Usage:
Start By:
a. remove alternator (if equipped)
b. remove accessory drive (front)
c. remove oil and water pump drive
d. remove auxiliary water pump (aftercooler)
e. remove fan drive
f. remove air compressor (if equipped)
g. remove air conditioning compressor (if equipped), bracket and belt tightener assembly
h. remove crankshaft front seal and wear sleeve
i. remove electronic control module
1. Remove the three bolts that fasten shaft (1) to the front drive housing and the engine block.
2. Use tooling (A) and remove shaft (1), gear (2) and washer (3) from the front drive housing. Remove O-ring seal (4) from shaft (1).
3. If necessary, remove the bearing from gear (2).
4. Remove cover (5) from the left front side of the drive housing. Remove the shaft gear (6) and washer (7), using tooling (A), the same as in Steps 1 through 3.
Typical Example
5. Install tooling (B) on top of the front drive housing and fasten a hoist. Remove two bolts, and install two 5/8" - 11 NC guide bolts (11). Remove the remainder of the bolts and remove front drive housing (10) from the engine block. The weight of the front drive housing is 209 kg (460 lb.).
NOTE: The following steps are for installation of the front drive housing.
6. Put a new front drive housing gasket in position. Install the front drive housing in the reverse order of removal. Install the bolts holding the front drive housing in the positions indicated on the Front Housing Bolt Installation Chart. Evenly tighten the bolts to a torque of:
a. 105 ± 20 N·m (75 ± 15 lb ft) for the 1/2"-13 NC bolts.
b. 215 ± 40 N·m (160 ± 30 lb ft) for the 5/8"-11 NC bolts.
NOTE: After the front drive housing is fastened to the engine block, trim the gasket flush with the bottom of the front drive housing.
7. If gear assembly (6) was disassembled heat the larger gear of gear assembly (6) to a maximum temperature of 400° (752°F) for installation onto the smaller gear of gear assembly (6).
8. Use tooling (C) to install the bearings in gears (2) and (6) until they are centered in the bore of the gears. After installation, the inside diameter of the bearing in gear (2) must be 90.00 ± 0.065 mm (3.543 ± .002 in.). Gear (6) must be 106.00 ± 0.065 mm (4.173 ± .002 in.).
| NOTICE |
|---|
Lubricate all seals, bearings, shafts and O-ring seals prior to assembling. |
9. Install the shafts and gears (2) and (6), and washers (3) and (7) in their respective locations. Make sure the pin in washer (3) and washer (7) aligns with the holes in the shaft and engine block.
End By:
a. install crankshaft front seal and wear sleeve
b. install auxiliary water pump (aftercooler)
c. install air compressor (if equipped)
d. install air conditioning compressor (if equipped), bracket and belt tightener assembly
e. install oil and water pump drive
f. install accessory drive (front)
g. install fan drive
h. install alternator (if equipped)
i. install electronic control module