4-5.4. 100 AMPERE DUAL VOLTAGE ALTERNATOR (12447110) CABLE REPLACEMENT
This task covers:
a. Removal
b. Installation
INITIAL SETUP:
Tools
General mechanic’s tool kit:
automotive (Appendix B, Item 1)
Maintenance and repair shop equipment:
automotive (Appendix B, Item 2)
Materials/Parts
Four lockwashers (Appendix G, Item 108)
Silicone compound (Appendix C, Item 48)
Tiedown strap (Appendix G, Item 239)
Manual References
TM 9-2320-280-10
TM 9-2320-280-24P
Equipment Condition
• Hood raised and secured (TM 9-2320-280-10).
• Battery ground cables disconnected (para. 4-73).
• Engine access cover removed (para. 10-15).
TM 9-2320-280-20-2
4-12.10
Change 2
a. Removal
b. Installation
NOTE
Ensure studs are clean before connections are made.
1.
Install grommet (23) on battery box (29).
2.
Route cable (1) through grommet (23) in battery box (29) and install cable (1) on power stud (25)
with washer (26), lockwasher (27), and nut (28). Apply silicone compound to power stud (25).
3.
Install tiedown strap (24) on cable (1).
4.
Install cable (1) on inner body flange (12) with washer (13), screw (14), clamp (11), lockwasher (16),
and nut (17).
5.
Install cable (1) to right cylinder head stud (19) on water manifold (18) with clamp (20),
lockwasher (21), and nut (22).
6.
Install cable (1) on thermostat outlet stud (10) with clamp (2), washer (3), lockwasher (4), and
nut (5).
7.
Install cable (1) on positive stud (9) with washer (7) and nut (6). Tighten nut (6) to 75-85 lb-ft
(8-10 N•m). Slide rubber boot (8) over nut (6).
NOTE
Prior to removal, tag leads for installation.
1.
Slide back rubber boot (8) and remove nut (6), washer (7), and positive cable (1) from positive
stud (9).
2.
Remove nut (5), lockwasher (4), washer (3), and clamp (2) from thermostat outlet stud (10). Discard
lockwasher (4).
3.
Remove nut (22), lockwasher (21), clamp (20), and cable (1) from right cylinder head stud (19) of
water manifold (18). Discard lockwasher (21).
4.
Remove nut (17), lockwasher (16), screw (14), washer (13), and clamp (11) from inner body flange (12).
Discard lockwasher (16).
5.
Inspect condition of edge trim (15) for damage and replace if damaged.
6.
Remove nut (28), lockwasher (27), washer (26), and cable (1) from power stud (25). Discard
lockwasher (27).
7.
Remove tiedown strap (24) from cable (1).
8.
Remove grommet (23) and cable (1) from battery box (29) and vehicle.
