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SERIES 40E FLYWHEEL HOUSING

To determine if repair or replacement of the flywheel housing is necessary, perform the following procedure. See Figure 21777 . ‪

Repair or Replacement of Flywheel Housing Flowchart

Removal of Flywheel Housing

Remove the flywheel housing as follows: ‪

  1. Remove eight (8) mounting bolts securing the flywheel housing to crankcase.
  2. Remove flywheel housing from crankcase.

    Note: For vehicles equipped with the MT-654CR transmission, a transmission adaptor ring is bolted to the transmission side of the flywheel housing. It is not necessary to remove this adaptor ring from the flywheel housing. This is a special flywheel housing with the adaptor ring bolted in place to match with the flywheel housing as it was machined.

Removal of Rear Oil Seal and Wear Sleeve

Remove rear oil seal as follows: ‪

Note: It is not necessary to remove the flywheel housing or oil seal carrier, if all that is being replaced is the oil seal and wear liner.

  1. Punch two holes into the rear oil seal at the 3 and 9 o'clock positions. Insert two sheet metal screws into these holes. See Figure 31965 .

    1. Hammer ‪

    4. Crankcase ‪

    2. Punch ‪

    5. Oil Seal Carrier ‪

    3. Crankshaft ‪

    Punching Holes Into Rear Oil Seal

  2. Using a slide hammer, alternately pry on each screw to remove rear oil seal from the carrier. Discard old oil seal. See Figure 31966 .

    1. Pry Bar ‪

    4. Rear Oil Seal ‪

    2. Crankcase ‪

    5. Screw (2) ‪

    3. Oil Seal Carrier ‪

    Rear Oil Seal Removal

Removal of Rear Oil Seal and Carrier

The flywheel housing must be removed before following these steps: ‪

  1. Remove six (6) bolts securing rear oil seal carrier to crankcase.
  2. Remove rear oil seal carrier. Using a hammer, remove the rear oil seal from the carrier. Discard oil seal.
  3. Remove rear oil seal carrier gasket and discard.

Removal of Wear Sleeve

Use this method only when the repair is being done in-chassis with the flywheel housing and rear oil seal carrier in place. Remove the rear oil seal as follows: ‪

NOTICE:

Ensure the crankshaft flange is not nicked during this procedure. This method is only used when the repair is to be done in-chassis with the flywheel housing and rear oil seal carrier in place. ‪

  1. Install the wear sleeve removal tool, J 42944 , to the crankshaft flange as follows:
    1. Install guide plate against crankshaft and attach three (3) collets around the wear sleeve, guide and crankshaft flange. See Figure 32011 .
    2. Wear Seal Removal Tool Collets

    3. Place the sleeve around the three (3) collets. See Figure 32012 .
    4. Sleeve Placement

  2. Attach a ratchet to the forcing screw and turn to remove the wear sleeve. See Figure 31950 .

    1. Crankcase ‪

    3. Wear Liner ‪

    2. Oil Seal Carrier ‪

    Wear Sleeve Removal

  3. Discard the wear sleeve and inspect the crankshaft flange for damage.

    Note: An alternate method to remove the wear sleeve is to use the following procedure with the flywheel housing removed.

Wear Sleeve Removal (with Flywheel Housing Removed)

Remove the wear sleeve as follows: ‪

  1. With the flywheel, flywheel housing and rear oil seal carrier removed, use a hammer and tap the O.D. of the wear sleeve.

    Note: This causes the wear sleeve to expand and slide off easily.

  2. Discard wear sleeve.

Installation of Rear Oil Seal and Wear Sleeve

Install a new rear oil seal and crankshaft wear sleeve assembly using installer tool as follows: ‪

Note: Install the rear oil seal and wear sleeve as a unit. Do not remove the seal from the wear sleeve prior to installation.

  1. Clean crankshaft flange and seal carrier bore thoroughly. Remove any debris.
  2. Attach rear oil seal/wear sleeve guide to crankshaft flange and secure with two (2) mounting screws. See Figure 31849 .

    1. Permatex #3 ‪

    3. Oil Seal Coated With Permatex #3 ‪

    2. Wear Sleeve ‪

    Rear Oil Sleeve/Wear Sleeve Guide

  3. Coat inner I.D. of wear sleeve and O.D. of oil seal with Aviation Permatex #3.
  4. Position oil seal and wear sleeve over crankshaft.

    Note: Proper use of installer tool will assure that seal and wear sleeve are pressed onto the crankshaft flange to the proper depth.

  5. Assemble rear oil seal/wear sleeve installer tool onto crankshaft. Using a wrench, turn forcing nut on installer tool until seal and sleeve are seated in the bore. See Figure 31850 .

    1. Forcing Nut ‪

    2. Installation Tool ‪

    Installer Tool

  6. Remove oil seal/wear sleeve installation tool.

Installation of Rear Oil Seal and Carrier (Flywheel Housing Removed)

Install rear oil seal carrier as follows: ‪

  1. Attach rear oil seal guide, J 41163 , to crankshaft flange and secure by tightening the two (2) mounting bolts. See Figure 31848 .

    1. Crankcase ‪

    3. Rear Oil Seal Guide ‪

    2. Rear Oil Seal Carrier ‪

    Carrier Guide

  2. Place a new gasket into rear oil seal carrier. Install rear oil seal carrier to crankcase and loosely secure with oil seal carrier mounting bolts.
  3. Install the driver guide tool, J 41163 , over the crankshaft. See Figure 32068 .

    Driver Guide Tool

  4. Tighten driver nut to center the oil seal carrier to the crankcase. Finger-tighten the carrier and remove the driver guide tool. See Figure 31851 .

    1. Crankcase ‪

    3. Rear Oil Seal ‪

    2. Oil Seal Carrier ‪

    4. Driver ‪

    Centering Oil Seal Carrier

  5. Rotate/twist the carrier, if necessary, to align carrier with crankcase rails. Use straight edge to verify.
  6. When the rear oil seal carrier is level, torque the mounting bolts to specifications. Refer to Specifications in Section 1.A. See Figure 31852 .

    1. Straight Edge ‪

    3. Oil Seal Carrier ‪

    2. Crankcase ‪

    4. Driver ‪

    Aligning and Securing Oil Seal Carrier

  7. Install a new rear oil seal and crankshaft wear sleeve assembly.
    1. Clean crankshaft flange and seal carrier bore thoroughly. Remove any debris.
    2. Attach rear oil seal/wear sleeve guide to crankshaft flange and secure with two (2) mounting screws.
    3. Coat inner I.D. of wear sleeve and O.D. of oil seal with Aviation Permatex #3. See Figure 31849 .
    4. 1. Permatex #3 ‪

      3. Oil Seal Coated With Permatex #3 ‪

      2. Wear Sleeve ‪

      Preparing Oil Seal and Wear Sleeve

    5. Position oil seal and wear sleeve over crankshaft.
    6. Note: Proper use of the installer tool will assure that seal and wear sleeve are pressed onto the crankshaft flange to the proper depth.

    7. Assemble rear oil seal/wear sleeve installer tool onto crankshaft. Using a wrench, turn forcing nut on installer tool until seal and sleeve are seated in the bore. See Figure 31850 .
    8. 1. Forcing Nut ‪

      2. Installation Tool ‪

      Oil Seal/Wear Sleeve Tool

    9. Remove oil seal/wear sleeve installation tool.

Installation of Flywheel Housing (Out Of Chassis)

Install flywheel housing to crankcase as follows: ‪

  1. Install new camshaft O-ring over camshaft end opening at rear of crankcase.

    Note: Ensure a new camshaft O-ring is installed before completing these steps.

  2. Install flywheel housing by guiding the housing and hollow dowels up against the crankcase. Secure using flywheel housing mounting bolts. Torque the eight (8) bolts to specifications. Refer to Specifications in Section 1.A. See Figure 31928 .

    1. Flywheel Housing ‪

    4. Oil Seal Carrier ‪

    2. Mounting Bolts (6) ‪

    5. Dowel Guide Pins ‪

    3. Flywheel Housing ‪

    Flywheel Housing Installation

Flywheel Housing Check

This procedure checks the flywheel housing and concentricity. The bore concentricity and face run-out is checked to ensure proper engine to transmission alignment. ‪

  1. Check flywheel housing bore concentricity as follows.
    1. Attach a dial indicator to the crankshaft and place the indicator tip against the flywheel housing bore.
    2. Zero the dial indicator.
    3. Rotate the crankshaft slowly and record the total indicator variation.
  2. Check flywheel housing face run-out as follows.
    1. Attach a dial indicator to crankshaft and place indicator tip against housing face.
    2. Measure at four points, 90 degrees apart for total face variation.
    3. Note: Keep the crankshaft end play at zero in the same direction for all measurements.

    4. For housing face run-out tolerance, refer to Specifications in Section 1.A.

Pilot Concentricity Check

Check crankshaft flywheel pilot concentricity as follows. See Figure 31967 . ‪

1. Dial Indicator ‪

3. Flywheel Housing ‪

2. Crankshaft Flange ‪

Flywheel Concentricity Check

  1. Attach a dial indicator to flywheel housing and place tip up against flywheel pilot.
  2. Rotate the crankshaft slowly and record the total indicator variation. Refer to Specifications in Section 1.A, for specifications for concentricity tolerance.

Installation of Flywheel

Install the flywheel as follows: ‪

  1. Install two (2) flywheel guide studs, J 43096 , into the 3 and 9 o'clock positions of the crankshaft.
  2. Install flywheel over guide studs and secure to crankshaft with ten (10) flywheel mounting bolts.

    Note: For applications using automatic transmissions, install spacer, flexplate(s) and reinforcing ring. Then install the ten (10) flywheel mounting bolts.

  3. Remove two (2) guide studs and install remaining two (2) mounting bolts. Torque all twelve (12) flywheel mounting bolts to specifications. Refer to Specifications in Section 1.A. See Figure 31949 .

    1. Flywheel Housing ‪

    3. Dowel Pins ‪

    2. Flywheel ‪

    4. Flywheel Mounting Bolts (12) ‪

    Torque Bolts

Removal of Rear PTO Housing Assembly, If Equipped

The flywheel is removed for this procedure. Perform the following steps. ‪

  1. Remove two (2) flywheel mounting bolts located at the 3 and 9 o'clock positions. Install two (2) guide dowel pins, made locally, at these locations. See Figure 32004 . The rear oil seal is in the rear PTO housing assembly. For removal of rear PTO housing assembly instructions, refer to section .

    1. Guide Pins ‪

    2. Installation Tool ‪

    Guide Dowel Pin Locations

  2. Remove remaining ten (10) flywheel mounting bolts.
  3. Slide flywheel out of the flywheel housing and off guide dowel pins.

    Note: For applications using automatic transmissions, install spacer, flexplate(s) and reinforcing ring. Then install the ten (10) flywheel mounting bolts.

Removal of Rear Oil Seal Carrier

Remove six (6) bolts securing rear carrier to crankcase. Remove carrier. ‪

Note: The rear cover cannot be removed until the four bolts mounted through the oil pan and into the bottom of the rear cover are removed.

Installation of Rear Oil Seal Carrier

Install rear oil seal cover as follows: ‪

  1. Place a new gasket into rear oil seal cover.
  2. Install rear oil seal cover. Secure to crankcase by finger-tightening the mounting bolts.
  3. Rotate/twist cover to align the oil seal cover with crankcase oil pan rail. Use straight edge to verify. See Figure 31852 .

    1. Straightedge ‪

    3. Oil Seal Carrier ‪

    2. Crankcase ‪

    4. Driver ‪

    Rear Oil Seal Carrier Alignment

  4. When the rear cover is aligned, torque the mounting bolts to specifications. See Figure 31852 . For installation of the rear PTO housing, refer to section .

    1. Straightedge ‪

    3. Oil Seal Carrier ‪

    2. Crankcase ‪

    4. Driver ‪

    Securing Rear Oil Seal Carrier

Installation of Flywheel

Install the flywheel as follows: ‪

  1. Install flywheel over dowel guide pins and secure to crankshaft with ten (10) flywheel mounting bolts.

    Note: For applications using automatic transmissions, install spacer, flexplate(s) and reinforcing ring. Then install the ten (10) flywheel mounting bolts.

  2. Remove two (2) dowel guide pins and install remaining two (2) mounting bolts. Torque all twelve (12) flywheel mounting bolts to specifications. Refer to Specifications in Section 1.A.