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Interchange: Soft Top Side Rail Screws (NAS1635-3LE12)

The screws at the front, middle, and rear of each rail are called out by different part numbers in the TM. The front screw (#1) 5305-01-210-6249 [5305012106249] with a manufacturer P/N of PL25D02P12 was not locatable.

The screw at the rear of the rail (#10) 5305-01-117-3396 [5305011173396] was similarly unlocatable, however we were able to locate this screw by its manufacturer P/N of NAS1635-3LE12. This is essentially a #10-32 x 3/4 screw. However, this has pre-applied locking compound. Additionally, we surmise this screw probably has a higher tensile strength than a standard 10-32 screw as it is an aircraft fastener.

As for the PL25D02P12 fastener called out for the front connection, at least one vendor (Kascar/real4wd.com) lists the NAS1635-3LE12 as an interchange. (at time of post, searching for the PL25D02P12 fastener comes up as NAS1635-3LE12) See: https://real4wd.com/store/catalog/search.aspx?keywords=PL25D02P12

In other words, we are comfortable that since both fasteners specifications are as a self-locking 10-32 x 3/4″, that use of the NAS1635-3LE12 is proper. There are apparently 50 in a box, and we have ordered 4 boxes to keep in stock.

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Wiring – Preparation for Dash Wiring

Rapco “686” Tan applied to dash and vent areas. Note: Paint is still wet, when dry it is completely flat.

Prior to assembling the gauge cluster, lighting switches, filter minder and other connections, we prepped the existing CARC to accept paint. Special attention was paid to masking the window rubber, as paint can rapidly degrade it. This was painted in Rapco “686” Tan (which corresponds with FS 33446).

By pre-painting the dash and vent areas, it ensures an even color when these areas are masked off for complete vehicle paint.

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Renovating Shifter Controls: Transmission Shifter Bushing

As our shifter was frozen solid, it required use of a hydraulic press, hammer, and punch to dissasemble the shifting mechanisms. In the process, we ended up destroying both the shaft and the bushing.

This bushing 3120-01-191-3232 [3120011913232] (indicated by red arrow) is made of thin nylon. Although after looking at it, we could have replaced it with an oilite or brass bushing, that would require machining of the shifting bracket. We then attempted to source the bushing using the NSN with no luck. However, we were able to located the part (currently available for order) from the manufacturer using the part number 10L18F. Applied Industrial Technologies carries this part available at https://www.applied.com/c-brands/c-thomson-industries/10l18f/Thomson-Nyliner-Bearing/p/101610126.

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Renovating Shifter Controls: Reverse Light Switch

Early shifter control for basic and A1 versions

The transmission shifter in our M1038 was frozen, in that the release button could not be depressed to release the shifter. Additionally, the lever 2520-01-189-1064 [2520011891064] (Fig. 99, Item 16) was broken at the connection point. After removing the entire assembly, we noticed that this was an atypical shifter in that it had not only the safety switch 2920-01-249-3492 [2920012493492](Fig. 99, Item 20), but also a reverse light switch (not shown in diagram).

Shifter showing neutral safety switch and reverse light switch. Reverse switch is the right arrow.

It is our current understanding that the reverse light switch was used only on Marine HMMWVs, but that it is also desirable for on-road civilian use in states that require a functioning reverse light. The lead from one of the wires was 467 (whereas the neutral safety is 14). Of note, the hole for the reverse switch appears to exist in all of the housing assemblies (Fig. 99, Item 10). (See diagram). Of further note, the switch appears to be the same as the neutral safety other than there is a bushing installed to allow the smaller switch to be installed in a larger hole

Arrow showing reverse light switch. Note bushing surrounding switch.

From this, it appears that a reverse light switch can be installed in any of the earlier shifters. Once we identify the threaded bushing dimensions, we will post it. It seems relatively difficult to source the reverse light switch as opposed to the neutral safety switch.

Neutral Safety Wire #4, Reverse Light Wire 467