TM-9-2320-260-20
TRUCK, 5-TON, 6X6, M809 SERIES (DIESEL)
TECHNICAL MANUAL; UNIT MAINTENANCE
APRIL 1995
TM-9-2320-260-20 - Page 645 of 1337
TM 9-2320-260-20
8-11. MASTER CYLINDER REPLACEMENT
THIS TASK COVERS:
a. Removal
b. Installation
INITIAL SETUP
APPLICABLE MODELS
REFERENCES (TM)
All
TM 9-2320-260-10
MATERIALS/PARTS
Eight locknuts
TM 9-2320-260-20P
EQUIPMENT CONDITION
Screw-assembled lockwasher
●
Parking brake set (TM 9-2320-260-10).
Cotter pin
• Transfer to forward-rear axle propeller shaft
Antiseize tape (Appendix C, Item 30)
removed (para. 7-2).
a. Removal
1. Remove screw-assembled lockwasher (1) and open master cylinder hatch (2). Discard screw-
assembled lockwasher (1).
2. Remove four locknuts (15), screws (18), washers (17), and shield (14) from air-hydraulic
cylinder (16). Discard locknuts (15).
3. Remove return spring (5) from brake lever (4) and bracket (6).
4. Remove cotter pin (7), straight pin (9), and pushrod clevis (8) from brake lever (4). Discard cotter
pin (7).
5. Loosen jamnut (10) and remove pushrod clevis (8) from pushrod (12).
6. Disconnect hydraulic line (19) horn master cylinder (20) and air-hydraulic cylinder (16).
7. Remove four locknuts (13), screws (11), and master cylinder (20) from bracket (3). Discard
locknuts (13).
8. Visually inspect master cylinder dust boot (21). Replace if darn aged.
b. Installation
1. Install pushrod clevis (8) on pushrod (12).
2. Install master cylinder (20) on bracket (3) with four screws (11) and new locknuts (13).
3. Apply antiseize tape to male threads of hydraulic line (19).
4. Connect hydraulic line (19) on master cylinder (20) and air-hydraulic cylinder (16).
5. Install pushrod clevis (8) on brake lever (4) with straight pin (9) and new cotter pin (7).
6. Install return spring (5) on brake lever (4) and bracket (6).
7. Install shield (14) on air-hydraulic cylinder (16) with four washers (17), screws ( 18), and new
locknuts (15).
8-20
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