M809 series front winch install.

[818 Test Pilot]

Purchasing and installing a M809 series Front Winch package on my M818 tractor. Anybody out there have a few up close pictures of this installed Winch? “Bubba” OIF1 88M

 

[Blaines2399]

I can take some pictures, let me know what you need

 

[G744]

The most critical part is getting the proper gear mesh on the PTO.

The hardest part is getting the bumper to line up with the extensions. A spud wrench really helps.

 

[818 Test Pilot]

The most critical part is getting the proper gear mesh on the PTO.

The hardest part is getting the bumper to line up with the extensions. A spud wrench really helps.

Watt do you mean by gear mesh ? Anything like changing ring and pinion in gm rear ends with dye to make sure gears mate correctly ?

 

[818 Test Pilot]

I can take some pictures, let me know what you need

Wow that rig in your pix is top shelf. Never ever sawr an 809? Series like yours. Could use pictures of how it mounts, connection underneath, cockpit controls if any. An idea of how the winch assy. looks installed. Noticed the interior cab fire wall has areas that could be used for additions like heater ect. Fort Drum 2003 there was a 1 in 3 chance your assigned 818 had a heater. Even if ya had one it was nothing to write home about.

 

[G744]

The PTO clearance is adjusted with a gasket stack.

One starts with a thin one, and run up a couple of the mounting nuts gently to check if it easy to turn the output shaft by hand with it in gear. It probably won't be, so dismount it and add another gasket. Keep at it until you can easily rotate the shaft, turning the trans countershaft as well (trans in neutral, a friend working the clutch), and feeling a little slop in it. You'll be OK, with it that way.

More PTO's are ruined by mashing the gears into each other and trying to use it that way.

There may be a process to set the backlash with gages, but working down past all the gears in that trans is just about impossible. It is a somewhat greasy job, as invariably some gear lube will be dripping on your hands (you did drain it all out?).

Then you get to fight the control lever hookup to fit, and the clevises will never get full operating positions on the first stab. Be patient, laying on your back is supposed to be restful...

Please don't forget to stage the driveshaft ahead of time. Also, take a hint from the 900-series trucks and install a second set of shackle mounts on the bottom of the bumper, usually with new longer bolts. It adds a bit of extra strength to the bumper assembly and gives you 2 more places to hook to.

Don't forget the correct shear pin on the winch input flange. It may save your setup from an expensive failure. I've seen a 5-ton or two over the years where the pin was just a bolt, and the whole winch was almost peeled right off the truck from pulling way too much weight.

 

[818 Test Pilot]

The PTO clearance is adjusted with a gasket stack.

One starts with a thin one, and run up a couple of the mounting nuts gently to check if it easy to turn the output shaft by hand with it in gear. It probably won't be, so dismount it and add another gasket. Keep at it until you can easily rotate the shaft, turning the trans countershaft as well (trans in neutral, a friend working the clutch), and feeling a little slop in it. You'll be OK, with it that way.

More PTO's are ruined by mashing the gears into each other and trying to use it that way.

There may be a process to set the backlash with gages, but working down past all the gears in that trans is just about impossible. It is a somewhat greasy job, as invariably some gear lube will be dripping on your hands (you did drain it all out?).

Then you get to fight the control lever hookup to fit, and the clevises will never get full operating positions on the first stab. Be patient, laying on your back is supposed to be restful...

Please don't forget to stage the driveshaft ahead of time. Also, take a hint from the 900-series trucks and install a second set of shackle mounts on the bottom of the bumper, usually with new longer bolts. It adds a bit of extra strength to the bumper assembly and gives you 2 more places to hook to.

Don't forget the correct shear pin on the winch input flange. It may save your setup from an expensive failure. I've seen a 5-ton or two over the years where the pin was just a bolt, and the whole winch was almost peeled right off the truck from pulling way too much weight.

Ten/four … the assy.

The PTO clearance is adjusted with a gasket stack.

One starts with a thin one, and run up a couple of the mounting nuts gently to check if it easy to turn the output shaft by hand with it in gear. It probably won't be, so dismount it and add another gasket. Keep at it until you can easily rotate the shaft, turning the trans countershaft as well (trans in neutral, a friend working the clutch), and feeling a little slop in it. You'll be OK, with it that way.

More PTO's are ruined by mashing the gears into each other and trying to use it that way.

There may be a process to set the backlash with gages, but working down past all the gears in that trans is just about impossible. It is a somewhat greasy job, as invariably some gear lube will be dripping on your hands (you did drain it all out?).

Then you get to fight the control lever hookup to fit, and the clevises will never get full operating positions on the first stab. Be patient, laying on your back is supposed to be restful...

Please don't forget to stage the driveshaft ahead of time. Also, take a hint from the 900-series trucks and install a second set of shackle mounts on the bottom of the bumper, usually with new longer bolts. It adds a bit of extra strength to the bumper assembly and gives you 2 more places to hook to.

Don't forget the correct shear pin on the winch input flange. It may save your setup from an expensive failure. I've seen a 5-ton or two over the years where the pin was just a bolt, and the whole winch was almost peeled right off the truck from pulling way too much weight.

ten/four The Assy. Waiting for the word to make the short trip. Will be removed from a donor truck at Eastern Surplus in Pa. soon. Going there to pick up goods. Thank You. OIF1 88M.

 

[Blaines2399]

Here's some pictures I got

 

[818 Test Pilot]

Here's some pictures I got

Cool Stuff. Just a guess I’m gonna be busy with this install. Tomorrow will relate pictures to my bare 818 front end. Three weeks till winch pick up in Penn. I send ya 5 dinar as payment for pictures. Thank You.