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 502 of 657
TM 9-2320-260-34-1
9-2. FRONT AXLE ENGAGEMENT AIR CYLINDER MAINTENANCE
THIS TASK COVERS:
a. Removal
d. Assembly
b. Disassembly
e. Installation
c. Cleaning and Inspection
INITIAL SETUP
APPLICABLE MODELS
All
TOOLS
General mechanic’s tool kit
(Appendix B, Item 1)
Torque wrench, 3/8-in. dr.
(Appendix B, Item 4)
MATERIAIS/PARTS
Four tab lockwashers
(Appendix D, Item 523)
Two seals (Appendix D, Item 432)
Two gaskets (Appendix D, Item 140)
MATERIALS/PARTS (Contd)
Locknut (Appendix D, Item 174)
Lubricating oil (Appendix C, Item 21)
Sealing compound (Appendix C, Item 43)
Antiseize tape (Appendix C, Item 50)
REFERENCES (TM)
TM 9-2320-260-10
TM 9-2320-260-34P-1
EQUIPMENT CONDITION
Air tanks drained (TM 9-2320-260-10).
a. Removal
1. Remove air line (6) and adapter (5) from cover (3).
2. Bend tabs on four tab lock washers (2) away from heads of screws (1) and cover (3) and remove
four screws (1), tab lockwashers (2), cover (3), and gasket (7) from air cylinder (4). Discard tab
lockwashers (2) and gasket (7).
3. Remove locknut (8) from front end of shifter shaft (11). Discard locknut (8).
4. Remove air cylinder (4), piston (9), and gasket (10) from shifter shaft (11) and front output shaft
cover (12). Discard gasket (10).
1. Remove piston (9) from air cylinder (4).
2. Remove two retainer rings (13), retainers (14), springs (15), and washers (17) from piston (9).
3. Remove two seals (16) from piston (9). Discard seals (16).
c. Cleaning and Inspection
1.
2.
3.
4.
5.
6.
7.
For general cleaning instructions, refer to para. 2-8.
For general inspection instructions, refer to para. 2-9.
Inspect springs (15) for bent, broken, or deformed coils. Replace both springs (15) if one or both is
damaged or mismatched.
Inspect air cylinder (4) for bends, cracks, dents, and internal surface scoring. Minor scoring is
acceptable. Replace air cylinder (4) if dented, bent, cracked, or severely scored.
Inspect piston (9) for cracks, burrs, dents, and damaged seal and retainer grooves. Replace
piston (9) if cracked, burred, dented, or grooves are damaged.
Inspect retainers (14) for bends and distortion. Replace retainer (14) if bent or distorted.
Inspect cover (3) for cracks and damaged threads. Replace cover (3) if cracked or threads are
damaged.
9-2
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