M809 Series 5-Ton 6×6 Trucks Repair Parts and Special Tools List TM 9-2320-260-24P-2

Description

This is the complete Unit, Direct Support, and General Support Maintenance Repair Parts and Special Tools List for the M809 Series 5-Ton 6×6 trucks (diesel), published as TM 9-2320-260-24P-2 and Air Force TO 36A12-1C-382-2. Volume 2 of the RPSTL covers the full M809 Series family — cargo, dump, tractor, wrecker, van, bolster logging, bridge transporting and rocket launcher chassis variants — and supplies the part numbers, National Stock Numbers, CAGEC codes and quantities required to identify, order or replace components in the motor pool or the field. The manual was issued on 30 September 2003 and supersedes both TM 9-2320-260-20P (May 1992) and TM 9-2320-260-34P-2 (June 1994).

File Details

• Manual Type: Unit, Direct Support, and General Support Maintenance Repair Parts and Special Tools List (RPSTL)
• Document Number: TM 9-2320-260-24P-2 / TO 36A12-1C-382-2
• Publication Date: 30 September 2003
• Volume: Volume 2
• Language: English
• Page Count: 1,020 pages
• File Format: PDF (instant download)
• Coverage: M809 Series 5-Ton 6×6 Trucks (Diesel)
• Supersedes: TM 9-2320-260-20P (May 1992) and TM 9-2320-260-34P-2 (June 1994)

Chapters Covered

The manual is organised into functional groups, each broken into illustrated figures with item numbers, SMR codes, NSNs, part numbers, CAGEC codes and quantities. The major groups and areas covered in this volume include:

IMAGES PREVIEW

• Group 18 — Body, Cab, and Hood: Van body assembly and mounting hardware, van splash guards, rear wall panels, hinged end panels, left and right rear door assemblies, ceiling and frame, air conditioning duct, underframe, retractable beams and ratchet shaft, hinged floor, counterbalance, right and left wall assemblies and weatherseal, interior side panels, side panel door checks and interior latch assemblies, retractable window sash, access doors, bonnet doors, main wiring harness, air conditioner and heater wiring harnesses, blackout by-pass, emergency lamp wiring, auxiliary hydraulic pump and 400 Hz converter wiring, telephone jack, 400 Hz converter wiring, circuit breaker control box, heater thermostatic switch, hinged roof plunger and blackout light switch, 3-phase and 400 Hz receptacles, ceiling switch and front wall switch, blackout and emergency switches, and ceiling lamp fixtures.
• Group 20 — Hoist, Winch, Crane, and Power Takeoff: Front winch brackets and mounting hardware, front winch assembly and wire rope assembly for wrecker and bolster logger, sheave assembly, tensioner and roller assemblies, propeller drive shaft assembly, bolster logger midwinch, basic winch drum and related parts, hand winch assembly, wrecker rear winch assembly complete, sheave swivel and trolley, cable tensioner, rear winch basic assembly, rear winch drive shaft and bearing assembly, rear winch controls and brake, wrecker winch and crane controls, dump hydraulic hoist, dump hoist safety latch, hoses and filter, dump hoist pump assembly, dump hoist control box, control valve, dump controls and connecting links, dump hoist propeller drive shaft, wrecker crane gondola, turntable, gear case, boom elevating cylinder, sheave and operator guard, boom assembly, inner boom extension and cylinder, crane hoist winch, hydraulic winch motor, tackle block, hoist drive and hoist shaft assemblies, hoist gear case, gondola hoist control valve, hydraulic hoses, lines and fittings, hydraulic oil tank, fluid filter, rear winch vertical and horizontal rollers, throttle control lever and cable, van hydraulic liftgate assembly, liftgate platform, frame and linkage, liftgate controls and safety latch, liftgate control assemblies, hydraulic tubing, oil tank and pump motor, liftgate pump, flow control valve, liftgate cylinder assemblies, closing cylinder assemblies, and liftgate pump drive shaft.
• Group 22 — Body, Chassis, and Accessory Items: Soft top assembly, mounting hardware and related parts, soft top post and rail assembly, cargo body adjustable safety strap and bow stowage strap, wrecker gondola canopy and seat, windshield wiper arm, blade and mounting hardware, rearview mirror assemblies, convex side view mirror, reflectors for cargo, dump, tractor, wrecker, van and bolster logger bodies, and data plates for engine, air cleaner, air restriction gage, surge tank, fuel pump, wrecker controls, front and rear winch, power takeoff controls, van body interior and exterior, liftgate, tire warning, fifth wheel, tow bar, transmission, power steering pump, emergency and service air, instrument panel, battery box, generator, engine, transmission, transfer containers, hood, brake fluid, dump body cab protector, cargo body tailgate and side gates.
• Group 33 — Special Purpose Kits: Shipping containers for engine, transfer and transmission, fuel burning personnel heater kits (including Model 10530-A24 and Model 10530B), heater exhaust and mounting hardware, pump, control and wiring harness, defroster assembly, alcohol evaporator, receptacle and shift lever dust boots, engine coolant heater kits, hood and grill cover, heater coolant assembly, control and wiring harness, battery box, exhaust and coolant hoses, thermal barrier kit, hot water personnel heater kits, defroster assembly and deflector, heater assembly, radiator cover, control switch, wiring leads and resistor assembly, hardtop kit, deep water fording kits (lines and fittings, control assembly and valve set, exhaust for M812A1), seat belt kit for fixed and floating driver’s seat, mud flap kits for tractor rear, wiper washer bottle kit, jet and pump assembly, slave receptacle kit, intervehicle power cable kit, A-frame components kit, pioneer tool bracket kit, machine gun mounting kit, air drop kit, bow and tarp kits for dropside and cargo short and long wheelbase, tarpaulin extension kit, dump body troop seat and tarpaulin kits, fire extinguisher kit, low air pressure warning light kit, tachograph kit, air hand brake kit, alternator conversion kit 60 to 100 amp, van body stabilizer kit, mini-lighting kits, convoy warning light kits for dump, van and general use, M14/M16 rifle mounting kit, front bumper step kit, vehicle tiedown kits, tach cable interference relief kit, portable decontamination mounting kit, cable reel kits, raised hood kit, power input receptacle kit, electric wiper kits, motor, arm and related parts, circuit breaker and wiring harness, hood spacer and bumper.
• Group 47 — Non-Electrical Gages: Tachometer and shaft assembly, speedometer and shaft assembly, air and oil pressure indicators.
• Group 94 — Repair Parts Kits: Fluid filter parts kits, filter elements, gasket sets, fuel injector parts kits, piston ring sets, bearing sets, shim assemblies, gear sets, horn button parts kits, brake shoe parts kits, dump body parts kits, winch front mount kits, winch midship and rear mount kits, cab replacement kits, PTO conversion kits, battery box kits, gasket and preformed packing kits, operation panel kits, air filter parts kits, drag link parts kits, valve parts kits, winch parts kits, driving axle parts kits, brake lining kits, kingpin parts kits, engine flange kits, clutch disc parts kits, bevel gear sets, fifth wheel parts kits, gasket and shim sets, and driving axle parts kits.
• Group 95 — Bulk Item: Welded chain, welldess chain, conduit, felt, air duct hose, nonmetallic hose, wire rope, nonmetallic special, plywood, cable assembly, rubber strip, seal, weather strip, wire, tube, tubing, webbing, electrical wire, wire fabric, and wood laminate.
• Group 26 — Tools and Test Equipment: Special tool kit for unit level (pressure checking kit and socket wrenches), special tool kits for direct support (torque adapter, mandrel set, plug driver, crankshaft flange puller, injector adjustment kit, bearing and seal inserters, crowfoot attachment, bearing removers and replacers, universal puller kit, mechanical puller, thermo seal mandrel, snap ring replacer, flange replacer, yoke replacer, adjusting tool, box and open wrench, engine barring tool, and power steering test set), and special tool kit for general support (seal inserter, pressure dial gage, bearing cover replacer, remover and replacer, and hand reamer).
• National Stock Number Index and Part Number Index: For cross-referencing stock numbers and manufacturer part numbers back to the correct figure and item number.

Beyond the illustrated parts breakdowns, this M809 Series 5-Ton 6×6 Repair Parts and Special Tools List gives the technician a complete, searchable-by-index parts reference for the whole truck family. Every assembly is exploded into its individual components with callouts, so you can trace a failed part from the system diagram down to its NSN and CAGEC. The National Stock Number Index and Part Number Index let you work in reverse — from a stock number or manufacturer part number straight to the figure and item number — which is exactly what you need when a part arrives without a diagram or when you are cross-referencing a superseded number. For unit-level, direct support and general support maintainers, this is the single reference that keeps the parts identification process accurate and consistent across all M809 Series variants.

Why This Parts List Matters

Ordering the wrong part for a 5-ton 6×6 is expensive in both money and downtime. This manual removes the guesswork by tying every component to its correct National Stock Number and manufacturer part number, with quantities listed so you know exactly how many fasteners, washers, springs or seals are needed for each assembly. Whether you are rebuilding a front winch, replacing a van body door, chasing a hydraulic leak on a wrecker crane, repairing a dump hoist cylinder, or sourcing a special tool for a direct support job, the figure and item breakdown in this volume points you to the right part on the first attempt.

Get Instant Access

This M809 Series 5-Ton 6×6 Trucks Repair Parts and Special Tools List is delivered as an instant PDF download — no shipping, no waiting, no physical binder to store. Open it on a laptop, tablet or phone in the shop, print the pages you need for the job, and keep the full 1,020-page reference on hand for every maintenance action across your M809 Series fleet. Whether you work on M813 cargo trucks, M816 wreckers, M817 dumps, M818 tractors, M820 vans or M821 bridge transports, this Volume 2 RPSTL is the parts reference that keeps the job moving.