TM-9-2320-387-24 HMMWV Direct Support & General Support Maintenance Manual Volume 2 Download
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11-2. FRONT DOOR AND HINGE REPLACEMENT This task covers: a. Removal b. Installation Personnel Required One mechanic One assistant Manual References TM 9-2320-387-24P General Safety Instructions Vehicle door is extremely heavy and must be supported during removal and installation. Maintenance Level Unit TM 9-2320-387-24-2 11-4 Change 1 WARNING Vehicle door is extremely heavy and must be supported during removal and installation. Failure to do so may cause injury to personnel or damage to equipment. CAUTION To prevent damage to armored glass, protect all exposed glass surfaces when replacing rivets. 1. Remove locknut (4), screw (2), and door check strap (8) from door bracket (3). Discard locknut (4). 2. Remove sixteen capscrews (10), washers (9.1), and door (1) from A-pillar (7). 2.1. Remove foam rubber strip (13) from rivet (11) heads. 3. Remove fifteen rivets (11) and hinge (12) from door (1). 4. Remove six capscrews (5), lockwashers (6), and two stop blocks (9) from door (1). Discard lockwashers (6). 5. Remove old adhesive completely from door (1), A-pillar (7), and hinge (12). Ensure all rust is removed from bonded area. 1. Install two stop blocks (9) on door (1) with six lockwashers (6) and capscrews (5). Tighten capscrews (5) to 10 lb-ft (14 N•m). 2. Apply adhesive to hinge (12) and door (1). Install hinge (12) on door (1) with fifteen rivets (11). NOTE New capscrews come with preapplied thread locking compound. If old capscrews are to be used, mating threads must be cleaned and sealing compound applied to threads of capscrews. 3. Apply sealing compound to sixteen capscrews (10) (for used capscrews only). Apply adhesive to hinge (12) and A-pillar (7). Install hinge (12) on A-pillar (7) with sixteen washers (9.1) and capscrews (10). Tighten capscrews (10) to 37 lb-ft (50 N•m). 3.1. Apply foam rubber strip (13) over rivet (11) heads on door (1). 4. Install door check strap (8) on door bracket (3) with screw (2) and locknut (4). b. Installation a. Removal INITIAL SETUP: Applicable Models M1114 Tools General mechanic’s tool kit: automotive (Appendix B, Item 1) Maintenance and repair shop equipment: automotive (Appendix B, Item 2) Riveter tool kit (Appendix B, Item 123) Materials/Parts Fifteen rivets (Appendix G, Item 351) Locknut (Appendix G, Item 166) Six lockwashers (Appendix G, Item 202) Closed-cell foam rubber (Appendix G, Item 23.1) Adhesive (Appendix C, Item 2.1) Sealing compound (Appendix C, Item 60)