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There's a little drop down menu in the bottom-left of your post that will expose an "edit" option that allows you to correct the original post (see below)

That's awesome stuff to have!

From all I've read on here over the years, the cracking t-case in reverse is an issue with the T-1138 in the 939 5-tons and not with the T-138 in the 809 5-tons. This is because the 10:1 reduction of the reverse gear in the Allison automatic created too much torque for the T-1138.

Don't back up with the transfer case in low (no bueno for the t-case) and when you shut down the engine, shut off the engine switch first then after the engine is done rotating shut off the battery switch. This prevents frying the voltage regulator in the alternator.

The brace would lose some strength but it would also bottom out on the valve cover after deflecting downward 1/4"+ or so. Probably not enough downward movement to permanently kink and deform the brace.

Before I straightened my curled plastic, the cover would touch the cab and when I got the truck the spot welds on one of the L-shaped reinforcement layers on the corner were popped from what I assume was years of being under tension. Were the plastic boxes introduced after production ceased...

what height does the top of your metal box measure from the diamond plate step surface? I'd like to compare to my plastic boxes.

You can fit 3 jakes heads on there without cutting a hole in the hood: https://www.steelsoldiers.com/threads/3-jake-heads-under-a-stock-m809-hood.195031/

How many of you 809 folks have battery box covers/steps that hit the bottom of the cab? My truck has the plastic batt boxes and has always hit but now that I have fixed the curled plastic, it definitely does not want to go back on. I'm thinking of cutting 1/2" of height out of it...

Lots of cool references! Don't forget to mail in your suggestions on how to improve the manuals or correct mistakes & typos...lol

Roto-broaches work really well on hardened steel frame rails !

Is that bridge formula adhered to by all states (national level) or can it vary state-to-state?

This is a similar thread : https://www.steelsoldiers.com/threads/weight-limit-for-5-ton-axle.80210/ Pretty sure my M809 axles are #44,000 units

Typically, doesn't the DoD own the "Technical Data Package" that is produced for a given contract and is free to have those designs manufactured by an entity of choice? Did Oshkosh develop the TAK-4 suspension independent of a military contract?

Those brakes are the gnarliest brakes I've seen on here since I joined! Lots of work

Even with my stubby muffler the loudness is manageable for about 30 minutes, but with the stack in the factory location the noise gets to be fork-in-the-ear sorta fatiguing. The stack behind the cab would help or a spiral, noise reducing insert like @Lonnie installed could help.

I found a way to add a front jake head (25B) without cutting the hood panel - only notching the hood stiffener cross member.

I also wonder about this especially with these being designed AFTER we had the 7.5 ton Mack NO with its massive cab. That being said, I like the proportions of a small cab with a massive hood!

Do you know what kind of engine the intake and cross over came off of? It looks like you could still fit 2 jake heads (front & back) with that setup 😁

That setup looks good, clean, open, and simple. I like the retention of the cold start pieces and I'm glad I didn't see any plumber's tape anywhere.