M38 Hand/Emergency Brake Cable routing

Mike_B · Post by **Mike_B** » Wed Oct 07, 2020 12:44 pm

My M38 came with a mangled up Hand Brake cable that wasn't connected at the tub end and a extra used cable in the ton of used parts I got with the Jeep. So the 2 beat up used cables both have a clip/bracket that looks like it attached to the bellhousing bolts to keep the cable off of the exhaust pipe. ORD 9 SNL G740 page 235 doesn't show this clip/bracket...was this a Bubba add?

Also, one of the cables has a small clip that looks like it would attach to the inner fender with a sheet metal screw just outside the firewall...again, not shown.

And finally, the Tub has a 1" knock out hole that was never knocked out, it lines up perfect with the hand brake handle and is dowm low on the firewall. Is this the correct hole to pass the cable through?

Thanks,

Mike B

Mike_B · Post by **Mike_B** » Wed Oct 07, 2020 1:08 pm

Looks like I found the answer to the firewall knock out hole issue. In Wes's Photo Gallery under M38 Body, page 6, the last picture (#119) shows the cable coming out of the hole I was asking about...wonder why that hole was never used on my tub???

Mike B

Kendall · Post by **Kendall** » Wed Oct 07, 2020 3:01 pm

This is the firewall (upside down) of my M38. The hole directly above the dimmer switch is where the cable goes through. Also shown are the cable attachments.

Mike_B · Post by **Mike_B** » Wed Oct 07, 2020 6:54 pm

Thanks Kendall!

I also figured out the bracket to keep the cable off of the exhaust pipe has to attach to the Engine Stay Cable Bolt.

The tub Knock Out was factory punched, but had a man installed KO blank like electricians use installed and then painted over...it came out easy.

So the only question left was there a small clip to support the cable at the inner fender?

Thanks,

Mike B

Post by **wesk** » Wed Oct 07, 2020 7:02 pm

Mike B,

You should use your ORD 9 parts manual it shows all the parts you mentioned clearly ID'd. If you do not have an ORD 9 SNL-G-740 they are free in PDF format on our downloads page. Just go to page 240 and start your search there!

J, K, L & P should get you started!

4x4M38 · Post by **4x4M38** » Wed Oct 07, 2020 8:22 pm

Part P does not attach to the stay cable. That clip, which has a little down turned pin, attaches to the crossmember.

Post by **wesk** » Wed Oct 07, 2020 10:45 pm

Again a short tour of my photo album will also answer that question.

Mike_B · Post by **Mike_B** » Wed Oct 07, 2020 11:46 pm

Both of my old used hand brake cables have a clip bracket located right at the bellhousing where the bolt end of the Stay Cable attached leading me to believe this clip was not added by Bubba. This clip is not shown on page 235 or 240, so that's why I asked about it. The clip looks factory made and would help in keeping the cable up and tight to the engine and away from the exhaust pipe. Maybe it was a later revision???

I'm good with the two outer jacket clamps located at both ends...

Thanks,

Mike B

4x4M38 · Post by **4x4M38** » Thu Oct 08, 2020 6:33 am

Hi Mike,
It would not be the first time we found out something new about something old.

Can you post a pic or two of the clip installed and not?

And I agree, it makes sense. That cable tends to want to lay over on the exhaust pipe.

Thanks,
Brian

RonD2 · Post by **RonD2** » Thu Oct 08, 2020 10:55 am

I couldn't find a picture of it in the manuals, but I have one (NOS) waiting to be installed that I can take and post a photo of later this evening.

I believe it's G740-7372668, WO-642724, listed on page 243 of the September 1955 ORD9.

Post by **wesk** » Thu Oct 08, 2020 10:55 am

Over these 70 years since production started on the M38 many changes have occurred. Most in the field based on problems developed during operation. Willys, Kaiser and the military have always done an excellent job of documenting them.

So I am forced to believe you have discovered another bubba mod that was probably driven by the incompatibility of many 1980's and up aftermarket parts replacements that have lost their dimensional accuracy over the years leading to fit and clearance issues such as repop parking brake cables that are longer than original and repop exhaust pipes with bends at varying angles to original.

The simple field solution is to add a steel clamp to the cable to move it away from something. All of these old emergency brake cables, choke cables and throttle cables are Bowden Type flex cables and have been around since 1902. There are hundreds of bare steel and insulated type clamps on the market for them specifically designed to grasp the outer cable housing snugly so it doesn't slip. Most of the clamp designs have mil specs and the old reliable military numbering system. So it was an extremely easy task for anyone in the last 70 years to add a proper fitting Bowden Cable Clamp to help with an interference issue.

RonD2 · Post by **RonD2** » Thu Oct 08, 2020 11:37 am

I found a picture of it in TM9-8012, Figure 32, on page 124. Not much detail, but you can see it attached on the engine stay cable in the lower right side of the figure.

I have one (NOS) waiting to be installed and I'll take and post a photo of later this evening.

I believe that clip is G740-7372668, WO-642724, listed on page 243 of the September 1955 ORD9.

Mike_B · Post by **Mike_B** » Thu Oct 08, 2020 1:35 pm

Ron, That's it! Mystery solved!

I was guessing it attached on the front side of the bellhousing, but that picture shows it on the back side, held in place via the stay cable jamb nut.

I'd post a picture of the clips, but I do it so infrequently that it's a huge learning curve every time I try, so I just give up. I'd be happy to email anyone a picture that wants it.

Thanks everyone!

Mike B

Post by **wesk** » Thu Oct 08, 2020 3:04 pm

"Photos are worth a thousand words"! One of the first things I learned when I entered this hobby in 1971 was this very well known phrase; "A photo is worth a thousand words" And each photo that we use to support inquiries is just that.

Here's a few photos that offer some odd perspectives:

TM 9-804 the first M38 Operator's Manual in 1950. No Clip at forward attachment of stay cable.

TM 9-8012 the 2nd M38 Operator's Manual 1956. Clip without an ID.

And of course the 3 clips and 2 clamps, which all do essentially the same thing, mention the hand brake application for them as "Cable Tube" for the 2 clamps , as "(handbrake cable to fender) for the 1st clip then as only "Attached to stay cable front" for our suspect clip then the final clip as "operating lever retracting spring"!

1955 ORD 9

To me it looks like Willys originally did not plane on the clip at the back corner of the engine and when they added the clip they never changed the schematic.

The 1951 M38 ORD 9 only shows one clamp at the fender and one at the tranny crossmember.

RonD2 · Post by **RonD2** » Thu Oct 08, 2020 3:58 pm