TM-9-2320-260-34-2

TRUCK, 5-TON, 6X6, M809 SERIES (DIESEL)

TECHNICAL MANUAL; DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE; VOLUME 2 OF 2

JULY 1994

TM-9-2320-260-34-2 - Page 549 of 863

TM 9-2320-260-34-2

16-25. HOIST BEVEL GEARCASE REPAIR (M816) (Contd)

e. Assembly

1.

2.

3.

4.

5.

6.

7.

8.

NOTE

Coat bearings with gear oil before assembly.

Install new woodruff key (9) on input shaft (7), and press bevel gear (10) on input shaft (7) using

arbor press. Seat bevel gear (10) to shoulder (8) of input shaft (7).

Position input shaft (7) and bevel gear (10) in gearcase housing (17) with splined end of input

shaft (7) protruding through front bearing bore (18).

NOTE

Assistant will help with steps 3 through 6.

Using arbor press, install bearing (24) on input shaft (7). Seat bearing (24) to shoulder (6) of input

shaft (7).

Using arbor press, install bearing and input shaft (7) on gearcase housing (17) until inner edge

of bearing (24) is even with inner edge of gearcase housing (17).

Using arbor press, install bearing (11) on input shaft (7) and gearcase housing (17). Seat

bearing (11) to bevel gear (10).

NOTE

Use new shims of same thickness as shims removed.

Install new shims (19), new gasket (20), and input drive housing (21) on gearcase housing (17) with

four new lockwashers (23) and screws (22). Tighten screws (22) 25-33 lb-ft (34-45 N•m).

Install spacer (5) and yoke (4) on input shaft (7) with washer (3), new lockwasher (2), and screw (1).

Tighten screw (1) 29-33 lb-ft (39-45 N•m).

Install new gasket (16), new shim (15), and cover (12) on gearcase housing (17) with four new

lockwashers (13) and screws (14). Tighten screws (14) 25-33 lb-ft (34-45 N•m).

16-150