock Wir CorTeR Pin ©). @ SCREW SHIFTING BALL © ON SHIFTING LEVER @. screw Lock Nur ® Asour Two Inces On To Apuustinc END & OF SHIFTING Roo. SCREW ADJUSTING END G INTO CLEVS Eno@) AGAINST Lock Nur ©. Bnsraes SHIFTING Roo CLEVIS END (®) On END OF SmiF TING Lever ®. INSERT PIND Ano Lock WITH COTTER PIN ®. (MSAISC-BF DES) 451452BASE SHOP DATA-Issve OF 17-418. UNIT OV ‘SuB-ASSEMALY SHEET D QERHALL eisMsiON 1) || 7 SCOUT CAR Dy ING Nore: Numeers In Ciscles DENOTE OPERATIONS. FoLLow IN ORDER. , 7 Ti PLACING TRANSMISSION FOR DISMANTLING Horst Transmission @ With Rope Sting ©) Ano CHain Hoist AND SeT On Work BENCH. MSATSC-BEFDI- 1 TAC asp. Transmission................ 65 453BASE_SHOP DATA-/ssue OF BOBS VEHICLE ‘UNIT OVERHAUL ‘Sus- ASSEMBLY ‘SHEET M3Al-\ D _ romee Tan TRANSMISSION [)] 2. e OF SHIF] ‘Remove Four CaP Screws Ano Lock WASHERS@). FiG.1, REMOVE GEAR SHIFTING Assemary @) Ano GaskeT ©). /AL.OF SHIFTING BAR HOUSING ASSEMBLY (OVE Six CAP SCREWS AND LOCK WASHERS Remove Sur BAR Housins© Ano GaskeT ©: EI HART AND COUNTERSHAFT. ‘BEARING CAPS Remove Correr Pw@ Ano Nur) Fis 2. Drie OFF COMPANION France) WiTH BRASS D remove Four CAP SOREWS AND LOCK WASHERS ®) Remove MansHArr REAR BEARING CAP ASSEMBLY Oxo Caser@- 6 |eemove Four CAP ScréwS Ano Lock WasHERs®). REMOVE COUNTERSHAFT Rear Bearins CrP Ano GasKeT @. (Drrewone Feet Ou. RETANER®) From Bearing CAP ©. _ PSAISC-BHOI- 240) 454BASE_SHOP DATA -/ssue Or 4-12-42 | VEHICLE UNIT OVERHAUL ‘Sus- ASSEMBLY ‘SHEET MB3Al| D Fone rmnl eMoucsin D) | 3 Sco coe or D8 )enoe Cap Scpew AO Lock WASHER @, Fic... Remove Speins®) Ao CLP ©Feom CLuTCH RELEASE BEARING CARRIER ©. Au Careice From MasHarr CaP ©. REMOVE SAFETY WIRE ) Ano Two Sarr Retainer Screws ©. Ors” Pat Gute PEDAL. SHAFT @ Fleom CLUTCH Reease YxE@, Remove Two Weoneurr Keys @ AnD Pa. SHAT@ Freon BELL Housine @. fe Voxé @ From CLurcH Stue SHAFT SLIDE Sus SHAFT INTO BELL HOUSING REMOVAL. AiG.2. @ REMOVE BEARING@D FROM CARRIER ®, Fic. 2, WITH Beass Bak AND MALLET. 12) Remove Four Nurs AND Lock Wasners ®, Fic.3, AnD Deve Beit Housins @ From TRansmission CASE® BV TaPpING On Stuns D WITHA LEAD MALLET. ALE TD)| 455BASE SHOP LATA ‘Issue OF 0-17-42. 4 | venice Mir ‘Sup- ASSEMBLY ‘SHE Wey) (f) -QeRALL Fe wawissiov Py |. POWER TRAIN ee REMOVAL OF MAINSHAFT FROM TRANSMISSION CASE SLive Space @ From MainsHArT ®), Fic. |. Deive REAR MAINSHAET BEARING © FROM Transmission Case ©) USING BRASS BAR Ate Maller. (REMOVE THREE Cap Screws AND Lock Wasners® Avo Sune Orr Maw Dowve Gear Beaains Cap © Ano Gisrer ©, Fig. 2. Remove Mam Dene Gear AssemeLy @ By Tapping Man Deive GeAe@) Our TeoucH TRANSMISSION CASE. REMOVE ROLLER Biarine BAND MainsHarT Taleo Axo Fouea SHiFT Hes O. (Remove TeANsMIssion MAINSHAFT AssemaLy @) By Movine Assemeny Tawaro Rear OF Case. LiFT Font OF ASSEMBLY AND Putt Our Top OF C45, PULLING SLIDING GEAR © OFF OF MANSHAT Sune ©. TORN SLioING GeAR @ One QuaeTER Ten ANd Remove Feom CASE. M3A/ SC BHDI- 440) 456BASE SHOP DATA-Issue OF /0-7-426 Wey [0 EEA thai 5) POWER TRAIN OUT CAR i R L @ Remove Cap Screw Ano Lock Washer @, Fig.l. Remove Lock @) From Reverse IDLER GEAR SHarT ©, Drive Our loLeR Suarr © Usine A Brass Ban AND MALLET. LIFT REVERSE IDLER GEAR ASSEMBLY © Our OF TRansmission Case ©. G Remove Two Cap Screws Ano Lock WasHers ©) AND REMOVE COUNTERSHAFT REAR BEARING WasHER@. © Wry Brass MALLET . Tap COUNTER SHAFT o of @ Toward Rear UnriL Free — OF Case ©. REMOVE REAR ° COUNTERSHAFT BEARING @) FROM COUNTERSHAFT. Tap LigHTLy On EoGe OF BEARING. LiFT CountersHarT @ From Case ©. REMOVE LOCATING WasHER ®. REMOVE SwAP Rng © FiG2, Ano Tap Out Pius @. Use A Brass Bar AND Matter To TAP Our ROLLER BEARING @. REMOVE Six Cao SCREWS AND LOCK WASHERS @. Prey Cover PLATE @AND GASKET ® FROM @ or TRANSMISSION CASE ©. Remove Six Cap Screws Ano Lock WasHers ©. Pry Cover PLATE © AND GASKET @ FROM TRANSMISSION CASE. [M3AT_SC-BH-DI-5(40)} 497BASE SHOP DATA ea 10-8 VEHICLE UNIT )UB- ASSEMBLY sal |p eee TRAIHHSSON [| [6 Power TRAIN Scour Cae é OVERHAUL. BEFORE’ OVERHAULING TRANSMISSION, WASH ALL Paps WiTH CLEANING SoLvENT AND Day WITH COMPRESSED AiR. DISMANTLING GEAR SHIFT LEVER ASSEMBLY So Remove Sprins @ Ano Serine Sear WASHER ® From Controt Toe © Wirh Pe Bar Ano LARGE Screw Driver. > Remove Gear Suit Kwoe ©) ANo RUBBER Cap © From Gear Suirt Lever ©. Pu Lever © From Con7ror Top ©. Ca) Remove Two Pivor Pws © From Conrroi Top. 458BASE SHOP DATA-Issue OF 4-77-4-€ VEHICLE ‘UNIT jj | Se-Assema ‘SHEET MBAI | D Phe non |Emtsson Dy | 7. ese @ ow &-o 6) HAUL OF SHIFT 2 ASSEMBLY. INSPECT GEAR SwET Hog ®@) FIG. 1, FoR cy @) DAMAGE Ce STRIPPED THREADS. REPLACE Ss, Je DamaceD. Inspect Gear SuFT Levee Dust Cover © For i Ceacics Oe TEARS. IF CRacxeD Oe Taen, REPLACE. @., Treesns © Ov Geae Ser LeveRD. GuecK Pin StoTs Ano Bat. ® For WeAe. Ger Lever Ar © For EXCESSIVE WEAR. UF Banty Waen, Burp UP WITH: WELD AND Grino 76 Peoree Sizé. ReeLace Lever IF NECESSARY. on Fig.1 insvect Pivor Pins @ Foe Wear, fig 2 IF WorN, REPLACE. INSPECT GEAR SHIFT LEVER ConTROL Top @, Fae Wear Oe Dawace. IF Woev O2 Damaced, REPLACE. Inspect GeAe Suir Por Wasnee@D For Wes. REPLACE IF NECESSARY. IS INSPECT GEAR SwET Lever SuproeT SPRING® FoR BROKEN SPRING OR COMPRESSION. IF BROKEN Oe WEAK, REPLACE. FIG. 2 WGATSCBHDI - 740) 459BASE SHOP DATA -Jssue OF 14-17-41 4 ence wt CEA | a Pi M54) D ~Bowee Tenn| PoMissiav D/ - ASSEMBLY OF SHIFTING LEVER UNIT 2 Sune Two Pror Pins @ sro Howes) In Geae Suir T Lever ConTeot Toe ©, Fig i. - Siwe Top OF Gear Swer Levee Q) UP THROUGH CavTeo. Tee Avo ALLow Heaps OF Pivor As To Suoe Ino LoT®. Invert Asstmev Avo Secure iv A Vise. PLACE Wasner ©) Aaanst Bat @ Qn SHIFTING LEVER. Place Seeins @ AsainsT Wasree AnD Twist INTO POSITION IN CONTROL TOP WITH LARGE ScREW Driver And Pev Bar. PLACE VERTICAL SPRING SHAFT @) FiG. 2, IN Fron OF Lue @ That Has A ?E SHOULDER, WaicH PerevenTs Seemc From ROTATING AND = LOOSENING. ® TURN ASSEMBLY RIGHT SibE Ue AND PLACE Dust C4eO Over SuiFTING LEVER AND CONTROL TOP Screw Ov GEAR Sarr KNOB. 4 f° f= [AIS BHDI-BC0)} 460BASE SHOP DATA-Issue OF 047-408 VEHICLE UNIT 7 ‘Su6- ASSEMBLY ‘SHEET ial | DOBRA, PeNstision D/ 3 | DISMANTLING OF THIRD "AND FOURTH SPEED ‘SHIFT UNIT. Invent Top Cover Assemacy @ Ano Remove Sarery Wike From Lock ScREWS ® Ano ©And Four Lock ScREWS ©. Rensore Lock Screw @ From THiRD AND FourTH SPEED SHIFT FoRK © Use A Smaut Brass MALLET AND TAP SHIFT FoRK To REAR (LeF7) OF COvER UNTIL Lock ScrEW HoLe ® In Suirr Roo © Is ExPoseD. Remove Lock Screw © From THinD AND FourTH SPéeD Suir Lue @. Puace A Brass Drivine PN IN HoLe © Ano Tap SuiFT ROD © 7 Front (Rice) OF Cover With Brass MALLET UNTIL PLuG @ Is DRIVEN FROM Cover AND Roo Is Prorrupine From Pius Hoe ® Grasp Roo Wire Puiers AND Put From Cover. Remove Fork ‘Ano Luc FRON REMOVE INTERLOCK Pv © From Fob. Remove BALL @ ANo Baus Sean @ From Hove Wir A Sworr Lenath OF Wit [M3AISC-BH-D!-9 40 461BASE SHOP DATA-Issuc OF /0-7-42.8 VEHICLE UNIT ‘SUB-ASSEMBLY ‘SHEET MSA) | D QERHAUL OVERHAUL lO "POWER TRAN | TRANSMISSION D/ 4040 DISMANTLING FE SHIFT UNIT. a, @) Remove Lock Screw @) ON “¢ REVERSE SuiFr Lus ©), Fig.l eo” oO ‘ ©, Tap REVERSE ‘Smet Fork©) ay Ano SHiFT Rov ©) To REAR (LEFT) WITH SMALL BRASS MALLET Ano Remove SHIFT Lue From SHIFT Rop, SCOUT CAR Tap SHiFT Fork AND SHIFT Rob To FRONT (RIGHT) ANO FORCE @) PLuG © AND SHIFT ROD OuT OF HOLE © IN ToP Cover ©. REMOVE Lock ScrEW @). GRASP ROD WITH PLIERS AND Putt Pop From Cover. Remove Suier Fork FROM Cover. @) Remove Bat @ Ano Batt SPRING @ From Hote ® MiTH A SHORT LENGTH OF WIRE. Femove Correr Key@) FiG.2. Ano Nur @), Fre. 2. foe Pinser © 9 NO SPRING @) From 6 sueruc®. te {Dram macy (WEATEC-BH-D-OGA 462BASE SHOP DATA-Issue OF 817-42 VEHICLE UNIT” (SUB- ASSEMBLY SHEET ee ee) @awe Lock Sceew ® Ow Fiesr Ano Secon Spee Suet Luc ®. Tae first AnD SECOND SPEED SHIFT Fork © Ano SHIFT HD ® To Ree (LEFT) AND Remove Suifr LuG Freon SuiFT ROD. ®rone SWIFT FoRK AND Suir Rap Front (RIGHT) Ano Daive Pus © AND SaiFT Roo Out OF Hate © in Top Cover ©. Remove Look Screw @. Gease Roo With Puges AND Put. Rap Feom Cover. Remove SwrT Fark Freon Cover. Gv, Cover, UnbeR Hoe @, Remove Bau @) ANo Bate SpeineD. iv Cover BETWEEN Hoes D,@, AND ®, Are Two INTERLOCK PLUNGERS ©, Remove These From Cover With A Wike.BASE SHOP DATA-Issug Or 1-0-4224 “YSAl 7) QUERHAUL TRINSMSSON DI ‘SHEET. he POWER TRAIN or 48 OVERHAUL OF SHIFT BAR _® Housing ASSEMBLY SIS 5 ee INSPECT SHIFTING RODS(REVERSE pow eo @, First AND SECOND SPEED Se SSS Tut AND FourTH SPEED )), For STRAIGHTNESS, Fic. | Fig. Cuecx Bau. Stor Locks For Wear. /F BENT OR SLOTS ARE Worn, REPLACE. e-® Inspect Tueee Suet Roo Lock Baus ©), Fia.2, For Scores AND Pits. IF SCORED Or PITTED, REPLACE. | INSPECT THREE SHIFT ROD Lock BALL SPRINGS (E) AG.2 9 +—© For TENSION. FREE LENGTH OF SPRING SHOULD t Be Nor Less THAN | 56. WHEN COMPRESSED To OnE © IncH IN LENGTH, COMPRESSION SHOULD BE Nor Less 8 THAN 18 Pounds. INSPECT SHIFT RODINTERLOCK FIN ©)AND Two INTERLOCK PLUNGER6@) For END WEAR. REPLACE IF NECESSARY. 66) INSPECT REVERSE SHIFTING Lus@)For Wear On DAMAGE,FIG3. Cueck Pruncer@)For Wear Or STRIPPED THREADS. INSPECT SPRING) FOR Com- Pression. RepLace Any OF THESE PARTS IF NECESSARY. InspEcr First ANO SECOND SPEED SHIFTING LuGQ/ANp THieD ANO FourTH SHIFTING LuG@) For Cracks, Or Wear. Reptac It Nor UssBle. bd 16 fIG.3. [M3Al SC-BH-DI-12G0). 464BASE SHOP DATA-Issuz Of 0-7-#2.$ VEHICLE UNIT 0 ‘Sue Assemecy ‘SHEET ee @® OVERHAUL OF SHIFT BAR HOUSING ASSEMBLY. Inspect Reverse Suirtine Fork @, FirsT AND SECOND SPEED SrirTine Fork @, Avo Taino Ano FOURTH SHIFTING Fork © FOR Wear, Op Twwst tw Fork. Inspect Lock ScREW Hotes ©) For STRIPPED THREADS. ff Damaté Or BENT, REPLACE. OF 40. EO) INSPECT SeiFT Bar Housins @) For Cracks OR Damace. Inspect SHAFT Guives (©) For Wear. INSPECT ALL THREADED HOLES ©), AND RETAP IF NECESSARY. JF Nor In A REPARABLE CONDITION, REPLACE. [M3AISCBH-DH3 ¢O 465BASE SHOP DATA-Issue Or /047-42 4 VEHICLE UNIT }UB- ASSEMBLY MAL \D een TAIGHSSION DI] "4. ° AS PLACE INTERLOCK PLUNGER®@ BETWEEN Two Ho.es® Ano© tn Housis©) USing A WiRe And SMALL ScREWDRIVER. GEE FiG2): PLACE SPRING © AND BALL ©WHoe® Fig PLace A BAR@ (LESS Tan SHIFT Roo DiameTER) W70 Rod From REAR (LEFT) SiDE. Puut Up Ov BAR AND PRESS Down ON BALL. ‘Sune Firs ANo Sscono SPéeD Roo@ InTo Housine, ResTins Ro AGAINST BAR). Tae Roo Tonaro REAR, Forcine Ba Our OF Housing Ano AuLow Roo) To Side Over BALL AND SPRING AND PROTRUDE SEVERAL INCHES FROM HOUSING. Place First Ano SECOND SPEED Suirt Fork®) Ow Seur7 Rov. Tap SHiet Roo To_PROPER POSITION . Lock Fork Qv Roo With Lock Screw ©; Eno OF Lock SCREW SHOULD SEAT In Hote @ On Roo. Sune First AND SECOND SPEED Ser Luc @ On Roo Ano Lock With Screw ®; Eno OF Lock Screw Srouto SEAT In Hoe @ On Stuer Rod. [M3AISC-BH-D’- 74 (40)]BASE SHOP DATA-Issve Or 107-49 SHEET VEHICLE UNIT Su6-ASSEMBLY Maal \D QUEREAL TNSHSSON [|| 15. o¥ a ® @ axe Serine ® Ano Puunaer © Inro é bes t io _ Sars Lue © Fk. | Secure In Pace Wir CaSTELLATED Nut (BLY OF REVERSE SHIFT UNIT Lock Winn New CorTer Pin). Nore: Set THAT HEAD OF PLUNGER®) Is FiusH Wo Face OF Sturt Lus®, Peace ireraocx Pounce © Bereeen Two Hoxes G) Ano @ In : Hesse D, Usins A Wik AnD SWALL ScREWORNER. (See Fis. 2.) @ sc Seens® Ao BaD Wn Hee) Soe AB (Less © Taaw SHAFT DAMETER) INTO SHAT HOLE Frou REAR (LerT) Sioe Over © Ba. Pare UP ON Bar Ano Press Down On Bau. Sune Reverse Sur Rap @ iro Housine, RESTING Roo AGAINST fae @. Tae Roo Towano Rean Forcinc Bar Our Or House Avo Aucowmns Roo To Stipe Over yp SPRinG AiO PROTRUDE Several Incres From Housie. Prace Reverse Suir Forr(©)On Swtrr Reo. Tar foo To Rear To Proper Fosrrion. D~§ €8)sex fcc seo wr Loe rev Fi 3, Eno OF SerEw SHOULD SEAT W Ha ®) Ov foo. Sune SHET Lus © Ow Roo Ano Lock QF wim Screw, 6.0 OF Screw Spon Sear ge Qn tereD On Ser Foo. 467BASE SHOP DATA-lssue OF 107-8. or — OVERHAUL ear D “Bowe ean TRANSMISSION [) } /6 VEHICLE. M3Al Scout CAR. ASSEMBLY OF THIRD AND FOURTH SPEED SHE UM &) “Sune fast Aw SeconD SuET Ur @ Fic.1 Aw Reverse Sauer Wut @ Inv Neuraa. Position. (SHIFT Forns ARE STRAIGHT ACROSS ‘Housing ©) ROM Exon OTHER) Pusu Inreatocn PLuvctRS©) Ano © (Berneen Hates OO, MO ®) Wnro NeuTRAL Norcnes Ov Suet Roos So Tua PLuncers ARE Nor PROTRUOING Inro CENTER “Sur Roo Hoe) Unoea Hove ©. (See Fic.2.) puace Spante ® Ano Bar® Ww Hare @, race A Bm GD (Less Thaw Sst Roo ‘Diawerer) Ino Roo Hour From ReaR\LErT) Sibé. Putt UP (Ow Bar Ano Press Down ON BALL, Dae Jaro Ano FourTa Sarr Luc @ In Proper Posirian in HOusin ©. 72 Soe Sart Roo®) Tarouc SHET Luc Ano INTO HoUsiNc, Restinc Rob Acanst Bar @ Tae Roo Towaro Rese, Forcinc Bar Our Or Housinc AND ALLOW Roo To SLIDE OVER aut AND SPRING AND PROTRUDE SEVERAL IncHES FRoM HOUSING. RH SCBF D164)BASE SHOP DATA-Issue Of-10-7-42 D OVERHAUL | Te vcmsion DI VERICLE M3Al ‘SHEET | iA oerene POWER TRAIN lor 40 ASSEMBLY OF THIRD AND FOURTH AO ar NTE SHIFT UNIT ©-+* tO —— oY @ PLACE Thro Ano FourTH SPEED SwFT Fork @ Ow SurT Roo). Sune In7er.ock Pin © Tirouset Hote ©) In Sie Roo. Tae Stier Roo To ‘UTRAL Fosimion. (WoTE: BE Sure Thar InTerLock Pin Does Nor Fat Our WHEN SHAFT To REAR.) O Swine Fork ON Roo Wirn Lock Screw©) Searina In Houe® On Rod. ) boc SwirT Lus @ On Roo Wit Lock Screw @ Searme In Hote Q) On 1 (M3AISC-BH-DI-1? 0) 469BASE SHOP DATA-Issue OF /0“7- #2 $ VEHICLE UN IE | (Sus: ASSEMALY SHEET aa |B eet lrenawscer 0 |18.| @) CHECK SHIFT UNITS@),@,AND © To SEE Tar THREE Bates ®), Two Inrercoc PLunsers®) AND PIN@ARE Funcrionine Wire Norcnes IN Toe SHiFT Roos (Ee 2). (78) Lock Aut Lock Scaens @ Fis.| Wire SAFETY WIRE THROUGH THE HEADAND AROUND SHIFT RODS. Drive Taree Pluss @InTO Hotes ON Housing AND FLATTEN PLUG USING SMALL HAMMER . 470BASE SHOP DATA: Issue Or 1-17-42 8 VEHICLE ‘UNIT Vi HA ‘Su8-ASSEMBLY SHEET MAI eT TOMMIION D/ | 19. SCOUT CAR, OVERHAUL OF FLANGE,AND BEARING CAPS. wa INSPECT SPLINES @ In Companion Fiance ©) FiG.1, FOR |) Nicks. InspecT Face © ON FLANGE FoR Bene BENT AND HUB @© For Excessive WeAR. REPLACE IF NECESSARY. © Inspect MainsHarT REAR BeaRine Cap © AND COUNTERSHAFT Rear Beane Cap © For Cracks Or Damace. REPLACE IF NECESSARY. ROLLER BEARING, AND SHIFTING HUB. @) Cueck Main Drive GEAR Bearine CaP @) FiG2, For Cracks OR DAMAGE. REPLACE IF NECESSARY. Fig. |. © CHECK ROLLER BEARING @xfOR SCORED OP WoRN ROLLERS. REPLACE IF DAMAGED. =) A= & Inspect THiRo AND FourtH SHiFT Hus QD For CRACKED, BROKEN, OP BADLY Worn TeeTH. IF UsaBeé Burr TéeTH AND Grin Nosé OF TeETH RounD. IF NECESSARY, REPLACE. .@ M3AI SC-BH-DI-I94) 4BASE SHOP DATA-(3suc OF 217-42 CVenese UNIT ‘Sus- ASSEMBLY [SHEET Maal | 0 Reem] eacissan Dy | c B40 OVERHAUL OF CLUTCH RELFASE ASSEMBLY © © 8) peceer cures Pow Snarr @ Ano Srus SHAT x = @® for Wear AnD STRAIGHTAESS. Inspect Two Kerways ©) Ano Two Wooorurr Keys for Wear Or Burrs. Repiace PARTS IF Nor IN Usaate ConoITION. ak INSPECT CLUTCH YOKE €) FoR STRAIGHTNESS, ANO WEAR AT CONTACT Ponts ®. INSPECT Hotes @). REPLACE Yoxe FF NECESSARY. INSPECT CLUTCH RELEASE BEARING CARRIER @ FoR CRACKS, Damace, OR Wear AT Your Contact Ponrs QD. CHECK To SEE Thar Ou. Hove ®) 1s Not PLUGGED. REPLACE CARRIER IF NECESSARY. OV porare Beare © To SéE IF BEARING Miu. CHATTER From Worn BALLS AND RACES. REPLACE IF DAMAGED. 30 INSPECT SPRING @ FOR DAMAGE. IF DAMAGED REPLACE 9/ QveRHAU_OF BELL HOUSING ‘WsPECT BELL. Housins @ For CRACKS OR DAMAGE. Inspect Two Q.urcty SHAFT Howes ®) FoR WEAR. NSRECT TREE ALEMITE FirTinGs@) For DAMAGE. FORCE GREASE Tarouce THEM To CLEAN. QZ.) Inspec Four Sruos@ For Srmpen Or BarréreD TRREADS. INSPECT CLUTCH RELEASE BeARING Ou. TUBES) AsamsT Banc PrusseD, Bent, Or BROKEN. RepLace Bett Housing OR ANY OF THESE PARTS IF NECESSARY. [MSATSC-BH- DF 204 47BASE SHOP DATA-lsse OF /017-40. iT VEHICLE, ONT OVERHAUL | SuBASSEMBLY MGA D POWER TRAI TRANSMISSION DI 2 si DISMANTLING MAINSHATT ASSEMBLY” (93) Remove Swap Rive @) FROM MunsHArT @). SPREAD Ring Ano Lit WiTx Two Screw DRIVERS. (4) Remon SPuine Wasi ©) Ao Plax Taiko SPEED Gear® From Mamsnarr. PLACE 36 Roccers ©) From Gear) Iv A ContainéR. Remove Busine ©, Loew ©, Ano wasver @ From Mansnarr. Remove Secon SreeD CER @) From MamsnarT AND PLAGE 34 Raweas @) From Gear @) A CowraineR. REMOVE SECOND SPEED Gear Spacing WasHeR Q From MAINSHAFT. (ASC BHDI-2 1 FO) 473BASE SHOP DATA-Issue Of 4-17-424 VEHICLE UNIT : OVERHAUL UB-ASSEMBLY SHEET. MGAl | D “Foner tean| TPAMOMSION 0) | a OVERHAUL OF MAINSHAFT INSPECT THIRD SPEED GEAR TEETH @) AND IN MESHING TEETH @) FoR CRACKED, BROKEN, OR SURRED TEETH. INSPECT BEARING Surrace © For SCORES. GRIND NICKS FROM TeeTH Ano Rounp THE Nose OF THE INTERNAL TEETH. IF BEARING SURFACE IS SCORED, HONE SMOOTH, REPLACE GEAR IF NECESSARY. InsPECT SECOND SPEED GEAR HELICAL TEETH ©) Ap Low Gear MesHing EetH © For CRACKED, BROKEN, OR Worn TEETH. INSPECT BEARING SuRFACE © FoR SCORES. GRIND NiCis AND BURRS FROM TEETH AND #0UND The Nose OF LOW GEAR MESHING TEETH. IF BEARING SURFACE /S LIGHTLY SCORED, HONE ‘SURFACE; REPLACE. 1G. 2 CHECK REVERSE , Low,AND SECOND SLIDING GEAR TEETH © AND INTERNAL TEETH @ FoR NicreD, BuRRED OR BROKEN TEETH. CHECK Spune @ For Wear ANO Burrs. Remove Burrs FROM TEETH AND SPLINES. GRIND Nose ON FRONT OF EXTERNAL AND INTERNAL TEETH. IF-GEAR IS DAMAGED, REPLACE. (M3AISC-BH Di-22(40) 474BASE SHOP DATA-tssue OF /0-19-004 [sneer VEHICLE UNIT Sus-ASSEMELY WisA| | QE RHAL rensmisSon Dy “2 3 Power TRAN 2F OVERUAL OF MANSAET E-0 Inspecr Tiree Wassers@,®, AO For Score, fic.1. tf Score, Rena (Oy ae, ® Ivspect NekDLe BeaRines©) Ano © For Scores Ano irs. It Scorea OR PirTeD, REPLACE. (0?) nsrecr Busuine (@) For Scores. IF re (Ci) oer Repcace. CHecn BusHing ko Lock PIN©® For Wear. REA It NECESSARY (PD) insecer SpaceR@ FoR Cracns OR Damace. Repract Ie Damacto. (2) InspecT REAR MamsxarT Bearinc@) To Cheon For ScoreD OR PITTED Races AND BALLS. REPLACE IF Gearing Does Not Ratt SMOOTHLY. Remove SNAP Ping®) WHEN CLEANING Bearns@). Inspect MawsuatT(L) Fic.2 BETWEEN Cewrers OF LATHE FoR STRAICHTNESS. INSPECT SPLINES @A),@, Ano) FoR Wear Ano Burrs, INSPECT _ BEARING SURFACES @,@), AND©@ FoR SCORES. Jp Usable, GRIND BURRS OFF SPLINES. Je. Bacty Worw, Benr, On BEARING Suresces ARE Score, REPLACE SHAFT. 475BASE SHOP DATA-/ssue OF 1017-998 "yh BEAL etbiO" P| POWER TRAIN 2 oF 40. ASSEMBLY OF MAINSHAFT. 0! ate Ones q CLamp Mainsuart @ UpriGHT in A Vise, Usine Sorr JAW LINERS. SLIDE WASHER @ OVER MAINSHAFT AND INTO POSITION. CE» PLACE SECOND SPEED GEAR © Over MainsHarT AND Pest IT On Waser ©. ‘SHEET INSTALL Taree NEEDLE Be ares © BETWEEN MAINSHAFT Ano GEAR. (APPROXIMATELY EQUAL DISTANCES Apa). SHove NecoLes Down Asainst WasHER @. ASSEMBLE REMAINING 3/ NEEDLES. (OIL THOROUGHLY). Note: BE Sure THERE Is Space For AN ADDITIONAL NEEDLE WHEN ASSEMBLY Is COMPLETE. Do Nor PLace A NEEDLE IN THiS SPACE. Phace WasHer © Ov Top OF SECOND SPEED GEAR ©. Supe BusHinc © AND Lock Pin. © OVER MAINSHAFT, RESTING Busting ON WASHER ©. PLACE THIRD SPEED GEAR ® ON Waser Ano Supe 36 Necove Besrines QO In Pace Bergen MAINsHAFT AND Gear. (Oi THOROUGHLY.) PLACE SPLINED WASHER ® ON GEAR ®. w Pace New Swap Pins © IN GROOVE @ USING RING EXPANDER. (3AISCBH-DF OF GO] 416BASE SHOP DATA-/ssue OF 700-94 [WenIcLe nr Sos SEMEL EEF RBA | 1) REAL etisinssan py) |"2.5 POWER TRAIN 40 SCOUT CAR DISHANTL,; TRINSWISSION _COUNTERSHAFT. Remove Snap Rinc @) From Couer Suarr @) Fic |. Press Ore Drie Gear ©) Ano Turd Sreeo Cean@) Wit HyDRAULIC ‘Press, OR OTHER PoweR PRES? AVAILABLE. (iyrowe Two Wooorur Keys ©) WirH a HAMMER. Cor OF Static Wn Noron®) On Man Dave Gurr © Fic. 2 WITH Cop CuseL, Avo Remove Bearing RETAINER NuT @. Go bine Susr Ar @ 0 a Exo OF gut Ow A BLooK OF LeAD To Remove Bearine @). 47BASE SHOP DATA-1sue OF 1-17-4306 ee a ee M3Al | D ee TRAISSON DI) 28 SCOUT CAR. OF OVERHAUL OF RSHAFT I waster @ For Sec oa ewe tel o @® (18 )nsrecr ROLLER BEARING @ FoR SCORED ROLLERS AND RACE. REPLACE, 5 C&S) fF DamaceD. i (U9 seer Taino Seeep Gear @) Avo COUNTERSHAFT Drive CEAR@) FOR BurréD, BROKEN, Av Worn Tee TH. Inspect Hey Scars For WeAR AYO Burrs. Remove Burrs Frow GEAR Teer Ano Key SEATS. REPLACE IF NECESSARY. 120) spect CouvrensnarT (© BETWEEN CENTERS Or LaTHe For STRAIGHTNESS, Fic. 2. InsPECT CERS@ AtD@ For NecreD, urpep, OR BROKEN TEETH. INSFECT ROLLER BEARING SURFACE @ for Scores. Inspect Key SEATS@® For NcKS AND WEAR: Gain OR Hone Burrs OFF Key Sears. Ir SHAFT is BENT, Reaact. Ip Swarr Is SernceaBle, Grin OFF Burrs AD Roun Tae Ends OF TeeT#. (e}ypsrter Boxe To Caeox For ScoRED OR PITTED Racks ‘On Bas, Ie Bearinc Does Nor Row. SwoorHur, REPLACE. fic2 A SCBHD/-26 (FO) 478BASE SHOP DATA sue OF IPAS VEHICLE UNIT VE SuB-ASSEMELY ‘Si WA) | GEBHAL reansmissow D |) 27 Scourcar OVERHAUL OF MAIN DRIVE GEAR ASSEMBLY @Quve. Drive Gear Ap Sart @, Fic. 1, BETWEEN CENTERS OF LATHE For \STRAIGHTNESS. CHECK INTERNAL (E) AND EXTERNAL. TeeTH© FoR CRACKED, Broren, OR BupreD Teer. Inspect SpLines © For Wear, BURRS, Op Mens, Insrect Oursiog Beaune Race ©) For Scores OR WEAR. Ie Drive SHAT-IS IN A SERVICEABLE CONDITION, GRIND NICKS AND BURRS Grr OF Spunes Ano Cem TeeTn, Gano THE Enos Or lnrenna, Teer Rouro. nsrecT Bese ®) To CHecr Cuasety For Scoreo On PrrreD Races ‘Or Baus. If BEARING DOES HoT Rott SMOOTHLY, REPLACE. OVERHAL OF IDLER SHAFT (2Aperect loner Sturt ©,Fic. 2, FOR STRAIGHTNESS, Wear Ab Scores. Rewact I NECESSARY. yspECT IouER GEAR) For Worn OR BROKEN TeETH, Round Enos OF TeetH Avo Remove Burrs. REPLACE IF Dawaceo. Inspect Busuinc D: For Wear OR Scores. lf DAMAGED, Press Our Busninc, Aub REPLACE Wirw New Ream To Size ik NECESSARY. 474BASE SHOP DATA-lssue Or 1-17-42-$. VEHICLE ‘UNIT Ol ER A ‘Sua-ASSEMELY ‘SHEET M3Al | D toner resin TRANSMISSION) 28 cour CAR 40 ASSEMBLY OF COUNTERSHAFT. © © @nsras Two New WoonrurF Keys #X/4X%. @ Into Kerways @ On CounrersHarT © FiG.! With LeAD HAMMER. 27 Press SECON AND THIRD SPEED GeARS @ Ano ©) On CounTeRSHAFT WITH HyDpAULIC Press, Use Werte LEAD ON SHAFT. Be Sure Key Wars @In Gears ARE IN LINE Wot Keys ON COUNTERSHAFT. ® PLE SNAP RING © In GROOVE @ ON COUNTERSHAFT WITH SNAP RING EXPANDER. SUE WASHER Q) ON COUNTERSHAFT. ASSEMBLY OF MAIN DRIVE GEAR UNIT. : SUDE BEARING ® Over Main Dawe SHarr © Resrine BeArine On THREADS @), Fi2. PICK UP UNIT, HOLDING SHAFT ©,ANO Jar GEAR @ ON LEAD Block. GREASE THOROUGHLY AND PRESS ON BEARING. Screw Nur ® Ow Sarr © Ano TihTEN Wir Nur WRENCHES, HOLDING SHAET © In VISE WiTH SOFT JAWS. SLIDE MAINSHAFT FLANGE @ Ow Sune ®. WiTH SET Punch AnD.HAmMmer Stake Nut Into NorcH ©. [MBAISCBH-DI-26 40) 430BASE SHOP DATA 1390 gay VEAICLE UNIT oH, TAU. jU8- ASSEMBLY SHEET MBA 2 HERA NSHESIOV [) / 29 | SCOUT CAR Remove THREE Cap SCREWS @Ano Lock wasters @) Fron Trawsuassion CASE ©, Fi. Remove Two Car Screws©) ‘Ano Lock wasters ©. Revove Fuser Plus® Avo IwsPEcr TRANSMYSSON CASE FOR CRACKS OR DAMAGE. IF CRACKED OR DAMAGED ‘Nor REPARABLE, REPLACE Wir NeW CASE. INSPECT ALL THREADED HoLes ®) ‘Ano Stuns) Fie 2, For STRIPPED THREADS. IF THREADS ARE STRIPPED AND Cawnor BE WELDED, ReDRIwED Ano RETAPPED, REPLACE Witt A NEW CASE. See Thar Ont RETURN Howes © ARE ThorousHLY CLEANED. [RAISED GO) 481BASE SHOP DATA-Issue OF /-/7-42$ VEMICLE uNiT OVERHAUL Sus: ASSEMBLY EET MSAI | D~Fomee renn| Pavsmssion D/ [ 3Q Scour CAS 40. ASSEMBLY Nore: Use New Cor7ER PINS, WASHERS, AND OI SEALS INASSEMBLY. OIL ALL SLIDING SURFACES Wir Motor Ort. ASSEMBLY OF COUNTERSHAFT IN TRANSMISSION CASE 8 PLACE COUNTER SHAFT(Q)IN TRANSMISSION CASE® WITH WASHER(C) ON COUNTER ~ “i? D er Drive Rower Bearine(D)inro Case, Wit © Drwer ©), Fie. 2. 7004 purs.NO. SLIDE FRONT OF COUNTERSHAFT INTO RoLLER BEARING AND DRIVE IN BALL BeaRING (CLOSED TYPE) ©) In REAR OF CASE, WiTH DeiveR@©). ROTATE SHAFT TOSEE THAT IT TURNS FREELY. 14.1 \Place BEARING WASHER (R)AGAINST COUNTER- “SHAFT AND SECURE WITH Tivo CAP SCREWS () ‘Anb Loc WASHERS @). (Dene Pus) Listy INTO TeAMsMISsiON CASE ‘AND Lock WITH SNAP RING (R)/N Groove ©). [MSA/SC-BHOyBASE SHOP DATA-tssu OF 12-17-4.4 VEHICLE fuNiT OVERHAUL Ue ASSEMBLY SHEET “MASAI | Soret, MEMS |) | 3 i ASSEMBLY OF SIDE CORR PLATES TO TRANSMISSION CASE” (®) APpLY GASKET CEMENT ON TRANSMISSION CASE Fiance fic.) Place CasneT ®) Ano Cover Plate © AcansT Case Ano Secure Wir Six Car Screws ©) Ato Look wasers ©. Repeat Asove Orerarion For THE Cover PLATE” ‘On Tue. Opposite Sie OF THe Taawsnaission CASE, FIG. 2. Place lover Gear ©). Into Pasttiay ‘Ow LEFT Rear Sine OF TRANSMISSION Case@. Deive lover Swarr © Wwto Case Ano Tipouch Inter Cear WiTH A LEAD HAMMER. Cre Jour SHAFT Lock @ Ino SLor@) Avo Secure Wir Cap Scaew ®) Ano Look Wasver ©). 483BASE Biciad alam OF 14d + UNIT }- ASSEMBLY _ REAL eiaSSON Py] | "32 © D POWER TRAIN GEM® ino Case (INTERNAL MESHING SruB-TeETH OJ © Tower FRONT OF Case) Fic. @ Sune Rear END OF MansuarT © Into GEAR @, Mesnine Tre Spuines OF SHirr Ano Running Eno\. OF SHarT OuT THROUGH REAR BEARING HOLE. SET YG, Fron END OF MawsHarT Down ON COUNTERSHAFT AND Sue MainsHarT TowaRD FRONT OF Case Into Position AT Sawe Tue. Drive ln Réar MamsHarT Bearing ©) Wirt Bearing Too. ©), Fie.2, TaP MAINSHAFT TOWARD REAR UNTIL FLUSH AGAINST BEARING. (ASSEMBLY OF MAN DRIVE SHAFT ‘SLIDE ThiRO AND FouRTH SPEED StuFT Hue @) NTO TRANSMISSION CASE MainsearT © Fie.t. —— Pace Secor BearinG @ nro Maw Drive Gear e XS @Ano Press Bearing QD Into" Transmission CASE ®) 6) Man Drive SHart © ONTO MAINSHAFT. 2 sur Siena GeAr@ InTO RevERSE, Low, AND SECOND Sreép Posirigns WirH SeiFT HuB IN NEUTRAL PosiTiON 70 } CHECK For Ease OF RoTATION By SPINNING Main DRIVE Gear Sur, Creck For Same WHEN Sune GEAR Is L1G2 "Iw NEUTRAL POSITION AND SHIT Hus Is In THIRD AND FourtH SPEED FosITIONs. 908795 ABATSC-BH- Oi 32 (40) 484BASE SHOP DATA-Issuz OF /0-17-424 VEHICLE UNIT ‘Sus- Asse ney SHEET Maal |D CRRA \resnaiion D) | 33, @ Press FeiT Ow SEAL @ INTO REAR MAINSHAFT BeaRine CaP ©. @ APPLY. GASKET CEMENT To TRANSMISSION CASE © AROUND REAR MAINSHAFT- Bearing ©. PLACE GaskeT © AND BEARING Cap ® AGawsr Case AND SECURE WiTH Four CAP Screws @® AND Lock WASHERS ©. (Tree SHORT AND ONE LONG ScREW.) : © Appcy GASKET: CEMENT To TRANSMISSION CASE AROUND REAR COUNTERSHAFT BEARING @. PLACE GASKET @ AND COUNTERSHAFT BEARING Cap ® AGAINST CASE AND SECURE WITH Four CAP Screws © AND Lock Wasners @. SLE SPACER @ ON MainsHarT ® AND Dpive ON. COMPANION FLANGE @ WITH LEAD HAMMER. @) screw Nut ® On Saar Avo TicHTEN. Lock Wir Correr Pin ©). (M3AISCBH-D/-33 40) 485BASE SHOP DATA-sssur OF 17-429 ! VEHICLE, UNIT VE ‘Sus-ASsem BLY ‘SHEET i M3Al| 1) CER RAUL eaiciaiSa0N [> | | 34,1 l scour CAR = OF CL % b g ELL HOUSING TO TRANSMISSION AE ( APPLY GASKET CEMENT TO TRANSMISSON 3s CASE®@ ARouno Maw Drive SHAFT BEARING E @ fah i= PLACE GasxeT © AND comme Cap ©) Acamsr Case Ano Secure Wir THREE One Screws © ANd LOCK WASHERS ©, Omir CaP Screw From Top Risar HOLE @, (Screw Two Thin HEADED CAP Screws In BorTom HOLES.) © nx CASE Ano, Secure In PLace Wit Four Nuts QD Ano Lock Wasners ®, Fis 2. B QDene Cup © WiTH Sprine @ AGAINST BEARING CaP AND BELL Housing l= ANO Secure With CaP Screw @) Ano { Lock Wasner ® Fig.3. PSAISC-BA- DI 3407 486BASE SHOP DATA-Issuz OF 1017-424 VEHICLE UNIT Sua Assemaeuy SHEET MBA | Sa AMON 2) | "35 ASSEMBLY OF CLUTCH RELEASE BEARING CARRIER UNIT. Press Bearine @ ON CuTcH RELEASE CarnmiéR ©); FiG.|, WITH A HYDRAULIC PRESS. SLIDE StuB SHAFT © INTO HOLE OIN BELL Houins ©, FiG2. "© Powe Yoxe © INTO Posmion Ow Stus SHAFT. @ SLIDE CLUTCH PEDAL SHAFT © THROUGH HOLE @ IN Bett HOUSING. Drive Two WoaprurF Keys @ Wwro Stars ® ON Starr ©. Orie SHart @ Into Hoe © In York. Screw Two Lock ScREWS @ INTO YOKE, SEATING IN'V"GROOVES @ IN SHAFTS © AND @. SECURE LOCK ScREWS WiTH SAFETY Wine THROUGH SCREW Heaps ANO AROUND SHAFTS. ‘ SLIDE CLUTCH RELEASE BEARING CanniéR @ ONTO MainsHAFT CAP ©). Hook Spine @ ONTO BEARING CaARiER AT HOLE ®. (3ATSC-BH-DI-35(40) 487BASE SHOP DATA /ssuz OF /h/7-42 8 VEHICLE ir OVERHAUL Se eee SHEET MIA | D. ~Panee renni| PAEM SIN D Ser Cae Fr © ASSEMBLY OF SHIFT BAR HOUSING TO TRANSMISSION CASE Apply GASKET CEMENT AND Place GaskeT @ Ow FiaceOn Top OF Transmission CASE®). Ot Tor SiE OF GASHET. Move SLIDING GEAR ©) AND FIRST AND SECOND SPEED SHIFTING Fork ©) FoRWA#O INTO SECOND SPEED PosiTioNn. supe SHiFT Hug © To REAR InTo THIRD SPEED POSITION, ALLOW THIRD AND FOURTH SPEED SHiFTING Fork ©) To REMAIN Iv NEUTRAL POSITION. ser Housine@ Ow CASE © (fear Eno CouracTs FinsT), REVERSE Fork ® Sues Onto loLer Gear D AND Suirtinc Fork © SLIDES ONTO SLIDING GEAR ©. Lower Front END OF HOUSING Jwo SHIFTING Fork © Wit SLIDE ONTO SHIFT Hus €) AND Move Hus FoRWwARD INTO NEUTRAL POSITION IN SAME OPERATION. @ SECURE HOUSING ON CASE WITH SIX CaP Screws © AND Lock wasners ©. 498BASE SHOP DATA-Issve OF 1017-434 L vewete wr OVERHAUL| = mer M3Al | D ~ Ponce rea} PAO"SION DI ASSEMBLY OF SHIFTING LEVER UNIT Housi ) Move SuiFrins Luss @), @ And © nro NEUTRAL POSITIONAS SHOWN IN Fig. 2. SHEET APPLY GASKET CEMENT ON FLANGE OF SHIFT BAR HOUSING ©), Fig./. Fig. 2. PLACE GASKET @AND SHIFTING LEVER UmiT @0N Housine AND Bor. Down WiTH Four CAP SCREWS @)AND LOCK WASHERS @. (MSAISCBHDI37(40) (MoM CE 489BASE SHOP DATA-Issue OF Amar d VEHICLE UNIT OVERHAUL. ‘SUE- ASSEMBLY EEF oF 40 M5A || D pone ren eronssioy Di |. 38 TESTING TRANSMISSION _ 2 @ Horst ANO SET TRANSMISSION @) ® / le On Test Stano. Fasten To STAND att Sk Witt CROSSBARS®AND BOLTS ©. eet) eh Naeeryec Des (7) Stine RUBBER SLEEVE ©) OVER as END OF SHAFT @)ANO SLIDE SPLINED FLANGE AND IMPUTUNIVERSAL SHAFT ©) Fie.2. ONTO DRIVESHAFT ©). eae amerien @) Remove Plus @AnDBe Sure PLuG @Is TiGHT IN TRANSMISSION CASE. POUR SIX AND ONE HALF QUARTS SAE.#E0 AIRCRAFT ENGINE OIL INTOCASE. ‘Sraer TesT1ne Moror Q) (1800 RPM.) Fis. 2. DISENGAGE CLUTCH WITH LEVER@AND THROW TESTING TRANSMISSION INTO SECOND GEAR Win Lever. (IOOORPM, OF INPUT SHAFT ©) ENGAGE CLUTCH AND ALLOW TRANSMISSION @) TO Run AFEWMINUTES To CreCULATE OIL. Fig. [MBAISCBH DIS 840) 490BASE SHOP DATA Issue OF Wi p-4e 8 SHEET. VERICLE iH OVERHA y8-ASSEMBLY TRANSMISSION [)/ MBA! POWER TRAIN TESTING TRANSMISSION. SHIFT Transmssion @ Fic. I. InTO ALL SPEEDS Wit Alp OF CurcH LevER © ON TESTING TRANSMISSION ©). NOTE EASE OR DIFFICULTY IN SHIFTING. ®) SHIFT TRANSMISSION @ INTO FourTH SPEED AND ALLOW To Run for AT LEAST ONE HALF Hour. CHECK THE CASE For Oit LEAKS AROUND GASKETS. AFTER Oil AND GEARS ARE THOROUGHLY WARM FROM RUNNING, SHIFT TRANSMISSION * @ INTO ALL SPEEDS. SHIFTING SuouLn Be Easier THAN AT First. CHECK ALSO FOR UNUSUAL. Stop Tesine Morar © FiG.2. RENWOvE Bats © Ano Gross Bars ©, Fic. h. PULL INPUT SHAFT @ AND RUBBER SLEEVE @ FROM TRANSMISSION @ AND HoisT FROM TEST STAND. THe TRANSMISSION 1S READY TOMBE i ASSEMBLED To SCOUT GAR. Noses. 44 M3AISCBHDIS94O)BASE SHOP. eee OF [0-1 he 4, : VEHICLE TH OVEPLAUL | Sue AEE? REET. M3A/ D Power TRAN TRASMISSIOV D / ce Tous REQUIRED 931057 | 36 333083 | 3B 778 ae fool DUENO| SHEET | OPER DET. gos79¢ | 30 | 739 | E 3oa7es | 30 | 40 | 6 ‘goe79s | 32 | 749 1 E z & (MBATSCBH 4040) 492BASE SHOP DaTA-Issuc Or fof vance unr OVERHALI,| SrAssemeer “eouca. | VALVE, Waal |e eee” ae, £9 ‘Nuweers In CIRCLES DENOTE OPERATIONS. FOLLOW IN ORDER. Use New Parts Onur When Necessary. WhEN ASSEMBLING, LUBRICATE ALL PARTS WiTH ENCINE OIL. SHEET oO Remove Four Cap Screws Ano Wassicrs @. Renove THe Vave ®. Rawowe Te CaveT ©. Was Ax Parts THoroustir IN GASOLINE, ANO DRY WITH COMPRESSED AIR. @ inspect Vave®. IF Wear Is APPARENT OR Ik RuBEER US HARDENED, REPLACE WITH NEW. Renew Ano RepLace Tue Caner ©. Drevase THe ABOVE PROCEDURE WHEN ASSEMBLING. MoAC-EREFUT) sam Vacuum Booster Vaive_._66 493BASE SHOP DATA -Issue OF 14/3/42 C WeHeLE our OVERHA Pe y SHEET. M3 A / Gye eae Mi ie B30 / ory INTAKE ~ HEAD DIAM. 34" EXHAUST ~ HEAD DIAM. 196° @ ees DP ® Wasw IvmaKe Ano Exwaust Vauves @, SPrines ®, Serinc Cap ©,PusH Rod @ Ano Varve SPRING SEAT Pin © Usive A Wire Brush. Wash IN PETROLEUM SOLVENT To Remove Ois Avo Day WitH COMPRESSED AiR. BuFF AND POLISH ‘ALL SURFACES, Gea Vawve HeADs To A 45° ANGLE WitH A’BLACK AnD DECKER’ (TYPED) SUPER SERVICE VALVE REFACER OR ITS EQUAL. GRIND SMOOTH Avy RouGHNEsS OR Pits AT ® AND ©. GRIND PusHRoD AT @) UNTIL SMOOTH. GRIND ANY Routes AND Pits Ar @) INsPEcT Vanve Srems For DisToRTION Or WaRPAGE ‘AND DISCARD IF NECESSARY. INSPECT VALVE SprinG Sear Pin © FoR WEAR. Replace WITH New /F WEAR IS APPARENT. INSPECT TENSION OF SPRINGS ® IN Rimac’ SPRING TESTING MacHiNe OR Equat. FREE HeicHT OF SPRINGS. ARE 236 INCHES. WITH 46 Las. OF PRESSURE ‘SPRINGS SHOULD MEASURE 16 INCHES IN HEIGHT. Valve Assembly & Push Rod... 67 445496FAGLE oe SHOP DATA~-/88ue OF Withee t i cg Suds nasemy sar / OVERALL ineets [4 D pwn Teun TIRES Dé REMOVAL OF TIRE FROM WHEEL NOTE: NuwBERS IN CiRCLES DENOTE OPERATIONS, FOLLOW In ORDER. ors J Dar To. In SLor@ Ano Pry Down Usiwe A Hammer© To Pouno Rin fig. OFF. 7: Att Tous Ustd On THE FOLLOWING SHEETS ARE STANDARD TIRE oous ® Turn Wee. Over On Btocks Or A Fixture Asour 12” HicH. DRIVE Tht Tire ©) OFF By RAPPING ON THE OPPOSITE SIDE FRoM VaLve Stem Wire ARueeer MaLieT ©). Push VALVE STEM THROUGH Hole To COMPLETE THE REMOVAL. Wheels & Tires..... 497BASE SHOP DATA-/ssuk OF tft. ENO [oar Sus= ASSEMBLY | Wee MAL OVERHAUL WHEELS C C. Power Tram | TIRES OF 5 CAR. REMOVING TUBE FROM _TIR} Fig. @ THROW THE SPREADERS Our To Position @) As SHOWN IN Fie). To ADMIT The Tire@). CLOSE SPREADER, AND ADJUST SNUGLY UNDER BEAD OF Tire, By Roraring Wee. ©, Put Lever) As INDICATED To SPREAD Tine@. Remove THe LineR © Ano ExtRact THE TueeE; From THe Tire. THE Tire Is Now Reapy To Be Examined IM3AISC ~BH-06-2(5)| 498BASE SoP DATA -(95ue OF selniee c VEHICLE ae OVE ‘Sue- ASSEMBLY SHEET MAL |\D QUERHAUL) “ices Dé| 3 CAR. Power Train TIRES OF. REPAIR OF TIRE AND TUBE @ VULCANIZE ALL PUNCTURES OR Tears Causine Exposure OF THE Cord. ) A MIXTURE OF LIQUID SOAP AND FLAKE GRAPHITE, MixED To A ConsiSTENCY OF PAINT Is APPLIED ON OUTSIDE SurFace OF Tire @) Wit A Brush. This SOLUTION Wine CounTERACT THE GREASE AnD On. That The Ties Have COME IN Conracr Win. IT Has No Orwer Serious EFFECT Ov RUBBER Awo Witt RETARD Ri CORROSION. © Hoes IN BULLET ResistinG TuBe SHOULD BE REPAIRED WITH COLD PATCHES Ony, (SAME METHOD AS EMPLOYED FOR CONVENTIONAL TuBES.) HoT PATCHES OR VULCANIZING SHOULD NEVER BE ATTEMPTED. Fig.2. IM3AISC -BH- 06-3 5)| 494BASE SHOP DATA-/SSUE OF lRE VEHICLE fier OVERH UL 06 ASSEMBLY MOAI |) —eeRE gets DG Power Tram | TIRES weet 4 as OAR ASSEMBLING TUBE IN TIRE ” In EVENT A NEW Tuse /s Use, REMOVE Cap Ano Core To Let Air Escare. REPLACE Cap Oney. White TiRE 1S In Macuine @) In = Spreao Position, InseRT Tuse®) INTO Tire. Remove TiRE FROM MACHINE AND Lay ON FLAT SURFACE. TAP With RusBER MALLET UNTIL LINER IS UnpER THE BEAD OF TiRE® COVERING THE EXPOSED PorTion OF TUBE. SAISC BH -06-4(5)] 500BASE SHOP DATA -/sSuE OF mfafasl 0B- ASSEMBLY Wee [ear dD OVERHAUL WHEELS VE a, Ss Power Tran TIRES UT CAR. ASSEMBLING TIRE ON WHEEL QO) Heck Wee. For CRACKS, *"AND REPLACE IF NECESSARY. LAY TIRE @ On Floor As Shown, PLACE WaeeL INTO TiRE AT AN ANGLE So THAT Srem Wie Come Throuce Opening ON Fit ‘Si0e OF WHEEL. Repiace Cap With Too. ©). To Do This, Drop Eno OF Toot THRouGH OPENING ON Sioe OF Wee Aw Screw Ow To Stem©. Wir Use Or Too Put STEM ThRouGH THe HoLe AND UPWARDS. WHEEL Wi THEN Fatt INTO PLACE. Turn Whee. Ano Tire Over Ano Remove Too. @). Nore: Ir BEAD ON Rim OF WHEEL 73 Btuir OR BATTERED, STRAGHTEN. Force Ring ® Down Wires te pe ©. SreAby Opposite Sine OF RING ( WH AnoTHER Too.® As SHOWN. \e STARTING AT POSITION MARKED ©, Pouno Arouno Rive Wirw Hammer @ UNTIL RING IS IN PLACE. PLACE CorE In STEM AND Fill TIRE WitH 60 To 70 Pounos OF AIR PRESSURE. FIG.2. REPLACE CAR. MBAISC-84- 06-51 5) 501sozBASE SHOP DATA - Issue OF “fs/ex 7 VEHICLE Lar OQVERHA UL. (SuBASSEMELY SHEET LISAl | F retnanicac epson FB / [Scour ae ACCESSORIES INKAGE OFF AOTE: NUMBERSIN CIRCLES DENOTE QPERATIONS, & IN ORDER. FOLLOW My NOTE: Fire PADDLE ASEM, ae WDETAL OO WTHA LionT GREASE OR VASELINE. GREASE The Qursipe OF PARiLe AL30. Qu iave IvDETAUL AnD Yheve Ov fap CoveR Wy FiGe Wey Ligutiy Wit THREEIMONE One. ® Nore: USE ONLY NEW GASKET UPON. ASSEMBLY REMOVE AND CHECK Hose @fok LEAKS ET REPLACE IF NECESSARY. REMOVE WIPER Aem @ By Pune OuTwaepAT ©. IsPecT AnD REPLACE If NECESSARY. Puomenn terAsinar, \SMANTLE WIPER MOTOR) ‘AS SHOWN IN FIG..2. INSPECT ALL PARTS FoR WEAR AND DAMAGE. REPLACE ALL PARTS NECESSARY. CHECK PADDLE AND SHAFT AS~ sewer ©, BE Sure PLastic FasRic @)/s Nor Cu7 Oe Worn. te © /s Worn OR CUT RESIOVE RvéT @ Avo DISCARD OLD PaDDLe @, PLACE SHAFTS OD Iw NEwW PADDLE AS SHOWNAT ® Anb ReeveT. CHECK Baby © 70 SEE IF IT 15 CRACKED OR WARPED. REPLACE It NECESSARY. ASSEMBLE ACCORDING TO FIER. NOTE: @) LLUSTRATES POSITIONS OF PADDLE OSCILLATING MEGHANISIT PRRTS (RE CLEARLY. IMBAISC- BH-EBV0) asa me Windshield Wipers & Linkage.............69 S03SouBASE SHOP DATA-fs5u8 OF Beaded VERICLE wir OVERH, ASSEMBLY Seer Waal | Fo RRR WiRiNG Fy || ACCESSORIES bee SCHEMATIC. 4 ASC HFF-TS) tn Wiring 70 SosBASE ‘SHOP DATA-Issus OF /0-22-424 VEMICLE UNIT OVERHAUL| ‘Sue ASSEMBLY (SHEET M3Al |F “acre | WIRING F Scour Cae CESSORIES re _| SCHEMATIC WIRING DIAGRAM. [WSABC-BFT-2(8)| 506BASE SHOP DATA-issue OF 10-22-4214 VEHICLE UNIT OVE JAUL Sue- ASSEMBLY SHEET Maal | Fo SERBAULIIRING =F | \Scour Can ACCESSORIES og SCHEMATIC_WIRING DIAGRAM GENERATOR [MBAISC-BHFI-3 (8); S507BASE SHOP DATA Issut OF 10:22-4>4 marae da — Maal | F CRU ING] Scour Can ACCESSORIES ee SCHEMATIC WIRING DIAGRAM ~DusTerauTor-/GniTiON Go Lenmion Swircn- HEATER SwiTch 7M 1-50 @) , Masiro.D 4-45" % Y 4 ASSEMALY S fr pla-35*- To Flee Tan wire La fe 1 weet AG. = DISTeLaUTL FueL GAGE > 4-17 = WW) < Ne 1 ‘(nSTRLIME NT Qustee Htatee Seto cee #14-10" > 10 HEATER motor’ sd y Fuse > ‘dunicTiON Z iz Block esuian Swarce PEASC-BHFI-#(6) _] 508BASE SHOP DATA-Issur Of /0 20-25 VEHICLE WIT OVERHAUL |s-8, ASsemacr SHEET Maa \F BHA LTRING =F) [5 IScour Can. ACCESSORIES 14-10% Fuel Gauce Tan Umer [MGAISC-BH F155 (8) sodBASE SHOP _DATA- Issue OF _/8-22-4>4 nr ee ae TS) [scout Cas ACCESSORIES t GRAM HEAD _LAMAS-TAlL LAMAS” BLACK OUT LAMPS 4-170" ‘SERWCE TAIL LiguT SWITCH BLACKOUT TAL. "14-170 TOPLIGHT SWITCH (PRESSURE TIE) S10BASE SHOP DATA-Issut OF 10-22-42. 4 VEHICLE MIT OVERHAUL Sue ASSEMBLY ‘SHEET M3Al | Fo ~etermese| WIRING F | cic ACCESSORIES ore SCHEMATIC WIRING DIAGRAM DASH SWITCHE: LIGHT: sul WABCBHFT- 708)BASE SHOP DATA-Issuc Or /0:22- 425 Reproduced by. and Porrearat, VEHICLE UNIT OVERHAU! ‘Sus-ASSEMaLY SHEET MA \F Seeee WRING F/ | Scour Car ae OFS. SSCHEMATIC WIRING DIAGRAM HoRNS copies sold by Parse she

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