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SERIES 50 REAR ENGINE POWER TAKE-OFF (REPTO) ASSEMBLY

The REPTO (Rear Engine Power Take Off) is an aluminum SAE #1 flywheel housing mounted against the rear of the cylinder block, it takes the place of a standard flywheel housing. It provides a cover for the flywheel and serves as a support for the cranking motor and the transmission. ‪

The aluminum flywheel housing has an internal idler gear that is driven off the rear of the crankshaft. Those gears drive an output yoke that faces the rear of the vehicle. The output yoke is located at the one o'clock position and has four different yoke configurations. It provides up to 300 hp intermittent and 240 hp continuous PTO power. ‪

A rear oil seal, which is pressed into the housing, may be removed or installed without removing the housing. Refer to section . ‪

The output yoke and its oil seals can be serviced. If there is any internal failure, the REPTO should be removed and replaced as an assembly. ‪

Repair and Replacement for the Rear Engine Power Take-Off Assembly

The REPTO assembly currently is a nonserviceable component; if there are internal problems with the REPTO it must be replaced as an assembly. ‪

To determine if repair is possible or replacement is necessary, perform the following procedure. See Figure 41381 . ‪

Flowchart for Repair or Replacement of REPTO Assembly

Removal of Rear Engine Power Take-off Assembly

Remove the REPTO assembly as follows: ‪

  1. Disconnect battery power. Refer to section .
  2. Remove cranking motor from the REPTO flywheel housing. Refer to section .
  3. Remove transmission and PTO driveshaft and any other parts attached to the housing.
  4. Remove the flywheel as follows:
    1. Remove two adjacent flywheel bolts.
    2. Insert two flywheel guide studs, J 36235 into the crankshaft. See Figure 41909 .
    3. Flywheel Guide Studs

    4. Remove the remaining flywheel bolts.
  5. Drain oil pan housing by removing the plug at the bottom of the housing. Remove the oil line from the cooler.
  6. Remove three plugs to gain access to bolts securing the housing to the block. See Figure 41860
  7. Remove the three bolts being careful not to drop them into the housing.

    Pipe Plugs on the Gear Set Cover Plate

    NOTICE:

    Do not drop the bolt or washer into the gear set. Engine or REPTO damage will occur. ‪

  8. Remove the remaining eight bolts.

    FALLING COMPONENT

    To avoid injury from a falling component, ensure a proper lifting device is used. ‪

  9. Attach a suitable sling or use a floor jack to support the flywheel housing, which weighs about 120 lbs. Gently tap the backside of the flywheel housing with a rubber mallet to loosen it from the block. Remove the housing.
  10. Remove any gasket material from the flywheel housing and block at this time. See Figure 41287 .

    Removal of Gasket Material

    EYE INJURY

    To avoid injury from flying sealant, do not use an impact gun on plugs with white sealant.

  11. Remove all sealing material from the block and housing. Refer to Section on Cleaning in the General Information Section.

Cleaning of Rear Engine Power Take-off Assembly

Clean the REPTO as follows: ‪

  1. Clean any residue from the end of the crankshaft and inside wall of the REPTO mounting hub.
  2. Clean any residue from the yoke sealing surface, washer and nut.
Inspection of Rear Engine Power Take-off Assembly

Inspect the REPTO assembly as follows: ‪

  1. Inspect the flywheel. Refer to section .
  2. Inspect flywheel housing for cracks and any other damage.
    1. If sealing surface is damaged, repair with emery cloth.
    2. If cracked, repair is not possible.
  3. Inspect the crankshaft where the rear oil seal makes contact. Refer to section .
    1. Check for groove in crankshaft.
    2. If crankshaft is grooved, install a wear sleeve over the crankshaft end. An oversized I.D. rear oil seal must be used with the rear sleeve. Refer to section .
  4. Inspect the bottom of the yoke.
    1. If burrs are found on the surface of the yoke, replace the component.
    2. If no damage is found, reuse part.
  5. Inspect the rubber yoke seal.
    1. If any defects are found, replace the seal.
    2. If no damage is found, reuse the seal.

Installation of Rear Engine Power Take-off Assembly

Install the REPTO as follows: ‪

  1. Apply a lubricant like white grease to the end of the crankshaft and inside the wall of the REPTO mounting hub. See Figure 41348 .

    Note: If installing a new REPTO housing, ensure that all 11 plastic shipping plugs are removed from the housing.

    1. Crankshaft ‪

    . ‪

    Application of Lubricant

  2. If installing a new REPTO housing:

    EYE INJURY

    To avoid injury from flying sealant, do not use an impact gun on plugs with white sealant.

    1. Install the pipe plug above the cranking motor mount on the REPTO flywheel housing. See Figure 41285 .

      Installation of Pipe Plug Above Cranking Motor Mount

    2. Install the bottom pipe plug located in the 6 o'clock position on the REPTO flywheel housing. See Figure 41861 .

      Installation of Pipe Plug in the 6 o'clock Position

    3. Install the pipe plug with a copper washer located in the 5 o'clock position on the REPTO flywheel housing. See Figure 41911 .

      1. Copper Washer ‪

      2. Pipe Plug ‪

      Installation of Pipe Plug in the 5 o'clock Position

      Note: Do not install any plugs in the two holes below the crankshaft on the back lower face (even though they are threaded), they are oil drain holes back to sump. See Figure 41862 .

      No Pipe Plug in these Two Threaded Holes

  3. Apply Gasket Eliminator, Kent-Moore part number or equivalent PT 7276 , to sealing surface of the flywheel housing or the block whichever is easier. See Figure 41287 .

    Application of Gasket Eliminator

  4. Install oil fitting on back of flywheel housing. See Figure 41288 .

    1. Oil Fitting ‪

    . ‪

    Installation of Oil Fitting

  5. Insert two flywheel guide studs, J 36235 into the crankshaft. See Figure 41910 .

    Flywheel Guide Studs

    FALLING COMPONENT

    To avoid injury from a falling component, ensure a proper lifting device is used. ‪

  6. Use a hoist to carefully slide the REPTO flywheel housing into position onto the guide studs. See Figure 41290 .

    1. Crankshaft ‪

    2. Guide Studs J 36235 ‪

    Installation of REPTO Flywheel Housing

    NOTICE:

    Do not drop the bolt or washer into the gear set. Engine or REPTO damage will occur. ‪

  7. Using a magnetic socket, install and torque all eleven flywheel housing mounting bolts in sequence to 112126 Nm (8393 lbft.) for 12 mm bolts or 160200 Nm (118148 lbft.) for 14 mm bolts. See Figure 41291 .

    Note: Ensure that the three bolts behind plugs are not overlooked in this step.

    Flywheel Housing Bolt Location and Torque Sequence

  8. Install the two pipe plugs located on the gear set cover plate and plug next to the cranking motor. See Figure 41860 .

    Pipe Plugs on the Gear Set Cover Plate

  9. Set crankshaft endplay as follows:

    NOTICE:

    Setting crankshaft end play must be done whenever the REPTO housing is installed to prevent crankshaft from damaging crankshaft thrust washers upon initial engine startup. ‪

    1. Bolt the flywheel to the unit using six flywheel bolts.
    2. Torque the flywheel bolts to 102 Nm (75 ftlb).
    3. Remove the flywheel. (This is necessary to remove the gap between the crankshaft and REPTO drive hub.)
    4. Attach driver handle, J 8092 , onto the setting tool, J 427221 . See Figure 41912 .
    5. Stack approximately 0.100 in. of shims, J 427224 , onto the nose of the setting tool. See Figure 41912 .
    6. Add or remove shims until 0.005 in. gap is measured at four points (90 degrees apart) with a feeler gage. See Figure 41912 .

      Installation of Shims

    7. Note: Tool must be held firmly in place and perpendicular to the housing.

    8. Hold the setting tool firmly against the drive hub; with a large hammer, hit the driver handle two to four times to set the gap between the crank and thrust washer. See Figure 41296 .

      Installation of Shims

    9. Remove the tool, ensuring no shims remain stuck to the hub.
  10. Bar the engine over from the front of the crankshaft. It should turn slightly harder than without the REPTO housing installed.
  11. Install flywheel and torque bolts. Refer to section .

    Note: Crankshaft endplay is set and there is no further need to check if this procedure was done correctly.

    Note: All cranking motors assembled to the REPTO housings should be installed with a new gasket.

  12. Install cranking motor. Refer to section .

    NOTICE: ‪

    Do not connect to the wrong port. Connecting to the wrong port will allow coolant to be fed to the gears and the engine will fail. ‪

    Note: Ensure the oil supply line is connected to the port next to the turbo oil supply line and not to the oil cooler assembly.

  13. Install the oil supply line to the brass fitting on the housing and the opened port.
  14. Test for REPTO Flywheel Housing Bore Concentricity as follows:
    1. Attach the base post onto the crankshaft palm.
    2. Assemble the dial indicators onto the base post.
    3. Position the dial indicator square with the flywheel housing inside bore of the bell. Ensure the indicator has adequate travel in each direction. See Figure 20188 .

      Measuring Flywheel Housing Bore Concentricity

    4. Adjust each dial indicator to read zero at the twelve o'clock position.
    5. Bar the engine and rotate the crankshaft one complete revolution, taking readings at 90 degree intervals (four readings each for the bore). See Figure 41859 .

      Flywheel Housing

    6. Remove the wrench or cranking bar before recording each reading to ensure accuracy.

      Note: The maximum total indicator reading must not exceed 0.33 mm (0.013 in.).

    7. If the run-out exceeds the maximum limits, check for dirt of foreign material between the flywheel housing and the cylinder block or oil pan.
    8. Clean the mating surfaces once again. Refer to section "General Information, Cleaning" in the beginning of this manual.
    9. Install REPTO Flywheel Housing. Refer to section .
    10. Check run-out again.
  15. Install transmission. Refer to OEM.
  16. Apply lube to the yoke seal surface and slide it onto the PTO spline. See Figure 41299 .
  17. Apply Loctite 565 or equivalent to both sides of the large washer and hand start nut. See Figure 41299 .

    1. Yoke ‪

    2. Washer ‪

    Apply Lube to Yoke Seal and Loctite 565 to Both Sides of Washers

  18. Insert a 3/4 in. drive wrench in the front pulley or use J 36375A flywheel lock tool in the flywheel housing to stop crank from turning.
  19. Install the nut to the spline and torque to 474542 Nm (350400 ft lbs).
  20. Install oil pan. Refer to section .
  21. Fill engine with clean lube oil. Refer to section .
  22. Install engine into vehicle.

    PERSONAL INJURY

    Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

    • Always start and operate an engine in a well ventilated area.
    • If operating an engine in an enclosed area, vent the exhaust to the outside.
    • Do not modify or tamper with the exhaust system or emission control system.
  23. Start and run engine for verification of proper engine operation.