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 470 of 657
TM 9-2320-260-34-1
8-6. TRANSMISSION MAINTENANCE
THIS TASK COVERS:
a. Disassembly
c .
Assembly
b. Cleaning and Inspection
INITIAL SETUP
APPLICABLE MODELS
All
TOOLS
General mechanic’s tool kit
(Appendix B, Item 1)
Mechanical puller (Appendix B, Item 14)
Torque wrench, 3/4-in. dr.
(Appendix B, Item 2)
2-318-in. socket, 1-in. dr.
(Appendix B, Item 18)
314-in. to 1-in. adapter
(Appendix B, Item 19)
2-1/8-in. socket, 1-in. dr.
(Appendix B, Item 20)
Companion flange replacer
(Appendix B, Item 96)
Inside micrometer (Appendix B, Item 9)
Outside micrometer (Appendix B, Item 8)
Arbor press (Appendix B, Item 7)
Lifting device
Rope sling
MATERIALS/PARTS
Thirteen lockwashers
(Appendix D, Item 219)
Nine lockwashers (Appendix D, Item 223)
Eight lockwashers (Appendix D, Item 217)
Six lockwashers (vehicles with PTO)
(Appendix D, Item 215)
Four lockwashers (Appendix D, Item 227)
Twelve screw-assembled lockwashers
(all vehicles except M816)
(Appendix D, Item 385)
Ten screw-assembled lockwashers (M816)
(Appendix D, Item 385)
Six screw-assembled lockwashers
(Appendix D, Item 389)
Six screw-assembled lockwashers
(Appendix D, Item 387)
MATERIALS/PARTS (Contd)
Gasket (Appendix D, Item 134)
Gasket (Appendix D, Item 130)
Gasket (Appendix D, Item 155)
Two gaskets (Appendix D, Item 131)
Gasket (Appendix D, Item 133)
Gasket (Appendix D, Item 135)
Gasket (Appendix D, Item 136)
Gasket (Appendix D, Item 138)
Five setscrews (Appendix D, Item 487)
Two cotter pins (Appendix D, Item 23)
Seal (Appendix D, Item 420)
Seal (Appendix D, Item 428)
Seal (Appendix D, Item 430)
Four woodruff keys (Appendix D, Item 548)
Woodruff key (Appendix D, Item 546)
Three expansion plugs (Appendix D, Item 323)
Locknut (Appendix D, Item 166)
Snapring (Appendix D, Item 513)
Snapring (Appendix D, Item 514)
Snapring (Appendix D, Item 515)
Snapring (Appendix D, Item 516)
Snapring (Appendix D, Item 517)
GAA grease (Appendix C, Item 14)
Sealing compound (Appendix C, Item 43)
Two puller screws (Appendix C, Item 38)
REFERENCES (TM)
LO 9-2320-260-12
TM 9-2320-260-34P-1
EQUIPMENT CONDITION
l Transmission drained (LO 9-2320-260-12).
“ Transmission removed (para. 8-4).
GENERAL SAFETY INSTRUCTIONS
All personnel must stand clear during lifting
operations.
a. Disassembly
1. Remove four screws (1), lockwashers (2), two spring clips (5), and pads (29) from clutch release
sleeve (28). Discard lockwashers (2).
2. Remove clutch release sleeve (28) from input shaft (9).
3. Remove grease fitting (26) and bearing (27) from clutch release sleeve (28).
4. Remove two screws (24), lockwashers (23), and spacers (22) from clutch release yoke (25). Discard
lockwashers (23).
8-14
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