CHAPTER 5
DIRECT SUPPORT AND GENERAL SUPPORT
MAINTENANCE INSTRUCTIONS
Section I. REPAIR PARTS, SPECIAL TOOLS, AND EQUIPMENT
5-1. Tools and Equipment
and repairing the materiel. Refer to paragraph 4-1.
Tools and equipment and maintenance parts over
5-2. Special Tools and Equipment
and above those available to using organization are
Refer to appendix C.
supplied to direct and support units for maintaining
Section Il. TROUBLESHOOTING
Refer to tables 3-2 and 4-2.
Section III. REMOVAL AND INSTALLATION OF MAJOR COMPONENTS
5-3. Disassembly of Springs
amount of powdered graphite between the leaves as
a lubricant. Compress the leaves, using a large
Disassembly of the springs requies the destruction
of the rebound clips and center bolt. Inspect the
clamp or vise, and assemble a new center bolt nut to
spring assembly for cracked or broken leaves and
the center bolt.
clips. Do not disassemble it unless damage is found.
c. Replace the spring rebound clips with new
a. Remove the spring assembly from the vehicle
ones and assemble them so that the small clips hold
(para. 4-11).
leaves one through four and the large clips hold
b. Clamp the spring leaves together in a vise or
leaves one through eight.
heavy clamp so that the leaves will not fan out as
5-6. Disassembly of Taillight Assembly
the center bolt and nut are removed.
NOTE
c. Before loosening the center bolt nut, remove
the rebound clips using a chisel and hammer.
Refer to appendix C for other light
d. Remove nut and center bolt. The individual
assemblies
leaves are now loose.
a. Remove Door Assembly. Loosen the six screws
5-4. lnspection, Repair, and Rebuild of Springs
holding the door assembly to the housing and
Examine the parts carefully for damage. The center
remove the door assembly. The rubber ring gasket
bolt and nut are staked after assembly and will be
will come off with the door assembly. The door
stripped after removal. They must be replaced.
screws are removed by taking the ring retainer off
Examine the bearing in the eye of No. 1 leaf. If this
the screw on the rear of the door.
bearing is scratched or scored it should be reamed
b. Remove Socket Plates. Remove the two filister
or broached to remove the defect. Remove bearing
head machine screws holding each socket plate to
the housing. Remove the plates.
if inside diameter is greater than 0.5705 inch. If
removal is necessary, press the bearing from the eye
c. Remove Baffle Plate and Body Grommet.
of No. 1 leaf (fig. 4-6) using a bushing pilot and a
Remove the three machine screws holding the
small hand press. If reaming or broaching will not
baffle plate and body grommet to the housing. The
remove the defect, a new bearing should be in-
cables, socket plates, baffle plate, and grommet can
stalled. Replace cracked or broken leaves and clips.
now be removed by pulling the cables and con-
nectors through the large grommet hole in the rear
5-5. Assembly of Springs
of the housing.
a. Using a small hand press and a bearing pilot,
d. Remove Cables. Work the terminal connector
press the new bearing into the pivot bolt eye of the
grommets over the end of the cables. The connector
shells and bushings will now slip off the cables. Pull
No. 1 leaf. The bearing inside diameter must be
the cable through the body grommet. The cables
reamed or broached to 0.5655 inch after assembly
into the leaf.
will now slip easily through the baffle plate and
b. Assemble the leaves in the proper order using a
socket plates.
new center bolt as a stacking guide. Place a small
5-1
