Usage:
3406E (5EK) Truck Engines
- SUPPLEMENT: 01/01/97
Truck Engine News, May 1996, Page 2, "New Gaskets And Fasteners Used In Front Cover-To-Plate And Plate-To-Block Connection; New Gear Assembly And Bearing Used In The Front Gear Train"
Under Beginning With 3406E (5EK60745) Truck Engine, Item 2 is NOT correct. The correct information follows:
Item 2: The new steel core with "paper" outer body 124-6014 Gasket (2) replaces the former 6I-3899 Gasket, used between the cylinder block and the front cover plate.
--------------- END SUPPLEMENT ---------------
- SUPPLEMENT: 08/01/96
Truck Engine News, May 1996, Page 2, "New Gaskets And Fasteners Used In Front Cover-To-Plate And Plate-To-Block Connection; New Gear Assembly And Bearing Used In The Front Gear Train"
Under Beginning With 3406E (5EK60745) Truck Engine, Item 2 is NOT correct. The correct information follows:
Item 2: The new steel core with "paper" outer body 123-6014 Gasket (2) replaces the former 6I-3899 Gasket, used between the cylinder block and the front cover plate.
--------------- END SUPPLEMENT ---------------
New gaskets, fasteners, bearing, and gear assembly are used in production for the front gear train. This article identifies the new or changed components and the engine serial numbers when these new or changed components became effective. Whenever a repair requires the removal of the front housing (timing gear cover), all of the applicable new components should be installed. Also, note that the tightening torque and/or the tightening sequence has changed.
NOTE: For service when bolts or studs with a lock patch are not available:
1. Remove the bolt (or nut).
2. Clean the bolt (or nut) with a wire brush.
3. Apply 9S-3263 Thread Lock to the bolt or stud.
4. Assemble and tighten to the specified torque.
NEW COMPONENTS
The following chart and the illustrations identify the new components.
Beginning With 3406E (5EK74363) Truck Engine
Item 11: A new 128-2659 Idler Gear Assembly (11) replaces the former 6I-3629 Idler Gear Assembly. The new gear assembly contains a steel backed bronze bearing to provide increased fatigue life. This is the only change to the assembly. The idler gears have not changed.
NOTE: For field service a new 131-7123 Bearing replaces the former 4N-0343 Bearing (steel backed aluminum). The new bearing can be used in either the new 128-2659 Idler Gear Assembly or the former 6I-3629 Idler Gear Assembly.
Beginning With 3406E (5EK60745) Truck Engine
Illustration 1. Location of the new components in Items 1 through 4.
Item 1: The new one-piece graphite body 124-6014 Gasket (1) replaces the former multi-piece 102-2226 Gasket, used between the front cover plate and housing.
Item 2: The new steel core graphite body 123-3786 Gasket (2) replaces the former 6I-3899 Gasket, used between the cylinder block and the front cover plate.
NOTE: The previous gasket extended below the oil pan mounting surface and filled the entire block to plate to front housing joint. The new 124-6014 and 123-3786 Gaskets (with a steel core) can not be trimmed after assembly. These gaskets are "flush" to "recessed" at the "tee" joint between the block, front plate, front housing, and the oil pan. Seal the areas not occupied with gasket material with 8T-9022 RTV Sealant (blue). This sealant is compatible with the gasket material.
Beginning With 3406E (5EK60487) Truck Engine
Item 3: Two new 120-9243 Studs (3) and new 129-5427 Sealing Washers replace the former 6I-4439 Studs and former 4H-6145 or 117-9053 Washers at the locations indicated.
Item 4: Twelve new 129-5428 Studs (4) with thread lock and 126-1757 Sealing Washers replace the former 6I-3893 or 120-9242 Studs and 6B-2250 or 5L-6267 Washers at the location indicated.
The new 129-5428 and 120-9243 Studs have a larger diameter head to provide a sealing surface between the head and front plate when used with the new 126-1757 and 117-9053 Sealing Washers. The new studs have thread lock on the threaded ends. The new washers are steel with a mechanically fastened O-ring seal. The former washers were copper. All of the threaded joints except the six 031-3185 Bolts (cam drive gear) and the one 0S-1571 Bolt (oil pump drive gear) have thread lock.
Illustration 2. Location of the new components in Items 5 through 11.
Item 5: Two 5P-4142 Bolts (5) with thread lock and 9X-6458 Washers are tightened to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
Item 8: Ten 9S-8752 Nuts (8) with 9X-6458 Washers are tightened to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
Illustration 3. Location of the new components in Item 12.
Item 12: Ten new 126-1756 Bolts (12) with thread lock replace the former 2B-2695 Bolts. Tighten the new bolts to a torque of 30 ± 7 N·m (22 ± 5 lb ft).
Beginning With 3406E (5EK60208) Truck Engine
Item 9: Use the new 128-8853 Adapter Assembly (9) to replace the former 102-8396 Adapter Assembly. The former adapter assembly is serviced by the new adapter assembly.
NOTE: It the camshaft drive gear is removed, the former 102-8396 Adapter Assembly should be replaced with a new 128-8853 Adapter Assembly. The former adapter assembly could yield if bolts (10) were tightened to tight. The new adapter assembly can be reused without damage.
Beginning With 3406E (5EK391) Truck Engine
Item 6: Five new 2J-3118 Bolts (6) with lock patch replace the former 0S-1588 Bolts. Tighten the five new bolts in following sequence (1,3,4,5,2,1,2,3,4,5,1) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
Item 7: Tighten one 0S-1571 Bolt (7) and one 1P-7346 Washer to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
Beginning With 3406E (5EK386) Truck Engine
Item 10: Use the six existing 031-3185 Bolts (10). But, tighten the six bolts to a torque of 240 ± 40 N·m (178 ± 30 lb ft).