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 544 of 657
TM 9-2320-260-34-1
9-4. TRANSFER REPAIR (Contd)
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Install new woodruff key (3) in rear output shaft (2). Ensure there are no burrs on woodruff
key (3) after installation.
Position gear (4) on arbor press with flat side down.
Position rear output shaft (2) over gear (4), aline woodruff key (3) with keyway.
Using bearing cone adapter, press rear output shaft (2) into gear (4). Seat gear (4) to shoulder of
rear output shaft (2).
Press tapered roller bearings (1) and (5) onto rear output shaft (2) with small diameter of bear-
ings (1) and (5) facing away from gear (4). Bearing (1) seats against shoulder (6) and bearing (5)
seats against gear (4).
Position fork (12) on collar (9) of synchronizer (10).
While holding fork (12) on collar (9), set input shaft (8) in housing (16) alining ball bearing (11) with
bore (15) of housing (16). Seat ball bearing (11) in bore (15) by tapping input shaft (8) with soft-head
hammer. Ball bearing (11) should be seated just above inside lip of housing (16).
Aline setscrew hole (14) in range shifter shaft (7) with setscrew hole (13) in fork (12) and slide range
shifter shaft (7) through fork (12) and into bore (17) of housing (15). Stop range shifter shaft (7)
when setscrew holes (14) and (13) are alined.
Install setscrew (23) in fork (12) and range shifter shaft (7). Tighten setscrew (23) 115-120 lb-ft
(156-163 N•m).
Working inside housing (16), pass new safety wire (24) through head of setscrew (23), around nose of
fork (12), and twist ends of safety wire (24) together. Cut off excess safety wire (24) and bend twisted
end flat over fork (12).
Install new ball bearing (18), plunger (19), spring (20), new lockwasher (22), and detent screw (21)
in housing (16).
Set bearing (26) on intermediate shaft (25) in bore of housing (16) with intermediate gears (27)
and (28) in mesh with gears of input shaft (8).
Set bearing (5) on lower end of rear output shaft (2) in bore of housing (16) with gear (4) in mesh
with gear (27) on intermediate shaft (25).
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