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 31 of 657

TM 9-2320-260-34-1
Table
2-1.
Mechanical Troubleshooting (Contd).
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
e. Replace rear companion flange oil seals if leaking (para. 8-6).
f. If transmission leak(s) continue, remove transmission (para. 8-4) and inspect (para. 8-6).
Repair transmission (para. 8-6) or replace (para. 8-4) if unrepairable.
END OF TESTING!
37. TRANSMISSION GRINDS AND/OR POPS OUT OF GEAR DURING SHIFTING
Remove transmission top cover exposing shift forks, gears, and synchronizers (para. 8-7).
a. Remove transmission and repair if synchronizers are damaged (paras. 8-4 and 8-6).
b. Remove transmission and replace damaged gears (paras. 8-4 and 8-6).
END OF TESTING!
TRANSFER CASE
38. TRANSFER CASE WILL NOT OPERATE FRONT DIFFERENTIAL
Step 1. Check that twin poppet valves (on transmission) and air lines are supplying signals to
transfer sprag air cylinder.
a. With air tanks full and engine off, loosen air lines at sprag air cylinder and listen for air
leaking as transmission is shifted into forward and reverse gears.
b. Replace poppet valve(s) or air lines if air signals are weak or absent (para. 8-2).
Step 2. Repeat test in step la and listen for sprag clutch engagement in transfer sprag unit.
a. Replace transfer sprag air cylinder if forward and reverse sprag engagements are not
heard (para. 9-2).
b. Repair sprag unit in transfer if sprag engagement is heard (para. 9-4).
END OF TESTING!
39. TRANSFER CASE WILL NOT OPERATE REAR DIFFERENTIALS
Step 1.
Step 2.
Step 3.
Confirm transmission-to-transfer propeller shaft turns.
a.
b.
Proceed to step 2 if transmission-to-transfer propeller shaft can be turned with
transmission and transfer case in neutral.
Proceed to differential and rear axle mechanical troubleshooting sections of
TM 9-2320-260-20 if propeller shaft will not turn. If lockup is not in propeller shaft or
axles, go to step 3.
Confirm transfer-to-forward rear axle propeller shaft can be turned. Place transfer shifter
into neutral and raise both rear wheels on one side of vehicle (TM 9-2320-260-20).
Remove and repair transfer case if propeller shaft turns (paras. 9-3 and 9-4).
Remove and repair transfer case (paras. 9-3 and 9-4).
END OF TESTING!
2-17


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