Usage:
1. Install Tool (A), chains and a suitable lifting device to flywheel (1) as shown.
2. Remove two flywheel bolts (2) and install Tool (B) in their place to help guide the flywheel off the crankshaft gear.
3. Remove remaining bolts (2) and washers.
4. Remove flywheel (1) from the crankshaft gear. The weight of the flywheel is approximately 52 kg (115 lb). Remove Tool (B).
5. Remove bolts (3) and remove crankshaft seal group (4).
6. Remove bolts (5) and washers. Remove cover (6) and the O-ring seal. Check the condition of the O-ring seal and replace with a new part if necessary.
7. Remove bolts (7). Remove bearing carrier assembly (8) and the O-ring seal. Check the condition of the O-ring seal and the lip-type seal in bearing carrier assembly (8) and replace with new parts if necessary.
8. Remove eight bolts (9).
9. Remove crankshaft gear (10) with Tool (B). There is an O-ring seal on the back of crankshaft gear (10). Check the condition of the O-ring seal and replace with a new part if necessary.
10. Remove bolts (11) and remove idler gear shaft (12).
11. Remove idler gear assembly (13).
12. Remove bolts (14), cover assembly (15), the O-ring seal and the thrust washer. Check the condition of the O-ring seal and replace with a new part if necessary.
13. Remove bolts (16) and remove thrust plate (17). Remove the thrust washer behind thrust plate (17).
NOTE: Upon installation, be sure thrust plate (17) is installed in its original location.
14. Take hold of the output gear (19) as the output gear shaft (18) is being removed.
15. Check the condition of bearing sleeves (20).
NOTE: Install the components of the Rear Power Take-Off (RPTO) in the reverse order of removal. Replace all worn O-ring seals, lip-type seals and bearing sleeves.
| NOTICE |
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Special installation procedure that must be followed to keep the crankshaft gear face O-ring seal in place during assembly. Use the following steps. |
16. Place output gear (19) in position and install gear shaft (18).
17. Place idler gear assembly (13) in position and install idler shaft (12). Install bolts (11).
18. Install the O-ring seal on the back of crankshaft gear (10). Use 1U-6396 O-ring Assembly Compound to hold the O-ring seal in place. Install crankshaft gear (10).
19. Install Tool (C) to hold crankshaft gear (10) and the O-ring seal in place during installation procedures.
20. Install cover (6), O-ring seal and a new crankshaft seal group (4).
21. Remove Tool (C).
22. Install Tool (B) to help guide the flywheel assembly onto the crankshaft gear.
23. Place flywheel assembly (1) in position on the crankshaft gear with Tool (A), chains and a suitable lifting device. The weight of the flywheel is approximately 52 kg (115 lb).
24. Install flywheel bolts (2).
25. Remove Tools (A) and (B). Install the remaining flywheel bolts.