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

  TM-9-2320-260-34-1 - Page 30 of 657

TM 9-2320-260-34-1
Table 2-1. Mechanical Troubleshooting (Contd).
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
32. VIBRATION DURING CLUTCH ENGAGEMENT
CAUTION
Vibration during clutch engagement indicates a warped and/or
burned pressure plate and flywheel. When this condition is evi-
dent, immediate vehicle clutch inspection is required. Prolonged
vehicle operation may result in permanent damage of flywheel and
damage to transmission.
Remove transmission (para. 8-4).
a.
b.
c.
Inspect pressure plate and clutch disc (para. 4-2). Replace pressure plate and clutch disc
if defective (para. 4-2).
Verify pilot bearing condition. Replace pilot bearing if defective (para. 4-2).
Remove pressure plate and clutch disc (para. 4-2). Verify flywheel condition. Replace
flywheel if burned or damaged (para. 3-21).
END OF TESTING!
TRANSMISSION
33. ENGINE STALLS WHEN CLUTCH IS ENGAGED AND TRANSMISSION IS IN GEAR
Verify engine operation (malfunctions 6, 10, 11, 21, and 23).
END OF TESTING!
34. VEHICLE WILL NOT MOVE WHEN CLUTCH IS ENGAGED AND TRANSMISSION IS IN GEAR
Step 1. Verify clutch condition (malfunction 29).
Step 2. Complete troubleshooting (malfunction 30).
END OF TESTING!
35. EXCESSIVE NOISE DURING SHIFTING
Step 1. Check clutch condition (malfunctions 30 through 32). Perform steps 2 and 3 if noise is not
from clutch system.
Step 2. Remove and inspect transmission (para. 8-4).
Repair or replace transmission if defective (para. 8-4 or 8-6).
Step 3. Check transfer case condition (malfunctions 38 through 42).
END OF TESTING!
36. TRANSMISSION OIL LEAKAGE
Check and verify approximate location of oil leak(s).
a. Replace top cover gasket if leaking (para. 8-7).
b. Replace PTO gasket if leaking (para. 16-40).
c. Replace transmission counter shaft bearing cover gasket if leaking (para. 8-6).
d. Replace transmission bearing cap gasket if leaking (para. 8-6).
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