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 462 of 657
TM 9-2320-260-34-1
8-4. TRANSMISSION (IN-VEHICLE) REPLACEMENT
THIS TASK COVERS:
a. Removal
b. Installation
INITIAL SETUP
APPLICABLE MODELS
REFERENCES (TM)
All
TM 9-2320-260-10
TOOLS
TM 9-2320-260-20
General mechanic’s tool kit
TM 9-2320-260-34 P-1
(Appendix B. Item 1)
EQUIPMENT CONDITION
Transmission lifting jack
Torque wrench, 3/8-in. dr.
(Appendix B, Item 4)
Lifting device
Chain
MATERIALS/PARTS
Twelve lockwashers (Appendix D, Item 215)
Thirteen lockwashers
(vehicles with front winch)
(Appendix D, Item 215)
Two screw-assembled lockwashers
(Appendix D, Item 385)
Locknut (vehicles with front winch)
(Appendix D, Item 170)
Gasket (Appendix D, Item 139)
Two screws (Appendix C, Item 36)
Two washers (Appendix C, Item 58)
Wheels chocked (TM 9-2320-260-10).
Cab tunnel, rear tunnel, and toeboard removed
(TM 9-2320-260-20).
Transmission-to-transfer case propeller shaft
removed (TM 9-2320-260-20).
Front winch propeller shaft removed
(TM 9-2320-260-20).
Gearshift lever removed (para. 8-3).
Rotochamber removed (M816) (para. 4-4).
Twin poppet valve removed (para. 8-2).
GENERAL SAFETY INSTRUCTIONS
l All personnel must stand clear during lifting
operations.
l Lifting capacity must be greater than weight of
transmission.
1. Remove clevis pin (6) and turnbuckle (5) from clutch release lever (7).
2. Remove screw (4), lockwasher (3), bracket (1), and spring (2) from bell housing (8). Discard lock-
washer (3).
3. Place transmission lifting jack under transmission (22).
4. Remove two screw-assembled lockwashers (15) from transmission shifter housing (12). Discard
screw-assembled lockwashers (15).
5. Install chain on transmission shifter housing (12) with two washers (14) and screws (13).
WARNING
l Lifting device and transmission lifting jack must have a weight
capacity greater than the weight of the transmission to prevent
damage to equipment and injury to personnel.
l All personnel must stand clear during lifting operations. A swing-
ing or shifting load may cause injury to personnel.
6. Attach lifting device to chain.
NOTE
Perform steps 7 and 8 for vehicles equipped with front winch.
7. Remove screw (18) and lock washer (19) from shift arm (16) and power takeoff (21). Discard lock-
washer (19).
8. Remove locknut (17), screw (20), and shift arm (16) from power takeoff (2 1). Discard locknut (17).
8-6
Back to Top
