1941-1945 Willys Jeep GPW MB Service Manual

WAR DEPARTMENT TECHNICAL MANUAL TM 9-803 %-TON 4x4 TRUCK (WILLYS-OVERLAND MODELMB and FORDMODELGPW) WAR DEPARTMENT . FEBRUARY 1944 Washington : 1947

WAR DE?ARTMENT Washington 25, D. C., 22 February 1944 TM 9-803, J/4-ton 4 x 4 Truck (Willys-Overland Model MB and Ford Model GPW), is published for the information and guidance of all concerned. [A. G. 300.7 (17 November 43)) BY ORDEROFTHESECRETARYOFWAR: G. C. MARSHALL, Chief of Staff. OFFICIAL: ’ J. A. ULTO, Major General, The Adjutant General. DISTRIBUTION:C&H (1). (For explanation of symbols, see FM 2 l-6) 2

TM 9-803 TRUCK (WILLYS-OVERLAND and KbR0 MODEL GPW) CONTENTS %K!TION 1 II III IV V . VI VII Introduction. . . . . . . . . . Dcacription and tabulated data. Driving control8 and operation. . Operation under unusual conditiona.................. First echelon preventive maintenance service. . . . . . . Lubrication. . . . . Tools and equipment stowage on the vehicle. . . . . . . . . . pmmgraphr Pmges 1 5-9 2-3 10-12 4-6 13-20 7-11 21-27 12-16 28-36 17-18 37-48 19-21 49-5 1 CART TWO-VEHICLE MAINTENANCE INSTRUCTIONS SICTION VIII IX X XI XII XIII XIV xv XVI XVII XVIII XIX Record of modifications. . . . Second echelon preventive , maintenance. . . . . . . . . New vehicle run-in test. . . . Organization tools and equipment. . . . . . . . . Trouble shooting. . . . . . . . Engine-description, data, maintenance, and adjustment in vehicle. . . . . . . . . Engine-removal and installation Ignition system. . . . . . . . . . Fuel and air intake and exhaust systems.................... cooling system . . . . . . . . starting nystem . . . . . . . . . . . . Generating system. . . . . . . . . . . . 3 22 52 23 53-67 24-26 68-72 27-28 73 29-49 74-103 50-59 104-115 60-61 116-117 62-69 118-125 70-78 126-136 79-86 137-143 87-90 144-145 91-94 146-149

TM 9-803 l/,-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) SECTION XX XXI XXII XXIII XXIV xxv XXVI XXVII XXVIII XXIX xxx xxx1 xxx11 REFERENCES. . . Paragraphs Battery and lighting system. . 95-106 Clutch....................... 107-112 Transmission. . . . . . . . 113-116 Transfer case.. . . . . . . . 117-121 Propeller shafts and universal joints...................... 122-125 Front axle.. . .!. . . . . 126-137 Rear axle.. . . . . . . . . . 138-145 Brakes....................... 146-152 Springs and shock absorbers. 153-157 Steering gear. . . . . . . . . 158-l 63 Body and frame.. . . . 164-175 Radio interference suppression system..................... 176-179 Shipment and temporary storage 180-182 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 150-166 167-171 172-175 176-178 179-180 181-188 189-192 193-204 205-210 211-215 216-220 221-227 228-232 233-234 INDEX............................................... 235 4

TM PART ONE-OPERATING INSTRUCTIONS Section I 9-803 1 INTRODUCTION Paragraph Scope . . . . . . . . . . . . . . . . . . . . . . . . .._....................... 1 1. SCOPE. a. This technical manual* is published for the information and guidance of the using arm personnel charged with the operation and maintenance of this materiel, b. In addition to a description of the I/4-tori 4 x 4 Truck (Willys- Overland model MB and Ford GPW), this manual contains technical information required for the identification, use, and care of the materiel. The manual is divided into two parts. Part One, sections I through VII, contains vehicle operating instructions. Part Two, sec- Lf_-_ x1111 LL_^.._.l_ “VVIT ^__L_:__ _._L:_,_ __:_e___,,, :_“C....,.C:~^.. Ll”rlS ” 111 rrll”uyrl **All, C”,,LIll,S “C,,,CK ,‘,alllLcllaL,L.c lllDl.l ULLl”llJ to using arm personnel charged with the responsibility of doing maintenance work within their jurisdiction, including radio suppression and shipment and temporary storage information. c. In all cases where the nature of the repair, modification, or adjustment is beyond the scope of facilities of the unit, the respon- sible ordnance service should be informed so that trained personnel with suitable tools and equipment may be provided, or proper instructions issued. d. This manual includes operating and organizational maintenance instructions from the following Quartermaster Corps lo-series technical manuals. Together with TM g-180349 and TM 9-1803B, this manual supersedes them: ,.\ mrr .I\ ..nrl nr\ .___.._A .nn. (11 llvl IV-lllJ.3, LU fwlgusr 1YLtl. (2) TM 10-1207, 20 August 1941. (3) TM 10-1349, 3 January 1942. (4) TM 10-1513, Change 1, 15 January 1943. *To provide operating instructions with the materiel, this technical manual has been published in advance of complete technical review. Any errors or omissions will be corrected by changes or, if extensive, by an early revision.

f RA PD 305251 Figure I--I/4-Ton 4 x 4 Truck-Left Front

0, c 0 0 TM 9-803 1 INTRODUCTION

TM 9-803 1 l/,-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) 8

TM 9-803 1 INTRODUCTION

TM 9-803 2-3 l/i-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) Section II DESCRIPTION AND TABULATED DATA Paragraph Description . 2 Data _.._., .._.... . 3 2. DESCRIPTION. mm._._ m,~?_ _~.,L_,_ . a. 1 YPe* ~nls vemcle is a generai purpose, personnei, or cargo carrier especially adaptable for reconnaisance or command, and designated as I/d-ton 4 x 4 Truck. It is a four-wheel vehicle with four-wheel drive. The engine is a 4-cylinder gasoline unit located in the conventional place, under the hood at the front of the vehicle. A conventional three-speed transmission equipped with a transfer case provides additional speeds for traversing difficult terrain. The body is of the open type with an open driver’s compartment. The folding top can be removed and stowed: and. the windshield tilted forward on top of the hood, or opened upward and outward. A spare wheel equipped with a tire is mounted on thr rear of the body, and a pintle hook is provided to haul trailed loads. Specifications of the vehicle are given under “Data” (par. 3). Genrral physical character- istics are shown in figures 1 through 4. h. Identification. The manufacturer’s chassis serial number is stamped on a plate inside the left frame side member at the front end, and on the name plate (fig. 6). The engine serial number is stamped on the right side of the cylinder block. front upper corner. The U.S.A. registration number is painted on both sides of the hood. 3. DATA. a. Vehicle Specifirations. Wheelbase 80 in. Length, over-all 1321/d in. Width, over-all .., 62 in. Height, over-all-top up 69$/4 in. -top down 52 in. Wheel size combat 16 x 4.50 E Tire size 16 x 6.00 in. Tire pressure (front and rear) 35 lb Tire type mud and snow Tire plies 6 Tread (center-to-center)-front 49 in. -rear 49 in. Crew, operating 2 Passenger capacity including crew 5 10

1941-1945 Willys Jeep GPW MB Service Manual

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