Headlight Door Screws

Nic · Post by **Nic** » Tue Apr 17, 2018 2:42 pm

Hi Guys

Does anyone have any idea what size screws (6 in total) are used in the headlight door surround on an M38a1. The ones I thought fitted do not tighten up in the internal screw mounts.

Checked the 758 but it basically just says door screws without a size associated with the description.

Any help would be appreciated

Regards

Nic

4x4M38 · Post by **4x4M38** » Tue Apr 17, 2018 4:57 pm

Nic,
I can see the confusion.

Looks like the door is the same on the M38 forvwhat it’s worth.

It’s a 1/4-20 NC on the M38.

4x4M38 · Post by **4x4M38** » Tue Apr 17, 2018 5:27 pm

If it’s the sheetmetal screws behind the door, the holes
have probably just been wallowed out. You can tap the back
of the holes lightly with a small hammer and drift and tighten
up the holes.

Post by **wesk** » Tue Apr 17, 2018 11:08 pm

Those three machine screws are special because they have a step or notch that is used for a retainer ring that stops them from falling out when the door is removed.

This was a post I made in 2006 on the G503 board:

They are a long screw with threads only half way and then the unthreaded grip length is narrowed down and a very small snap ring snaps onto this wasp wasted area and acts as a retainer son the screw remains attached to the door all the time after you unthread it from the bucket.
They are FSN 5305-695-7209 for the original type and 5305-226-9267 for the service replacement supercedure. The M38 SNL's don't show them. The M38A1 SNL does.
Screw, ORD PN 7525935, GL # 5939783, ORD STK # G742-7539541. FSN 5305-695-7209 (original) superseded by 5305-226-9267.
Ring, screw retaining, ORD PN 7320642, ORD STK # G251-7320462, FSN 6220-732-0642

4x4M38 · Post by **4x4M38** » Wed Apr 18, 2018 6:38 am

Hi Wes,
So that is different from the M38.

The A1 doesn’t have the brush guards, necessitating
the ability to remove the screws.

It sounds like the same type of screw that goes in
the tail light assemblies, which had little clips that
kept the screw from coming out of the door.

I saw item 6 in the drawing in my copy of the Ord 9,
but it was further aft in the drawing. Is that a different
version of the Ord 9 than what is on line?

Thanks,

Post by **wesk** » Wed Apr 18, 2018 9:45 am

Try to be specific when you mention ORD, 7, 8, & 9's weather you are referring to early vs late, M38 vs M38A1 etc. The M38A1 in addition to the familiar ORD's, 7, 8 & 9's also had the late 50's TM supply manuals TM 9-2320-208-20P (Pages pictured above), TM 9-2320-208-34P with early & late versions.

Hi Wes,
So that is different from the M38.

No Both use the same Door Assembly 7525936

The A1 doesn’t have the brush guards, necessitating
the ability to remove the screws.

You must remove the three door screws on either jeep to change the headlamp bulb.

It sounds like the same type of screw that goes in
the tail light assemblies, which had little clips that
kept the screw from coming out of the door.

Type yes but size no. Tail Lamps use 8x32.

I saw item 6 in the drawing in my copy of the Ord 9,
but it was further aft in the drawing. Is that a different
version of the Ord 9 than what is on line?

See supply manuals comment at top.

Post by **wesk** » Wed Apr 18, 2018 10:04 am

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Nic · Post by **Nic** » Wed Apr 18, 2018 10:45 am

Thanks for the advice guys as always much appreciated.

I had downloaded the ORD TM 9-2320-208-34-P & the screw size was not displayed on the copy. Upon downloading the TM 9-2320-208-20P there it was.

Regards

Nic

mdainsd · Post by **mdainsd** » Wed Apr 18, 2018 11:01 am

In addition to the M38 and the M38A1, those headlight doors and that screw is used on M715 and M725 as well as the early deuce and a halves (various M numbers and manufactures).

Might make it easier to hunt some down.

Post by **wesk** » Thu Apr 19, 2018 12:22 am

This should help you Nic!

Remember to install lock washer first then lock ring.

4x4M38 · Post by **4x4M38** » Thu Apr 19, 2018 7:01 am

That is different than the M38.

Thanks Wes!

Post by **wesk** » Thu Apr 19, 2018 9:40 am

The M38 uses the same Headlamp door assembly ORD# 7525936 that the M38A1, M170, M715 series, M34/35 series and on and on from 1950 thru 1970.

Willys produced both the M38 and the M38A1 initially with the same door screw. The military later superseded that screw but allowing it's continued issue until stocks were depleted and then switch to the newer screw.

They used the ORD# 7525935, FSN 5305-695-7209 (5305-00-638-5174) first then that screw was superseded January 1963 by ORD# 132848, FSN 5305-00-226-9267.

Since the M38A1 was still in production 1964 thru 1971 it stands to reason that after Jan 1963 that the headlight assemblies installed by Willys/Kaiser would probably have doors with the new screws 132848. If I can locate a copy of the Canadian M38A1 CDN2 & CDN3 IPL we could probably verify this since they were produced thru 1971 at Wiily/Kaiser Toledo.

These headlight assemblies have been interchanged many times in the field from 1950 thru 2018. You could have anyone of 3 different M series headl light assemblies or anyone of the two doors or anyone of the two screws.

If you have the short 7/16" screw it is the early screw 7525935 and if you have if you have the long 1" screw it is the late 132848 screw.

Again: The M38 & M38A1 left Willys with the same three short screws (ORD# 7525935) in the same door assy (ORD# 7525936).

Nic · Post by **Nic** » Thu Apr 19, 2018 10:36 am

wesk wrote:This should help you Nic!

Thanks once again Wes

Nic

ROBCDN3 · Post by **ROBCDN3** » Thu Apr 19, 2018 11:46 am

Hi. group. Sorry my 71 has ss screws about 1' long. I do not have the parts list for the 71. Rob 1971 M38A1 CDN3C