TM-9-2320-387-24 HMMWV Direct Support & General Support Maintenance Manual Volume 1 Download
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INITIAL SETUP: Tools General mechanic’s tool kit: automotive (Appendix B, Item 1) Maintenance and repair shop equipment: automotive (Appendix B, Item 2) Special Tools Pulley installer (Appendix B, Item 121) Materials/Parts Lockwasher (Appendix G, Item 239) O-ring seal (Appendix G, Item 286) Manual References TM 9-2320-387-10 TM 9-2320-387-24P Equipment Condition • Hood raised and secured (TM 9-2320-387-10). • Serpentine drivebelt removed (para. 3-81). Maintenance Level Unit 8-23. POWER STEERING PUMP AND PULLEY REPLACEMENT This task covers: a. Removal b. Installation TM 9-2320-387-24-1 a. Removal CAUTION Cover or plug all hoses and connections immediately after disconnection to prevent contamination. Remove all plugs prior to connection. 1. Loosen two clamps (2) and disconnect return lines (1) and high-pressure line (5) from power steering pump (3). Remove O-ring (4) from high-pressure line (5). Discard O-ring (4). 2. Remove nut (7), clamp (8), and wiring harness (6) from power steering pump (3). 3. Remove nut (15), lockwasher (14), washer (13), capscrew (9), washer (10), and idler pulley (11) from bracket (12). Discard lockwasher (14). 4. Remove two capscrews (17), capscrew (18), and power steering pump (3) from mounting bracket (16). 5. Remove capscrew (19), washer (20), and power steering pulley (21) from power steering pump (3). CAUTION Serpentine belt failure (abnormal wear or drive belt dislodgement) can be caused by misalignment of pulleys, improper installation, or foreign objects introduced into belt path. Inspect power steering pump pulley for proper installation and ease of rotation. Any wobble or misalignment will cause belt failure. Refer to para. 3-81 for pulley alignment procedures. NOTE Ensure flat surface of pulley is facing out and is flush with pump shaft. 1. Using pulley installer, install pulley (21) on power steering pump (3). 2. Secure pulley (21) to power steering pump (3) with washer (20) and capscrew (19). Tighten capscrew (19) to 37 lb-ft (50 N•m). 3. Install power steering pump (3) on mounting bracket (16) with capscrew (18) and two capscrews (17). 4. Install idler pulley (11) on bracket (12) with washer (10), capscrew (9), washer (13), lockwasher (14), and nut (15). 5. Install O-ring (4) on high-pressure line (5) and install high-pressure line (5) on power steering pump (3). 6. Install two return lines (1) on power steering pump (3) and tighten clamps (2). 7. Install wiring harness (6) and clamp (8) on power steering pump (3) with nut (7). b. Installation 8-64 Change 1