TM 9-2355-335-23 0106

CAPSULE DOOR REPLACEMENT

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Preconditions Materials/Parts
Park vehicle Push Pin (12) (Item 1 and 11)
Engine OFF Locknut (Item 6)
Wheels chocked Locknut (Item 13)
Batteries disconnected (WP 0129) Compound, Sealing, Loctite 242

Tools and Special Tools Personnel Required

Suitable Lifting Device Two
Tool Kit, General Mechanic’s: Automotive
Follow-On Maintenance
Connect batteries (WP 0129)
Remove and stow wheel chocks

FRONT CAPSULE DOOR REMOVAL

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ATV1258

NOTE
• Perform Steps (1) through (3) for driver side.
• Perform Steps (4) through (6) for passenger side.

1. Remove two push pins (1), four screws (2), CTIS controller (3), and dash panel (4) from dash (5). Discard
push pins (1).

2. Remove locknut (6), screw (7), cushion clip (8), and wire (9) from dash (5).

3. Disconnect connector (10).

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ATV1262

4. Remove ten push pins (11) and dash panel (12) from dash (5). Discard push pins (11).

5. Remove locknut (13), screw (14), cushion clip (15), and wire (16) from dash (5). Discard locknut (13).

6. Disconnect connector (17).

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ATV0814

WARNING
Capsule doors are extremely heavy. Do not attempt to lift or move capsule doors
without the aid of an assistant and suitable lifting device. Failure to comply may
result in injury or death to personnel.

NOTE
Front driver and passenger side doors are removed the same way. Passenger side door
shown.

7. Attach a suitable lifting device to support weight of capsule door (18).

8. Remove screw (19) and washer (20) from top hinge (21).

9. Remove two screws (22), washers (23), and capsule door stop bracket (24) from top hinge (21).

10. Remove two screws (25) and mirror assembly (26) from top hinge (21).

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ATV0815

11. Remove three screws (27) and washers (28) from bottom hinge (29) and capsule door (18).
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ATV0816

12. Remove screw (30) from top hinge (21) and capsule door (18).

13. With the aid of an assistant and lifting device, remove capsule door (18) from vehicle.

END OF TASK

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FRONT CAPSULE DOOR INSTALLATION

WARNING
Capsule doors are extremely heavy. Do not attempt to lift or move capsule doors
without the aid of an assistant and suitable lifting device. Failure to comply may
result in injury or death to personnel.

NOTE
Front driver side and passenger side capsule doors are installed the same way.
Passenger side capsule door shown.

1. Attach suitable lifting device to capsule door (18).

2. With the aid of an assistant and lifting device, align screw holes in top hinge (21) with screw holes in capsule
door (18).

WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water. Failure
to comply may result in injury or death to personnel.

3. Apply sealing compound, Loctite 242, to threads of screw (30).

4. Install screw (30) in top hinge (21) and capsule door (18).

5. Apply sealing compound, Loctite 242 to threads of three screws (27).

6. With the aid of an assistant and lifting device, align screw holes in bottom hinge (29) with screw holes in
capsule door (18) and install three screws (27) and washers (28).
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ATV0814

WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water. Failure
to comply may result in injury or death to personnel.

7. Apply sealing compound, Loctite 242, to the threads of two screws (25), (22), and screw (19).

8. Install mirror assembly (26) on top hinge (21) with two screws (25).

9. Install capsule door stop bracket (24) with two screws (22) and washers (23).

10. Install screw (19) and washer (20) in door stop bracket (24) and top hinge (21).

11. Remove lifting device from capsule door (18).

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ATV1262

NOTE
• Perform Steps (12) through (14) for passenger side capsule door.
• Perform Steps (15) through (17) for driver side capsule door.

12. Connect connector (17).

13. Install wire (16) and cushion clip (15) on dash (5) with screw (14), and new locknut (13).

14. Install dash panel (12) on dash (5) with ten new push pins (11).
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ATV1258

15. Connect connector (10).

16. Install wire (9) and cushion clip (8) on dash (5) with screw (7), and new locknut (6).

17. Install dash panel (4) and CTIS controller (3) on dash (5) with four screws (2) and two new push pins (1).

END OF TASK
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REAR CAPSULE DOOR REMOVAL

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ATV0817

WARNING
Capsule doors are extremely heavy. Do not attempt to lift or move capsule doors
without the aid of an assistant and suitable lifting device. Failure to comply may
result in injury or death to personnel.

NOTE
• Rear driver side and passenger side capsule doors are removed the same way. Driver
side capsule door shown.
• Both hinges are removed the same way. Bottom hinge shown.

1. Open capsule door (1) and attach suitable lifting device to support weight of capsule door (1).

2. Remove three screws (2) and washers (3) from hinge (4) and capsule door (1).

3. Repeat Step (2) for top hinge.

END OF TASK

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REAR CAPSULE DOOR INSTALLATION

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ATV0817

WARNING
Capsule doors are extremely heavy. Do not attempt to lift or move capsule doors
without the aid of an assistant and suitable lifting device. Failure to comply may
result in injury or death to personnel.

NOTE
• Rear driver side and passenger side capsule doors are installed the same way. Driver
side capsule door shown.
• Both hinges are installed the same way. Bottom hinge shown.

1. Attach suitable lifting device to support weight of capsule door (1).

2. With the aid of an assistant and lifting device, align screw holes in bottom hinge (4) with screw holes in
capsule door (1).

WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water. Failure
to comply may result in injury or death to personnel.

3. Apply sealing compound, Loctite 242, to threads of three screws (2).

4. Install three screws (2) and washers (3) in bottom hinge (4) and capsule door (1).

5. Repeat Steps (2) through (4) for top hinge.

6. Remove lifting device from capsule door (1).

7. Perform all Follow-On Maintenance tasks.

END OF TASK

END OF WORK PACKAGE

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