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 222 of 657
TM 9-2320-260-34-1
3-52. OIL PUMP REPAIR (Contd)
9. Using arbor press, remove idler gear (10) from idler shaft (11) and drive gear (9) from driveshaft (4).
10. Remove inner body (7) and gasket (6) from oil pump body (2). Discard gasket (6).
11. Remove idler gear (12) from idler shaft (11) and drive gear (3) from driveshaft (4).
12. Remove idler shaft (11) and driveshaft (4) from oil pump body (2).
13. Remove gear (1) from driveshaft (4).
NOTE
Perform step 14 if dowel pins are damaged.
14. Remove dowel pins (5) and (8) from oil pump body (2) and inner body (7).
b. Cleaning and Inspection
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
For general cleaning instructions, refer to para. 2-8.
Inspect oil pump body (2) for rust, corrosion, nicks, burrs, and cracks. Replace oil pump body (2) if
rusted, corroded, nicked, burred, or cracked.
NOTE
Oil pump body bushings must be replaced as a pair.
Inspect two bushings (16) in oil pump body (2) for wear. Refer to table 3-3, Oil Pump Wear Limits,
for measurements. Replace bushings (16) with arbor press if worn past limits.
Inspect filter head (14) for rust, corrosion, nicks, burrs, and cracks. Replace filter head (14) if rusted,
corroded, nicked, burred, or cracked.
Inspect bushing (15) in filter head (14) for wear. Refer to table 3-3, Oil Pump Wear Limits, for
measurements. Replace bushing (15) with arbor press if worn past limits.
Inspect inner body (7) for rust, corrosion, nicks, burrs, and cracks. Replace inner body (7) if rusted, __
corroded, nicked, burred, or cracked.
Inspect idler shaft (11) and driveshaft (4) for breaks, cracks, galling, and wear. Refer to table 3-3,
Oil Pump Wear Limits, for measurements. Replace idler shaft (11) or driveshaft (4) if broken,
cracked, galled, or worn past limits.
Inspect plunger (13) for binds or bends. Replace plunger ( 13) if bent or binding.
Inspect drive gears (3) and (9), idler gears (10) and (12), and gear (1) for cracks, chips, pits, or broken
teeth. Replace gear(s) if cracked, chipped, teeth are broken, or if pits in teeth exceed one-quarter
width of active tooth area.
NOTE
Idler gear bushings must be replaced as a pair.
Inspect four bushings (17) in idler gears (10) and (12) for wear. Refer to table 3-3, Oil Pump Wear
Limits, for measurements. Replace bushings (17) with arbor press if worn past limits.
Table 3-3. Oil Pump Wear Limits.
ITEM
NO.
4&11
15
16
17
ITEM/POINT OF MEASUREMENT
Idler shaft and driveshaft - outside diameter
Bushing, filter head - inside diameter
Bushing, pump body - inside diameter
Bushing, idler gears - inside diameter
WEAR LIMITS/TOLERANCES
INCHES
0.6145
0.6185
0.6185
0.6185
MILLIMETERS
15.608
15.710
15.710
15.710
3-170
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