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 643 of 863
TM 9-2320-260-34-2
16-41. TRANSMISSION POWER TAKEOFF REPAIR (Contd)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14,
15.
16.
●
●
●
NOTE
Coat roller bearings with straight mineral oil prior to
installation.
Coat threads of external screws and retainers and gaskets with
sealing compound prior to installation.
Coat internal parts with light coat of lubricating oil prior to
installation.
c. Assembly
Install plug (3) and two screws (7) in PTO housing (8).
Using arbor press, install bearing (1) in bore (2) of PTO housing (8). Ensure bearing (1) is flush with
inner face of bore (2).
Install new woodruff key (4) in reverse gear shaft (5).
Insert reverse gear shaft (5) through bore (6) of
PTO
housing (8) and insert through one thrust
washer (11), reverse gear (12), and second thrust washer (14), and start into bearing (1). Ensure
woodruff key (4) alines with keyway of reverse gear (12).
Continue to press reverse gear shaft (5) until hole in reverse gear (12) and reverse gear bore (6) will
admit installation of pin (13).
Install pin (13) in reverse gear (12) and reverse gear shaft (5) with new cotter pin (10). Bend ends of
cotter pin (10) around reverse gear (12). Cotter pin (10) ends must be higher than roots of gear teeth
on reverse gear ( 12).
Using arbor press, install bearing (9)
over
reverse gear shaft (5) and into PTO housing (8). Rolled
edges of bearing (9) may be above edge of bore (6) in PTO housing (8).
Install gear (18) on front output shaft (19). Slide gear (18) up to splines on front output shaft (19).
Position thrust washer (17) over front output shaft (19) and on gear (18) and install with
snapring (16).
Using arbor press, install bearing (15) on front output shaft (19). Seat to snapring (16).
Place splined end of front output shaft (19) through bore (21) in PTO housing (8). Position gear (20)
over end of front output shaft (19), and slide gear (20) onto splines of shaft (19). Fork groove of
gear (20) is toward rear of PTO housing (8).
Continue insertion of front output shaft (19) and use arbor press to seat bearing (15) in bore (21)
of PTO housing (8). Seat bearing (15) flush with inner face of bore (21).
Using arbor press, install bearing (26) on rear end of front output shaft (19) and into bearing
bore (27) of PTO housing (8). Press bearing (26) flush with inner face of bore (27) and to shoulder
on front output shaft (19).
Coat outer surface of spacer (25) with light coat of GAA grease and place spacer (25) in bore (27)
against bearing (26).
Install new seal (29) in cover (24).
Install new gasket (28) and cover (24) on PTO housing (8) with four new lockwashers (23) and
screws (22).
16-244
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