| Required Tools | |||
| Tool | Part Number | Part Description | Qty |
| A(1) | 9U-7489 | Lift Stand | 1 |
| 350-7768 | Electric Hydraulic Pump (115 V) | 1 | |
| 350-7769 | Electric Hydraulic Pump (230 V) | 1 | |
| 4C-5749 | Mobile Base | 1 | |
| A1 | OR | ||
| 504-9826 | Lift Gp (50/60Hz)(2) | 2 | |
| 504-9827 | Lift Gp (50/60Hz)(3) | 2 | |
| B | 538-8367 | Lifting Group | 1 |
| C | 309-2793 | Load Leveler | 1 |
| D | 435-3382 | Wrench | 1 |
| (1) | Use Tooling (A) or (A1) based on requirements. |
| (2) | Operating Voltage (380-500V) |
| (3) | Operating Voltage (180-300V) |
Start By:
- Remove the modular front end.
- Remove the rear hood.
- Remove the front hood.
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Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin. At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the cooling system pressure cap is cool enough to touch with your bare hand. Remove the cooling system pressure cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury. |
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In order to prevent possible personal injury, release the air pressure from the air tank before disconnecting any components of the air system. |
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A high pressure fuel line must be disconnected. To avoid personal injury or fire from fuel spray, the engine must be stopped before the fuel line is disconnected. |
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Contact to high pressure fuel can cause personal injury or death. Do not allow high pressure fuel to contact your skin. |
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The space between the body and the frame becomes a zero clearance area when the body is lowered. Failure to install the retaining cable can result in injury or death to personnel working in this area. |
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Personal injury or death can occur from heavy components falling during removal or installation. Properly support the component with a suitable lifting device during removal or installation. |
- Refer to Operation and Maintenance Manual, "Cable (Truck Body Retaining)".
- Turn the fuel supply to the OFF position.
- Turn the power disconnect switch to the OFF position.
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Illustration 1 g06214700 For Tooling (A). - Use Tooling (A) to support front frame assembly (1).
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Illustration 2 g06385904 For Tooling (A1). - Use Tooling (A1) to support front assembly (1). Refer to Tool Operating Manual, NEHS1334, "Lift Group (Stand - 150 Ton)" for more information on Tooling (A1).
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Illustration 3 g03422712 - Disconnect hose assemblies (2) and remove the connecting hardware.
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Illustration 4 g03263262 - Attach a suitable lifting device onto cross member (3). The weight of cross member (3) is approximately
116 kg (256 lb) . - Remove bolts (4). Remove cross member (3) and the shims from Location (A) and Location (B).
Note: Note the location and the quantity of shims (4) for installation purposes. If shims (4) are lost or damaged during removal procedure or the engine cross tube is replaced with new, refer to "Engine and Torque converter - Install", "Engine Cross Tube Shimming procedure" section for the correct installation procedure.
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Illustration 5 g03423903 - Disconnect hoses (5) and hoses (6),
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Illustration 6 g03423941 Right Hand Side - Disconnect harness assemblies (7).
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Illustration 7 g03422898 Show/hide table
Illustration 8 g03422939 Right Hand Side - Disconnect hoses (8). Remove clamps (9). Remove tubes assemblies (10).
- Repeat Step 10 through Step 11 for the opposite side.
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Illustration 9 g03424135 - Disconnect hose assemblies (11).
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Illustration 10 g03424136 - Disconnect hose assemblies (12).
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Illustration 11 g03424137 - Disconnect hose assemblies (13).
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Illustration 12 g03423993 - Disconnect hose assembly (14).
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Illustration 13 g03424032 - Disconnect harness assemblies (15).
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Illustration 14 g03424077 - Disconnect V-band clamps (16) and V-band clamps (17). Remove bellows (18).
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Illustration 15 g03424149 - Remove drive shaft covers (19).
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Illustration 16 g03424174 - Attach a suitable lifting device onto drive shafts (20).
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Illustration 17 g03424421 Show/hide table
Illustration 18 g03424423 - Remove bolts (21) and bolts (22). Use a suitable pry bar to retract the universal joint of the drive shafts. Secure the drive shafts out of the way.
Note: Bolts (21) and bolts (22) are not reusable. Discard bolts (21) and bolts (22).
Note: Do not separate the universal joint and the drive shaft. The drive shafts are assembled with the universal joints in phase for balancing purposes. If the drive shaft must be separated, use a paint pen to make aligning marks on both sides of the slip joint. When reassembling the drive shaft, make sure the aligning marks match to ensure proper universal joint phasing and balance performance.
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Illustration 19 g03424737 Show/hide table
Illustration 20 g03424757 - If equipped with an electric starting motor, disconnect harness assembly (23), remove clip (24), disconnect cable assembly (25), and cable assemblies (26).
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Illustration 21 g03424762 - Disconnect hose assembly (27).
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Illustration 22 g03424782 - Disconnect hose assemblies (28).
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Illustration 23 g03424838 - Remove clamps (29). Repeat this step for the opposite side.
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Illustration 24 g03425116 Front of Engine Show/hide table
Illustration 25 g03425112 Rear of Engine - Install Tooling (B) onto the engine.
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Illustration 26 g03424866 - Attach Tooling (C) and a suitable lifting device onto Tooling (B).
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Illustration 27 g03425125 - Remove bolts (30). Remove cap (31). Repeat this step for the remaining rear engine mount.
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Illustration 28 g03425119 - Remove bolt (32) and washer (33). Disconnect harness assembly (34) and remove the connecting hardware.
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Illustration 29 g03425126 - Remove bolt (35) and washer (36). Disconnect ground strap (37).
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Illustration 30 g03425127 Show/hide table
Illustration 31 g03425734 - Use Tooling (B), Tooling (C), and a suitable lifting device to remove engine (38). The weight of engine (38) is approximately
11,612 kg (25,600 lb) .
