Assembly Procedure
Required Tools     | |||
Tool     | Part Number     | Part Description     | Qty     |
A     | 1P-0510     | Driver Group     | 1     |
NOTICE |
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Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
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Illustration 1 | g00830328 |
(1) Bolts (2) Cover (3) O-ring (4) Bearing (5) Flywheel housing (6) Bolts (7) O-ring (8) Cover (9) O-ring (10) Crankshaft rear seal (11) Bolt (12) Pump drive gear (13) Idler gear (14) Dowel pin (15) Bearing (16) O-ring (17) Hydraulic pump adapter (18) Bolt (19) Bearing (20) Idler gear shaft (21) Bolt (22) Crankshaft drive gear (23) O-ring (24) Cover (25) Bolt |
- Install O-ring (9) and rear crankshaft seal (10) into flywheel housing (5). Align holes in flywheel housing (5) and rear crankshaft seal (10). Install bolts (11) and washers into rear crankshaft seal (10) and tighten to 12 ± 3 N·m (106 ± 27 lb in) in order to properly seat rear crankshaft seal (10) .
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Illustration 2 | g00829289 |
- Use Tool (A) to install bearing (4) into flywheel housing (5) .
Note: Bearing joint (W) must be within 15 degrees (X) of the vertical axis. The bearing joint must be on the bottom.
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Illustration 3 | g00828738 |
Bearing (W) Bearing joint (X) Amount of angular misalignment (V) Relief groove |
- Use Tool (A) to install bearing (15) into hydraulic pump adapter (17) .
Note: Bearing joint (W) must be within 15 degrees of vertical. Bearing joint (W) must be on the bottom. Bearing (15) must be recessed to a dimension (S) from the inside edge 3.5 ± 0.5 mm (0.138 ± 0.020 inch). Oil passage (T) in the hydraulic pump adapter needs to be toward the bottom.
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Illustration 4 | g00828646 |
Hydraulic pump adapter (T) Oil passage |
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Illustration 5 | g00829629 |
Cross section of hydraulic pump adapter (L) Location of bearing (T) Oil passage |
- Install pump drive gear (12) into flywheel housing (5) .
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Illustration 6 | g00829249 |
- Install O-ring (16) onto hydraulic pump adapter (17) .
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Illustration 7 | g00829624 |
- Install hydraulic pump adapter (17) onto pump drive gear (12). Line up bolt holes on flywheel housing (5) and hydraulic pump adapter (17). Install six bolts (18) and tighten to a torque of 55 ± 12 N·m (41 ± 9 lb ft).
- Use Tool (A) in order to install Bearing (19) into Idler Gear (13).
Note: Bearing relief groove (V) must line up with the relief groove (U) in Idler Gear (13) within two degrees (Y). Bearing (19) must not extend beyond either face of gear (13) .
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Illustration 8 | g00828734 |
Bearing (V) Relief groove (W) Bearing joint |
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Illustration 9 | g00828623 |
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Illustration 10 | g00828599 |
Idler gear (U) Relief groove in gear (V) Relief groove in bearing (Y) Angular misalignment between the bearing and the gear can not exceed two degrees. |
- Install Idler Gear Shaft (20) into Idler Gear (13). Position the idler gear assembly into flywheel housing (5). Make sure that there is no binding between gears (12) and (13). Install three bolts (21) and tighten to a torque of 100 ± 20 N·m (74 ± 15 lb ft).
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Illustration 11 | g00829256 |
- Install O-rings (3) and (7) on covers (2) and (8) before you fasten the covers to flywheel housing (5) with bolts (1) and (6). Tighten bolts (1) to a torque of 240 ± 40 N·m (177 ± 30 lb ft) and bolts (6) to a torque of 100 ± 20 N·m (74 ± 15 lb ft).
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Illustration 12 | g00829283 |
- Install O-ring (23) and fasten cover (24) with bolts (25). Tighten bolts (25) to a torque of 240 ± 40 N·m (177 ± 30 lb ft).
- Install Crankshaft drive gear (22). Idler gears (13) might need to be rotated in order to get the gear teeth to align properly.
End By: Install the flywheel. Refer to Disassembly and Assembly, "Flywheel - Install".