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 230 of 657
TM 9-2320-260-34-1
3-54. CRANKSHAFT AND MAIN BEARING INSTALLATION
THIS TASK COVERS:
Installation
INITIAL SETUP
APPLICABLE MODELS
All
TOOLS
General mechanic’s tool kit
(Appendix B, Item 1)
Torque wrench, 1/2-in. dr.
(Appendix B, Item 3)
Main bearing-cap puller (Appendix B, Item 92)
Lifting straps (Appendix B, Item 155)
Chain
Lifting device
MATERIALS/PARTS
Fourteen locktabs (Appendix D, Item 206)
Woodruff key (Appendix D, Item 549)
Plastigage (Appendix C, Item 30)
Lubricating oil (Appendix C, Item 21)
REFERENCES (TM)
TM 9-2320 -260-34P-1
Installation
NOTE
Perform step 1 if crankshaft gear was removed from crankshaft.
1. Position new woodruff key (13) on crankshaft (9) and press crankshaft gear (12) on crankshaft (9).
2. Install seven ring dowels (7) on cylinder block (6).
3. Apply lubricating oil to seven upper main bearing shells (8) and install thrust ring halves (5) and
upper main bearing shells (8) on cylinder block (6).
4. Install lifting strap on lifting device and crankshaft (9).
5. Install crankshaft (9) on cylinder block (6).
6. Remove lifting device and lifting strap from crankshaft (9).
7. Install plastic clearance gage on main bearing journals (4).
CAUTION
Ensure main bearing caps are installed in their original position.
8. Apply lubricating oil to seven lower main bearing shells (10) and main bearing journals (4) and
install thrust ring halves (3), lower main bearing shells (10), and main bearing caps (11) on
journals (4), crankshaft (9), and cylinder block (6) with fourteen new locktabs (2) and screws (1),
9. Tighten screws (1) as follows:
a. Tighten screws (1) 140 lb-ft (190 N•m) in sequence.
b. Tighten screws (1) 300 lb-ft (407 N•m) in sequence.
c. Loosen screws (1) completely.
d. Tighten screws (1) 140 lb-ft (190 N•m) in sequence.
e. Tighten screws (1) 300 lb-ft (407 N•m) in sequence.
10. Remove fourteen screws (1) and locktabs (2) from main bearing caps (11).
11. Using main bearing cap puller, remove seven main bearing caps (11) and lower main bearing
shells (10).
12. Using plastic clearance gage package, determine oil clearance. Clearance should be 0.0015 -0.0050 in.
(0.038-0.127 mm). If clearance is incorrect, replace crankshaft (9) or send to next higher level main-
tenance for grinding. Install oversize bearings if crankshaft (9) is ground.
13. If clearance is correct, repeat steps 8 and 9. Bend tabs of locktabs (2) over heads of screws (l).
3-178
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