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 659 of 863
16-45. TRANSFER POWER TAKEOFF REPAIR (M815, M819)
THIS TASK COVERS:
a. Disassembly
c.
Assembly
b. Cleaning and Inspection
INITIAL SETUP
APPLICABLE MODELS
M815, M819
TOOLS
General mechanic’s tool kit
(Appendix B, Item 1)
Mechanical puller kit (Appendix B, Item 14)
Spring tester (Appendix B, Item 10)
Torque wrench, 3/8-in. dr.
(Appendix B, Item 4)
Torque wrench, 1/2-in. dr.
(Appendix B, Item 3)
Torque wrench, 3/4-in. dr.
(Appendix B, Item 2)
1-1/2-in. socket, 3/4-in. dr.
(Appendix B, Item 118)
Inside micrometer (Appendix B, Item 9)
Outside micrometer (Appendix B, Item 8)
Feeler gage (Appendix B, Item 58)
Arbor press (Appendix B, Item 7)
Vise (Appendix B, Item 38)
MATERIALS/PARTS
Eleven lockwashers (Appendix D, Item 247)
Two check valves (Appendix D, Item 13)
Two cotter pins (Appendix D, Item 48)
Cotter pin (Appendix D, Item 42)
Seal (Appendix D, Item 470)
Seal (Appendix D, Item 415)
Shim (Appendix D, Item 498)
Shim (Appendix D, Item 497)
Shim (Appendix D, Item 496)
Gasket (Appendix D, Item 116)
Gasket (Appendix D, Item 122)
Woodruff key (Appendix D, Item 567)
Woodruff key (Appendix D, Item 568)
Lubricating oil (Appendix C, Item 21)
Sealing compound (Appendix C, Item 45)
REFERENCES (TM)
TM 9-2320-260-34P-2
EQUIPMENT CONDITION
Transfer power takeoff removed (para.16-43).
a. Disassembly
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Place housing (6) in vise.
Remove cotter pin (4), nut (5), and washer (3) from yoke (2) and shaft (1). Discard cotter pin (4).
Using puller, remove yoke (2) from shaft (1).
Remove housing (6) from vise.
Remove two cotter pins (10), nut (9), two washers (8), and lever (11) from stud (7) and shifter
rod (12). Discard cotter pins (10).
Remove two screws (15), lockwashers (14), four washers (13), and bracket (16) from cover (17).
Discard Iockwashers (14).
Remove plug (18), Iockwasher (19), spring (20), and ball bearing (21) from housing (6). Discard
lockwasher (19).
Remove four screws (25), Iockwashers (24), oil pump (23), and gasket (22) from housing (6).
Discard gasket (22) and lockwashers (24).
Remove plug (26) from housing (6).
Remove setscrew (27) and shifter rod (12) from fork (30) and housing (6).
Remove seal (28) from shifter rod (12). Discard seal (28).
Remove clutch (29) and fork (30) from housing (6) and shaft (1).
16-260
TM 9-2320-260-34-2
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