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 483 of 657

TM 9-2320-260-34-1

8-6. TRANSMISSION MAINTENANCE (Contd)

8. Inspect gears (6), (7), (8), (9), (10), and (11) for wear. Refer to table 8-5, Wear Limits, for

measurements. Replace gear (6), (7), (8), (9), (10), or (11) if worn past limits.

ITEM

WEAR LIMITS/TOLERANCES

NO.

ITEM/POINT OF MEASUREMENT

INCHES

MILLIMETERS

6

Countershaft drive gear

Inside diameter

2.3745-2.3755

60.3123-60.3377

Outside diameter

8.255-8.265

209.6670-209.9310

7

Countershaft fourth gear

Inside diameter

2.6215-2.6225

66.5861-66.6151

Outside diameter

8.967-8.977

227.7618-228.0158

8

Countershaft third gear

Inside diameter

2.6245-2.6255

66.6623-66.6877

Outside diameter

6.429-6.439

165.2966-163.5506

9

Countershaft second gear

Inside diameter

2.6295-2.6305

66.7893-66.8147

Outside diameter

4.599-4.609

116.8146-117.0686

10

Output shaft – outside diameter

5.475-5.485

139.0650-139.3190

11

Reverse idler gear

Inside diameter (bearing journals)

2.0005-2.0015

50.8127-50.8381

Outside diameter (large gear)

4.525-4.535

114.9350-115.1890

Outside diameter (small gear)

3.652-3.662

92.7608-93.0148

Table 8-5. Wear Limits.

8-27