TM-9-2320-260-34-1
TRUCK, 5-TON, 6X6, M809 SERIES (DIESEL)
TECHNICAL MANUAL; DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE; VOLUME 1 OF 2
JULY 1994
TM-9-2320-260-34-1 - Page 118 of 657
TM 9-2320-260-34-1
3-21. FLYWHEEL AND GEAR REPLACEMENT
THIS TASK COVERS:
a. Flywheel Removal
c. Ring Gear Installation
b. Ring Gear Removal
d. Flywheel Installation
INITIAL SETUP
APPLICABLE MODELS
All
SPECIAL TOOLS
Engine barring tool (Appendix B, Item 66)
TOOLS
General mechanic’s tool kit
(Appendix B, Item 1)
Soft-head hammer (Appendix B, Item 47)
Torque wrench, 1/2-in. dr.
(Appendix B, Item 3)
Two dowel pins (Appendix E, Figure E-1)
Two puller screws (Appendix C, Item 41)
MATERIALS/PARTS
Safety wire (Appendix D, Item 373)
Tempilstik crayon (Appendix C, Item 10)
REFERENCES (TM)
TM 9-2320-260-10
TM 9-2320-260-34P-1
EQUIPMENT CONDITION
• Parking brake set (TM 9-2320-260-10).
• Transmission removed (para. 8-4).
• Clutch and pressure plate removed (para. 4-2).
GENERAL SAFETY INSTRUCTIONS
• Wear gloves at all times when handling heated
parts.
• Flywheel is heavy; use caution when removing.
a. Flywheel Removal
1. Remove safety wire (4) from screws (5). Discard safety wire (4).
2. Remove two screws (5) and washers (6) from flywheel (7) and install two dowel pins.
3. Remove four screws (5) and washers (6) from flywheel (7).
WARNING
Flywheel is heavy. Use caution when removing from flywheel
housing. Failure to do so may cause injury to personnel.
NOTE
Assistant will help with step 4.
4. Install two puller screws (3) on flywheel (7). Tighten jackscrews (3) alternately and remove
flywheel (7) from crankshaft (1).
5. Remove puller screws (3) from flywheel (7).
6. Remove dowel pins from crankshaft (1).
b. Ring Gear Removal
WARNING
Wear gloves at all times when handling heated parts. Failure to do
so may cause injury to personnel.
CAUTION
Do not heat ring gear above 600°F (316°C). Overheating of ring
gear may cause damage.
3-66
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