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 17 of 657
TM 9-2320-260-34-1
MECHANICAL SYSTEMS TROUBLESHOOTING
SYMPTOM INDEX (Contd)
MALFUNCTION
NO.
MALFUNCTION
TROUBLESHOOTING
PROCEDURE
PAGE
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
COOLING SYSTEM
Loss of coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine coolant temperature gage above 230°F (110°C) . . . . . . . . . . . . . .
CLUTCH
Vehicle will not remove with clutch engaged. . . . . . . . . . . . . . . . . . . . . . .
Burning odor evident with clutch engaged. . . . . . . . . . . . . . . . . . . . . . .
Clutch noisy during engagement and disengagement . . . . . . . . . . . . . . .
Vibration during clutch engagement. . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION
Engine stalls when clutch is engaged and transmission is in gear . . . . .
Vehicle will not move when clutch is engaged and transmission
is in gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Excessive noise during shifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission oil leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission grinds and/or pops out of gear during shifting . . . . . . . . . .
TRANSFER CASE
Transfer case will not operate front differential . . . . . . . . . . . . . . . . . . .
Transfer case will not operate rear differentials . . . . . . . . . . . . . . . . . . .
Transfer case oil leakage.
.......
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer case noisy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer case grinds or pops out of gear during normal vehicle
operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIFFERENTIAL
Differential noisy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential clunks during turns or initial takeoff. . . . . . . . . . . . . . . . . .
Differential vibrates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential leaks oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Abnormal tire wear (front axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Abnormal tire wear (rear axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING GEAR
Excessive play in steenng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vehicle shimmy (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering gear leaking oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil leaking from power steering pump . . . . . . . . . . . . . . . . . . . . . . . . .
Excessive power steering pump noise . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering wheel hard to tum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR COMPRESSOR
Low air pressure (no air leaks, governor properly adjusted and
operative) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air compressor passes excessive oil (excessive oil bled from air
reservoirs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air compressor does not unload (air governor adjusted and operative) . . .
Air compressor head leaking water. . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER TAKEOFF
(Transmission-driven) power takeoff inoperative . . . . . . . . . . . . . . . . . .
(Transfer case-driven) power takeoff inoperative . . . . . . . . . . . . . . . . . .
Power takeoff slips out of gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission power takeoff leaks oil . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer power takeoff leak soil.
... . . . . . . . . . . . . . . . . . . . . . . . . . .
2-14
2-14
2-14
2-15
2-15
2-16
2-16
2-16
2-16
2-16
2-17
2-17
2-17
2-18
2-18
2-18
2-19
2-19
2-19
2-19
2-19
2-20
2-20
2-20
2-20
2-20
2-20
2-20
2-21
2-21
2-21
2-21
2-22
2-22
2-22
2-22
2-23
2-3
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