Removal Procedure
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Table 1
| Required Tools |
| Tool |
Part Number |
Part Description |
Qty |
| A |
8T-0514 |
Guide Bolt |
2 |
| B |
1P-0520 |
Driver Group |
1 |
Start By:
- Remove the flywheel.
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| NOTICE |
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Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
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| Illustration 1 | g00520761 |
- Install Tool (A) in the crankshaft.
- Remove bolts (1) and crankshaft seal (2) .
- Remove bolts (3), cover (4), and the gasket. Inspect the condition of the gasket. Replace the gasket, if necessary.
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| Illustration 2 | g00520762 |
- Remove crankshaft gear (5) from the crankshaft. Remove the O-ring seal from crankshaft gear (5) .
- Remove Tool (A) .
- Remove bolts (6) that fasten shaft (7) to the flywheel housing.
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| Illustration 3 | g00520763 |
- Use a pry bar in order to remove shaft (7) and gear assembly (8) .
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| Illustration 4 | g00520764 |
- Inspect the condition of the bearing in gear assembly (8). If necessary, remove bearing (9) from the gear with Tool (B) .
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| Illustration 5 | g00520766 |
- Remove bolts (10) that fasten carrier assembly (11) to the flywheel housing. Install two bolts (10) opposite each other at location (12). Use these bolts as forcing screws in order to remove carrier assembly (11) .
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| Illustration 6 | g00520767 |
- Remove O-ring seal (15) and lip type seal (13) from carrier assembly (11) .
- Inspect the condition of bearing (14). If necessary, use Tool (B) to remove bearing (14) from carrier assembly (13) .
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| Illustration 7 | g00520769 |
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| Illustration 8 | g00520770 |
- Remove bolts (16), cover assembly (17), and thrust washer (18). Replace the O-ring seal.
- Inspect the condition of thrust washer (18). Replace thrust washer (18), if necessary.
Note: The minimum allowable thickness for thrust washer (18) is 4.665 mm (.1837 inch).
- Inspect the condition of the dowels for thrust washer (18) in cover assembly (17). Remove the dowels if replacement is necessary.
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| Illustration 9 | g00520771 |
- Remove bolts (19) and thrust plate (20) from the output shaft.
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| Illustration 10 | g00520772 |
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| Illustration 11 | g00520773 |
- Remove hex socket head bolts (21) that fasten gear (23) to output shaft (22) .
- Remove output shaft (22) from gear (23). Remove gear (23) from the flywheel housing.
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| Illustration 12 | g00520774 |
- Remove thrust washer (24) from the flywheel housing.
- Inspect the condition of thrust washer (24). Replace thrust washer (24), if necessary.
Note: The minimum allowable thickness for thrust washer (24) is 4.665 mm (.1837 inch).
- Inspect the condition of the dowels for thrust washer (24) in the flywheel housing. Remove the dowels if replacement is necessary.
- Inspect the condition of bearing (25). If necessary, remove bearing (25) from the flywheel housing with Tool (B) .
Installation Procedure
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Table 2
| Required Tools |
| Tool |
Part Number |
Part Description |
Qty |
| A |
8T-0514 |
Guide Bolt |
2 |
| B |
1P-0520 |
Driver Group |
1 |
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| NOTICE |
|---|
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
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| Illustration 13 | g00520774 |
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| Illustration 14 | g00520775 |
- Install bearing (25) in the flywheel housing with Tool (B) .
Note: The split in the bearing should be located at angle (XX), which is 23 ± 10 degrees from the horizontal centerline. The bearing should be installed to depth (YY), which is 1.5 ± 0.5 mm (.06 ± .02 inch).
- Install the dowels for thrust washer (24) in the flywheel housing.
Note: The dowels should extend beyond the surface of the flywheel housing by a distance of 3.0 ± 0.2 mm (.12 ± .01 inch).
- Install thrust washer (24) on the dowels in the flywheel housing.
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| Illustration 15 | g00520773 |
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| Illustration 16 | g00520772 |
- Hold gear (23) in the flywheel housing and install output shaft (22) in gear (23) .
- Fasten gear (23) to output shaft (22) with hex socket head bolts (21) .
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| Illustration 17 | g00520771 |
- Fasten thrust plate (20) to the output shaft with bolts (19) .
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| Illustration 18 | g00520770 |
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| Illustration 19 | g00520769 |
- Install the dowels for thrust washer (18) in cover assembly (17) .
Note: The dowels should extend beyond the surface of cover assembly (17) by a distance of 3.0 ± 0.2 mm (.12 ± .01 inch).
- Install thrust washer (18) on the dowels in cover assembly (17). Fasten cover assembly (17) to the flywheel housing with bolts (16) .
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| Illustration 20 | g00520767 |
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| Illustration 21 | g00520768 |
- Install bearing (14) in carrier assembly (11) with Tool (B).
Note: The split in the bearing should be located at angle (X), which is 112 ± 10 degrees from the centerline in the upper bolt hole in carrier assembly (11). The bearing should be installed to depth (Y), which is 1.6 ± 0.5 mm (.06 ± .02 inch).
- Install O-ring seal (15) and lip type seal (13) in carrier assembly (11). Lubricate lip type seal (13) lightly with the lubricant that is being sealed.
Note: Lip type seal (13) should be installed to a depth of 2.5 ± 0.5 mm (.1 ± .02 inch).
- Install carrier assembly (11) in the flywheel housing. Install bolts (10) .
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| Illustration 22 | g00520764 |
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| Illustration 23 | g00520765 |
- Install bearing (9) in gear (8) with Tool (B) .
Note: Bearing relief groove (U) must line up with the relief groove in gear (8) within two degrees. Bearing (9) must not extend beyond either face of gear (8) .
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| Illustration 24 | g00520762 |
- Install shaft (7) and gear assembly (8) in the flywheel housing. Fasten shaft (7) to the flywheel housing with bolts (6) .
- Install Tool (A) in the crankshaft. Install a new O-ring seal on crankshaft gear (5) .
- Install crankshaft gear (5) .
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| Illustration 25 | g00520761 |
Note: Some flywheel housings have locating dowels for cover (4). If the flywheel housing does not have these locating dowels, care must be taken in order to ensure that the cover is properly aligned. Ensure that the gap between the dust lip and the crankshaft gear is uniform in order to avoid damage to the crankshaft seal.
- Hold cover (4) and the gasket in position on the flywheel housing and install bolts (3) .
- Install crankshaft seal (2) and bolts (1) .
- Remove Tool (A) from the crankshaft.
End By:
Install the flywheel.
