M38 Manual and TB List

Based on data initially compiled by Howard Sabin for Army Motors

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M38 Technical Manuals

TM 5-5213 17 FEB 53
Engine, Gasoline driven, L-head and F-head, Models MC38-MC38A1 basic engine:
Conversion for stationary power, Willys Overland Motors.

TM 9-804 29 SEP 50
1/4-ton, 4x4, utility truck M38 (Willys-Overland) Operation and maintenance manual.

TM 9-804 Change 1 16 FEB 51

TM 9-804 Change 2 18 May 51

TM 9-804 Change 3 10 APR 53

TM 9-1804A 11 JUN 51
Ordnance maintenance: Engine (Willys-Overland Model MC) and clutch for 1/4-ton,
4x4, Utility truck M38

TM 9-1804B 16 JUL 52
Power Train, Body and Frame for 1/4-ton, 4x4, Utility truck M38

TM 9-8012 12 JAN 56
1/4-ton, 4x4, utility truck M38 (Willys-Overland) Operation and Organizational
maintenance manual
Superseded TM 9-804.

TM 8-8012 Change 1 22 MAR 56

TM 9-8012 Change 2 13 JAN 58

TM 9-8012 Change 3 18 JUN 58

TM 9-1825A 12 JAN 44
Ordnance Maintenance: Electrical Equipment (Delco Remy)

TM 9-1825A Change 1 31 MAR 47

(supercede by TM 9-8627)

TM 9-1825B 20 JAN 44
Ordnance Maintenance: Electrical Equipment (Auto-Lite)

TM 9-1825B Change 1 30 APR 47

TM 9-1825B 3 NOV 52
Ordnance Maintenance: Electrical Equipment (Auto-Lite)
Supercedes 9-1825B dated JAN 44

TB 9-1826A 11 FEB 44
Ordnance Maintenance: Carburetors (Carter)

TB 9-1826A 10 DEC 52
Ordnance Maintenance: Carburetors (Carter)
Supercedes 9-1826A dated FEB 44

TM 9-1827C 21 JAN 44
Ordnance Maintenance: Hydraulic Brakes (Wagner Lockheed)

TM 9-1827C 2 JAN 53
Ordnance Maintenance: Hydraulic Brakes (Wagner Lockheed)
Supercedes 9-1827C dated JAN 44

TM 9-1828A 9 MAR 45
Ordnance Maintenance: Fuel Pumps

TM 9-1828A 29 DEC 52
Ordnance Maintenance: Fuel Pumps
Supercedes 9-1828A dated MAR 45.

TM 9-1828A Change 1 ? _______

TM 9-1828A Change 2 ? _______

TM 9-1829A 15 APR 44
Ordnance Maintenance: Speedometers, Tachometers, and Recorders.

TM 9-2853 7 JUL 45
Preparation of Ordnance Material for deep water fording.

TM 9-2853 Change 1 7 JUN 48

TM 9-2858 8 MAY 45
Cooling Systems: Vehicles and Powered Ground Equipment

TM 9-2858 Change 1 ? ________

TM 9-8627 Electrical Equipment Delco Remy (supercedes TM 9-1825A)

TM 9-2858 Change 2 ? ________

TM 10-500-10 11 AUG 65
Airdrop of Supplies and Equipment: Rigging 1/4-ton Utility trucks.

TM 10-500-10 Change 1 ? _________

TM 10-500-10 29 JAN 71
Airdrop of Supplies and Equipment: Rigging 1/4-ton Utility trucks
Supercedes 10-500-10 dated AUG 65.

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Technical Bulletins

TB ORD 247 14 May 51

Wll Transport Vehicles, Headlight adjustment

TB ORD 370 9 AUG 54

1/4-ton, 4x4, trucks, Ford Model GPW, Willys Model MB, M38, and M38A1: 3/4-ton
Dodge trucks models WC51, WC52, WC53, WC54, WC56, WC57, WC58, WC59,
WC61, WC64, M37, M42, M43, M56 and M201: 1 1/2-ton 6x6 trucks, Dodge Models
WC62 and WC63: Use of front axle non driving flanges for temporarily converting
vehicles from four-wheel drive to two-wheel drives.

TB ORD 434 14 Mar 52

Combat & Transport vehicles with 24-volt electrical systems: Instructions for checking
24-volt instruments that do not zero.

TB ORD 445 7 MAY 52

TB ORD 467 11 AUG 52

1/4-ton and 3/4-ton, 4x4 trucks and 2 1/2 and 5 ton, 6x6 trucks "M" models: Use of
proper fuel tank filler caps.

TB ORD 470 9 SEP 52

1/4-ton and 3/4-ton, 4x4 trucks and 2 1/2 and 5 ton, 6x6 trucks "M" models: Instructions
for proper cleaning of crankcase valve assembly.

TB ORD 479
Ordnance motor vehicles: Standardization of electric type instruments.
TB ORD 485 19 JAN 53
1/4-ton and 3/4-ton, 4x4 trucks and 2 1/2 and 5 ton, 6x6 trucks "M" models: Servicing
data plate corrections.

TB ORD 487 3 FEB 53

Identification and maintenance of fuel filter.

TB ORD 499 4 MAR 53

1/4-ton and 3/4-ton, 4x4 trucks and 2 1/2 and 5 ton, 6x6 trucks "M" models:
Identification and replacement of hydraulic stoplight switches.

TB ORD 524 8 JUN 53

Installed metal fuel tanks: Cleaning and preserving

TB ORD 547 18 DEC 53

1/4-ton, 4x4, utility trucks M38 and M38A1: Prevention of crankshaft pulley failures.

TB ORD 554 1 MAR 54 Rev 7 JAN 55

1/4-ton, 4x4, truck M38 series; 3/4-ton, 4x4, truck M37 series; 2 1/2-ton 6x6, truck M34
series; and 5-ton, 6x6, truck M40 series: Removal of flywheel housing drain plug.

TB ORD 560 13 MAY 54

1/4-ton, 4x4, utility trucks M38 and m38A1: Revision of tire pressures on servicing data
plates.
.
TB ORD 589 7 JAN 55
1/4-ton. 4x4, truck M38, M38A1, M170 : Installation of distributor point set.

TB ORD 610 13 JUN 55

1/4-ton, 4x4, utility truck M38, M38A1C, 1/4-ton, frontline ambulance truck M170:
Operating of fording valve.

TB ORD 621 2 DEC 55

Tandem hitch 2540-735-8343 (8-H-1826): Installation on 1/4-ton, 4x4 trucks MB, GPW,
M38 and M38A1.

TB ORD 625 5 Jan 56

All tactical wheeled vehicles: Cleaning of power train case ventilating valves

TB ORD 626 1 OCT 57

Tactical transport vehicles: Excessive fuel tank pressure.

TB ORD 1007 2 DEC 57

1/4-ton, 4x4, utility trucks, M38, M38A1, and M38A1C, and 1/4-ton, 4x4, frontline
ambulance truck M170: Instructions for reinforcing clutch release fork at fulcrum seat or
pivot point.

TB ORD 2300-20/4 18 AUG 58

1/4-ton, 4x4 trucks M38, M38A1, (etc): Stowage locations for pioneer tools and brackets

TB 9-804-1 8 JUL 52
1/4-ton. 4x4, Utility truck, M38: Prevention of damage to the oil filter flexible line.

TB 9-804-2 17 JUL 52
1/4-ton, 4x4, utility truck, M38: Eliminating ________ brake line entanglement.

TB 9-804-3 16 JAN 53
1/4-ton, 4x4, utility truck, M38: Replacement of the lifting shackle pin retaining clip.

TB 9-804-4 ?__________

TB 9-804-5 16 FEB 53
M38 Improper Thermostat retainer dimensions

TB 9-804-6 17 FEB 53
1/4-ton, 4x4, utility truck, M38 Correction of vapor lock in fuel pump to carburetor line.

TB 9-804-7 13 MAR 53
1/4-ton, 4x4, utility truck, M38: Mounting of vent line clip.

TB 9-804-8 13 MAR 53
1/4-ton, 4x4, utility truck, M38: Elimination of transfer case noise.

TB 9-804-9 20 MAY 53
1/4-ton, 4x4, utility truck, M38: Repositioning of trailer coupling receptacle to prevent
damage to reflector.

TB 9-804-10 15 JUN 53
1/4-ton, 4x4, utility truck, M38: Removing engine hood hazard.

TB 9-804-11 22 JUL 54
1/4-ton, 4x4, utility truck, M38: Elimination of fuel pump diaphragm failure.

TB 9-804-12 3 DEC 53 Rev 9 MAR 53

1/4-ton, 4x4, utility truck, M38: To prevent contact of front wheels against chassis frame,
fender and lifting hook.

TB 9-804-13 29 APR 54 REV 1 NOV 55

1/4-ton, 4x4, utility truck, M38: To prevent chaffing of fuel and vent lines at fuel tank.
TB 9-804-14 6 JUN 54 REV 19 OCT 55
1/4-ton, 4x4, utility truck, M38: Identification of speedometer flexible shaft assembly by
vehicle serial number.

TB 9-1804B-1 24 FEB 54
1/4-ton, 4x4, utility truck M38: Kingpin bearing cap screw selection

TB 9-1825S-1 18 JUN 53
Electrical connector repair kit41-K-103-100: Proper use of tools.

TB 9-1859-8 9 MAR 53
1/4-ton, 4x4, Command Reconnaissance Truck: Time schedule guide.

TB 9-2300-206-15 28 NOV 58
1/4-ton, 4x4 trucks, M38, M38A1, M38A1C, M170 equipped with high capacity AC-DC
100 ampere 28v generating systems: Test and rebuild of generating system.

TB 9-2300-206-15 Change 1 ?_________

TB 9-2300-210-20 21 JAN 59
Truck, 1/4-ton, 4x4, M38, M38A1, M38A1C, M170: Interchangeability of air and oil
pressure sending units and gauges and installation instructions.

TB 9-2300-225-20 10 DEC 59
Truck, 1/4-ton, 4x4, M38, M38A1, M38A1C, M170: Generator nut torque specifications.

TB 9-2300-228-20 Tactical Transport and Combat Vehicles: Troubleshooting for

Instrument Cluster Gages, Switches, Circuit Breakers, Sending Units and Related Wiring
dated 8 July 1960

TB 9-2830-55 23 May 55
Truck -ton M38 Windshield glass conversion to 2 piece. It authorizes replacing a one
piece windshield with a two piece windshield when replacement glass is in critically
short supply. It states that if over half of the broken windshield is usable, then you cut the
glass in half, ditch the broken half and cut a matching other half from a piece of scrap
glass. The two halfs were joined together using a cut piece of aluminum flat stock and
two lengths of weatherstripping and rubber strip filler.

TB 9-2855-2 23 DEC 52
Instructions for the installation of personnel heater kit for 1/4-ton, 4x4, utility truck M38
(Willys MC) (24V) (G-740).
TB 9-2855-3 16 DEC 52
Instructions for the installation of power plant heater kit for 1/4-ton, 4x4, utility truck
M38 (Willys MC) (24V) (0 to -65 degrees F).

TB 9-2855-4 27 OCT 52
Instructions for installation of hardtop closure kit for 1/4 - ton, 4x4, utility truck M38
(Willys MC) (G-740).

TB 9-2855-37 10 DEC 56
1/4 - ton 4x4, utility truck M38: Instructions for installation of hot water personnel heater
kit.

TB 9-8012-2 11 OCT 56
1/4-ton, 4x4, utility truck M38: Replacement of fuel pump.

TB 9-8012-1 20 JUN 56
1/4-ton, 4x4, utility truck M38: Elimination of interference between front spring rebound
clips and tie rods.

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Modification Work Orders

MWO ORD G740-W1 3 DEC 51

1/4-ton, 4x4, utility truck M38: Relocate Aux Pwr Recpt CB to firewall.

MWO ORD G740-W2 13 NOV 52

1/4-ton, 4x4, utility truck M38: Deactivate primer pump.

MWO ORD G740-W3 5 NOV 52

1/4-ton, 4x4, utility truck M38: Rear axle vent leakage.

MWO ORD G740-W4 24 NOV 52

1/4-ton, 4x4, utility truck M38: Bell housing front plate cover.

MWO ORD G740-W5 27 OCT 52

1/4-ton, 4x4, utility truck M38: ID On/Off position on ignition switch.

MWO ORD G740-W6 14 MAY 53

1/4-ton, 4x4, utility truck M38: Reinforcement of rear body corners.

MWO ORD G740-W7 15 JUL 53

1/4-ton, 4x4, utility truck M38: Addition of oil seals to front hubs.
MWO ORD G740-W8 20 OCT 55
1/4-ton, 4x4, utility truck M38: Addition of angles to battery hold dwon frames.

MWO ORD G740-W9 2 FEB 56 & Chg 1 5 JUN 56

1/4-ton, 4x4, utility truck M38: Waterproofing of steering gear and draining of steering
jacket.

MWO ORD G740-W10 6 OCT 55

1/4-ton, 4x4, utility truck M38: Securing front passenger seat pivot pin to seat hinge
pivot.

MWO ORD G740-W11 1 NOV 56 & Chg 1 18 SEP 57

1/4-ton, 4x4, utility truck M38: Installation ac-dc generator kit.

MWO ORD G1-W63 19 SEP 57

1/4-ton, 4x4, trucks M38, M38A1, M38A1C, and M170: 3/4-ton .: Replacement
of air and oil pressure gauges, sending units, and installation of pipe coupling

MWO ORD G1-W85 22 MAR 57

1/4-ton, 4x4, trucks M170, M38, and M38A1: Installation of castellated nut and cotter
pin on steering bellcrank pivot shaft.

MWO ORD G1-W88 3 OCT 56

1/4-ton, 4x4, utility truck M38, M38A1, M38A1C and front line ambulance truck M170:
Modification of clutch release pedal rod.

MWO ORD G1-W94 29 OCT 56

1/4-ton, 4x4, utility truck M38: 1/4-ton, 4x4, utility trucks (Ford model GPW and Willys
Model MB): Installation of 105-mm rifle M27A1 with 105-mm rifle mount M75A1 or
106-mm rifle M40 (M170E1) with 106-mm rifle mount M79.

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M38 Supply Manuals

SM ORD 8 SNL G-740, Vol. 9 25 JAN 55
Winterization Equipment for truck, utility, 1/4-ton, 4x4, M38 (SNL G-740)

SM ORD 7 SNL G-740 26 FEB 51

Organizational Maintenance Allowances for Truck, utility: 1/4-ton, 4x4, M38

SM ORD 7 SNL G-740 Change 1 29 APR 52

SM ORD 7 SNL G-740 26 FEB 53

Organizational Maintenance Allowances for Truck, utility,: 1/4-ton,4x4, M38

SM ORD 7 SNL G-740 Change 1 26 OCT 54

SM ORD 7 SNL G-740 15 FEB 55

Organizational Maintenance Allowances for Truck, utility,: 1/4-ton,4x4, M38

SM ORD 7 SNL G-740 25 JUN 56 $21 ebay feb 04

Organizational Maintenance Allowances for Truck, utility,: 1/4-ton,4x4, M38

SM ORD 7 SNL G-740 Change 1 25 APR 60

SM ORD 8 SNL G-740 1 DEC 50

Field and depot maintenance allowances for Truck, utility: 1/4-ton, 4x4, M38

SM ORD 8 SNL G-740 16 MAR 53

Field and depot maintenance allowances for Truck, utility: 1/4-ton, 4x4, M38

SM ORD 8 SNL G-740 16 FEB 55

Field and depot maintenance allowances for Truck, utility: 1/4-ton, 4x4, M38

SM ORD 8 SNL G-740 25 JUN 56

Field and depot maintenance allowances for Truck, utility: 1/4-ton, 4x4, M38

SM ORD 9 SNL G-740 ? 1950

SM ORD 9 SNL G-740 19 NOV 51 $212 Ebay Feb 04

List of all service parts of truck, utility: 1/4-ton, 4x4, M38

SM ORD 9 SNL G-740 1 SEP 55

List of all service parts of truck, utility: 1/4-ton, 4x4, M38

Miscellaneous Pubs

DA Pam 108-1

DA Pam 310-

DA PAM 310-29 ORD 1 Index of supply manuals, ordnance

ORD 3 SNL K-1 Cleaners, preservatives, lubricants, recoil fluids, special oils and
related maintenance materials.

ORD 3 SNL K-2 Items of soldering, metallizing, brazing,and welding materials,

gases and related items.