1939-1943 WILLYS TM 9-803 Complete Service Manual

The document is a technical manual (TM 9-803) for the 1/4-ton 4x4 truck models Willys-Overland MB and Ford GPW, dated February 22, 1944. It provides detailed operating and maintenance instructions, including vehicle specifications, troubleshooting, lubrication, tools, and spare parts, for military personnel.

General Description and Specifications

•    Vehicle type: ¼-ton 4x4 truck for personnel or cargo, adaptable for reconnaissance.

•    Engine: 4-cylinder gasoline unit, conventional placement.

•    Transmission: 3-speed with transfer case for difficult terrain.

•    Dimensions: Length 132.25 in., Width 62 in., Height (top down) 52 in. [26-27].

•    Performance: Max speed 65 mph, grade ability 60%, turning radius 17.5 ft [32-34].

•    Capacities: Fuel tank 15 gal, engine crankcase refill 4 qt, cooling system 11 qt [36-39].
Operating Instructions

•    Controls and instruments: Includes speedometer, ammeter, blackout light switches [42-54].

•    Driving operations: Procedures for starting, shifting gears, and stopping the vehicle.

•    Blackout light operation: Safety lock to prevent accidental activation of service lights [55-57].
Maintenance Instructions

•    Lubrication: Regular intervals for engine, transmission, and other components [70-71].

•    Troubleshooting: Guidance for transmission, brakes, and electrical system issues [69-81].

•    Tools and equipment: Stowage locations for spare parts, tools, and equipment [60-64].
Special Features

•    Radio outlet box: For 6-volt battery use, located near the right front seat.

•    Auxiliary generator: 12-volt, 55-amp generator for specific vehicles.

•    Blackout system: Includes headlights, stoplights, and driving lights [101-102].

•    Technical Manual for 1/4-Ton 4x4 Trucks: Covers Willys-Overland Model MB and Ford Model GPW trucks, providing information on operation and maintenance.

•    Vehicle Specifications: Includes dimensions, weight, engine details, and performance data such as speed, fuel capacity, and towing capacity.

•    Operating Instructions: Details on driving controls, instruments, and operation under unusual conditions.

•    Maintenance Guidelines: Includes lubrication, preventive maintenance, and troubleshooting for various systems like engine, transmission, and brakes.

•    Troubleshooting: Offers solutions for common issues in systems like transmission, transfer case, and brakes.

•    Tools and Equipment: Lists tools, spare parts, and their stowage locations on the vehicle.

•    Special Features: Includes radio interference suppression and auxiliary generator setup.

•    References and Index: Comprehensive list of related documents and detailed index for ease of navigation.

Here is the list of all chapters (sections) in the technical manual for the 1/4-Ton 4x4 Trucks (Willys-Overland Model MB and Ford Model GPW):


Part One:
Operating Instructions

1.    Introduction

2.    Description and Tabulated Data

3.    Driving Controls and Operation

4.    Operation Under Unusual Conditions

5.    First Echelon Preventive Maintenance Service

6.    Lubrication

7.    Tools and Equipment Stowage on the Vehicle


Part Two:
Vehicle Maintenance Instructions

1.    Record of Modifications

2.    Second Echelon Preventive Maintenance

3.    New Vehicle Run-In Test

4.    Organization Tools and Equipment

5.    Troubleshooting

6.    Engine - Description, Data, Maintenance, and Adjustment in Vehicle

7.    Engine - Removal and Installation

8.    Ignition System

9.    Fuel and Air Intake and Exhaust Systems

10.    Cooling System

11.    Starting System

12.    Generating System

13.    Battery and Lighting System

14.    Clutch

15.    Transmission

16.    Transfer Case

17.    Propeller Shafts and Universal Joints

18.    Front Axle

19.    Rear Axle

20.    Brakes

21.    Springs and Shock Absorbers

22.    Steering Gear

23.    Body and Frame

24.    Radio Interference Suppression

25.    Shipment and Temporary Storage
Additional Sections


•    References

•    Index


This structure ensures comprehensive coverage of the operation, maintenance, and technical specifications of the vehicle [6-11].

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