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 32 of 657

TM 9-2320-260-34-1
Table 2-1. Mechanical Troubleshooting (Contd).
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
40.
41.
42.
TRANSFER CASE OIL LEAKAGE
Step 1.
Step 2.
Check transfer case-to-PTO oil feed line. Repair or replace oil feed line if feed line is leaking
(para. 9-4).
Check and verify approximate location of oil leaks.
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
TRANSFER
Replace transfer front output flange oil seal if leaking (para. 9-4).
Replace transfer input flange oil seal if leaking (para. 9-4).
Replace transfer front output cover gasket if leaking (para. 9-4).
Replace transfer input shaft bearing cover gasket if leaking (para. 9-4).
Replace transfer housing gasket if leaking (para. 9-4).
Replace transfer rear output bearing cover gasket if leaking (para. 9-4). Remove parking
brake (TM 9-2320-260-20) and replace gasket (para. 9-3).
Replace intermediate shaft rear bearing cover gasket if leaking (para. 9-3). Remove
parking brake (TM 9-2320-260-20) and replace gasket (para. 9-3).
Replace rear output shaft oil seal if leaking (para. 9-3).
Replace rear output shaft bearing retainer gasket if leaking (para. 9-3). Remove parking
brake (TM 9-2320-260-20).
Replace top cover gasket if leaking (para. 9-3).
Remove PTO if leaking oil. Repair oil leaks (malfunction 63).
Remove transfer case if leak(s) continues (para. 9-3). Disassemble and replace defective
components or repair condition causing leak(s) (para. 9-4).
END OF TESTING!
CASE NOISY
Step 1. Confirm origin of noise.
a. Remove transmission-to-transfer propeller shaft and operate transmission in forward and
reverse.
b. Noise is from transfer case if no noise is present during test.
Step 2. Disconnect transfer rear propeller shaft and front axle propeller shaft (TM 9-2320-260-20).
a.
b.
c.
TRANSFER
Turn transfer front input shaft and feel for looseness and roughness in three shift
positions and when front axle is engaged and not engaged.
Remove transfer case if noise is present (para. 9-4). Disassemble transfer case and repair
(para. 9-4).
If noise is not present, check differential for proper operation (malfunction 43).
END OF TESTING!
CASE GRINDS OR POPS OUT OF GEAR DURING NORMAL VEHICLE OPERATION
Step 1. Check condition and adjustment of transfer control linkages (TM 9-2320-260-20). Ensure
shift shaft has good detent action. If so, proceed to step 2.
Step 2. Remove transfer case (para. 9-3). Repair transfer case if defective (para. 9-4).
END OF TESTING!
2-18


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