M11 Series – Service Manual – 016-007   Flywheel Housing, REPTO

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

CAUTION  Place a wooden block, the width of the oil pan, between the floor jack and oil pan to prevent damage to the engine.

• Remove the transmission, clutch, and all related components, if equipped. Consult the manufacturer’s instructions.
• Remove the flywheel. Refer to Procedure to 016-005.
• Use a floor jack or a suitable lifting fixture to support the rear of the engine.
• Disconnect the battery cables.
• Remove the starting motor. Refer to Procedure 013-020.

Remove the capscrews and both rear engine mounts.

Remove the four oil pan rear mounting capscrews.

Loosen six capscrews on each side of the oil pan at the end closest to the flywheel housing. This will allow enough clearance to remove the flywheel housing.

Be careful not to tear the oil pan gasket. If the oil pan gasket is damaged, the oil pan must be removed and the gasket replaced.

Remove the oil supply line from the flywheel housing.

Remove the rear crankshaft oil seal. Refer to Procedure 001-024

Remove capscrews (1 and 2) and install two guide pins.

CAUTION  Do not attempt to back out or rotate the plugs from the housing. The cup plug bore will be damaged and oil leakage will occur.

CAUTION  Do not use a hammer when installing the idler shaft and capscrew. The part can be damaged.

To gain access to the housing capscrews, use a cup plug driver, Part Number 3824927, to drive the cup plugs straight through into the housing.

Retrieve the plugs from inside the housing.

Remove the crankshaft drive gear.

Remove the two guide pins from the crankshaft.

Remove the idler shaft retaining capscrew.

CAUTION  When the idler shaft is removed, the idler gear can fall and become damaged. Hold the idler gear before pulling the idler shaft out.

Use idler shaft puller, Part Number 3823709, to remove the idler shaft.

Remove the access hole cover and gasket from the REPTO housing.

Remove threaded plug from the access hole.

Rotate the engine crankshaft until a set screw is accessible through a tapped hole on the engine side of the REPTO housing.

Screw the set screws in to lock, if equipped with a scissor gear.

CAUTION  Do not drop the idler gear bearings as the idler gear is removed. Damage to the bearings can result.

Remove the idler gear to gain access to the rest of the housing capscrews.

Remove two of the mounting capscrews, and install two guide pins to support the housing during removal.

Use offset wrench, Part Number 3824928, to remove the capscrews that are not in view. These capscrews are inside the housing.

WARNING  This component weighs 23 kg [50 lb] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift the component.

Remove the remaining capscrews.

Use a rubber hammer to loosen the flywheel housing.

Do not damage the rear of the oil pan gasket when removing the flywheel housing.

Remove the flywheel housing.

Remove the gasket material from the flywheel housing oil seal gasket surface.

Clean the sealant from the cylinder block surface.

WARNING  When using a steam cleaner, wear protective clothing, as well as safety glasses or a face shield. Hot steam can cause serious personal injury.

Use steam or solvent to clean the flywheel housing. Dry with compressed air.

Inspect all surfaces for nicks, burrs, or cracks.

Use fine crocus cloth to remove small nicks and burrs.

Inspect the rear engine power take off housing for cracks at the rear engine mounting surfaces and the flywheel bore.

Replace the housing if it is cracked.

Inspect the idler shaft bushing for wear.

Replace the bushing if it is worn.

Inspect all threaded capscrew holes for damage.

Repair or replace the housing if the capscrew holes are damaged.

Closely inspect the bore, side faces, and teeth of the rear engine power take off idler gear.

Replace the gear if there are cracks, discoloration from excessive heat, or other damage.

Scissor Gear

Remove the snap ring and inspect the springs and ball bearings.

Replace any broken components.

Inspect both bearings.

Replace if damaged.

Check the output shaft rolling resistance with a torque wrench.

The rolling resistance must be between 0.6 to 1.1 N•m [5 to 10 in-lb].

If the resistance does not meet these specifications, add or subtract shims to obtain the correct rolling resistance. Refer to the L10, Engine Shop Manual: Bulletin 3810476

NOTE: Adding shims will increase resistance; removing shims will decrease resistance. Any combination of shims can be used.

Install two guide pins in the cylinder block to help support and align the housing during installation.

Apply a 2 mm [1/16 in] bead of silicone sealant, Part Number 3823494, on the mounting surface of the housing and around each capscrew hole.

Apply silicone sealant to each rear corner of the oil pan gasket and flywheel housing mating surface.

WARNING  This component weighs 23 kg [50 lb] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift the component.

Use a hoist when installing the rear engine power take off flywheel housing over the guide pins.

Install the flywheel housing over the guide pins.

Do not damage the oil pan gasket when installing the flywheel housing.

The flywheel housing bore must be aligned with the crankshaft. Do not tighten the capscrews to the final torque value until the flywheel housing is aligned.

Install the capscrews. Remove the guide pins, and install the remaining two capscrews.

Bore Alignment

Use dial indicator gauge (1), Part Number 3376050, and dial gauge attachment (2), Part Number ST-1325, to measure the bore alignment.

Adjust the dial indicator gauge to zero “0”.

Use the accessory drive shaft to rotate the crankshaft one complete revolution (360 degrees).

If the maximum bore alignment does not meet the specifications, use a rubber hammer to move the housing in the necessary direction and repeat the measurement procedure.

If the bore alignment will not meet the specifications or the bore is not round, the housing must be replaced.

Face Alignment

CAUTION  The tip of the gauge must not enter the capscrew holes or the gauge will be damaged.

Install the contact tip of the dial indicator gauge against the flywheel housing face.

Push the crankshaft toward the front of the engine.

Adjust the dial indicator gauge to zero “0”.

Monitor the dial indicator gauge while turning the crankshaft.

Use the accessory drive shaft to rotate the crankshaft one complete revolution (360 degrees) while keeping the crankshaft end thrust pushed forward.

If the maximum face alignment does not meet the specifications, the flywheel housing must be replaced.

Tighten all capscrews in the sequence shown.

Measure the bore and face alignment again.

If bore and face alignment does not meet the specifications, loosen the housing capscrews. Tighten the capscrews and measure the bore and face alignment again.

Standard Gear

Manufacture a sleeve from 38.1 mm outside diameter (O.D). [1.50 in O.D.] (D) PVC, aluminum, thin wall hose, or equivalent, to the following dimensions:

Apply Lubriplate™ 105 multi-purpose lubricant , or equivalent, on the outer races and the bearings.

NOTE: The outer bearing races of new replacement gears are already pressed into the gear.

Install the bearing and spacer into the idler gear. Use the manufactured sleeve to hold the bearing assembly together when installing the idler gear assembly.

Apply a thin film of Lubriplate™ 105 multi-purpose lubricant, or equivalent, into the idler shaft bore of the housing and on the idler shaft.

Install the idler gear assembly into the flywheel housing.

Hold the idler gear and bearings in place and remove the plastic sleeve.

CAUTION  Do not use a hammer when installing the idler shaft and capscrew, or the part can be damaged.

Use clean Lubriplate multi-purpose lubricant to lubricate the idler shaft o-ring and install the o-ring onto the shaft.

Hold the gear assembly in place and insert the idler shaft through the housing and idler gear bearings.

Scissor Gear

Insert the large spacer ring into the bore of the thicker gear. Press it in until the ring snaps into the groove that has been machined into the center of the bore.

Lubricate both of the bearing races with Lubrbriplate 105™ multi-purpose lubricant, or equivalent.

CAUTION  The outer bearing races of new replacement gears are already pressed into the gear. Excessive grease in the housing insert or on the shaft can create a hydraulic lock. Use moderation when applying lubrication.

With the larger diameter of the tapered race facing out, press each bearing race into the bore until it stops against the spacer ring.

Lay the thicker gear on a table with the hub (1) facing up.

Select two short, cone shaped set screws (2) from the parts kit. Screw each one into a threaded hole with the coned end pointing up.

Turn the set screws in until they stop.

Place a spring from the parts kit in each of the three remaining holes.

Rest a ball bearing from the parts kit on top of each spring.

There are five machined cones on the face of the thin gear. Three of these cones (1) are evenly spaced apart.

Place the thin gear (1) over the hub of the thick gear (2).

The cones machined into the thin gear (1) must face the thick gear (2)

Rotate the thin gear (1) on the hub of the thick gear (2) until the balls mate with the three evenly spaced cones in the thin gear.

Select two spacers of the same height.

Position the spacers 180 degrees apart on top of the thin gear. Leave enough room between the spacers and the hub of the thick gear so that the snap ring can be installed over the hub.

Using a press, compress the spacers until the thin gear has been pushed tight against the thick gear.

Install a snap ring over the hub of the thick gear. If the snap ring interferes with the spacers, release the press and move the spacers out from the center of the bore. Repeat the preceding step.

Turn the set screws until they are extended into the coned holes of the thin gear. Make sure that the teeth of the thin gear and the thick gear align when the set screws stop. The set screws are in the holes that are 180 degrees apart.

The small spacer ring (1), roller bearings (2), idler shaft (3), and the races that have already been installed on the thick gear, comprise a matched set. The gear and bearing hardware must be kept together until it is installed in the REPTO housing.

Fabricate a sleeve from PVC, aluminum, or equivalent material with an outside diameter of 38.1 mm [1.50 in] (D), with the following dimensions:

CAUTION  The outer bearing races of new replacement gears are already pressed into the gear. Excessive grease in the housing insert or on the shaft can create a hydraulic lock. Use moderation when applying lubrication.

Apply Lubriplate™ 105 multi-purpose lubricant or equivalent, to the outer races and the bearings.

Install the bearings (1) and spacer (2) into the backlash gears. Use the fabricated sleeve (3) to hold the bearing assembly together until it has been inserted into the REPTO housing.

Use Lubriplate™ 105 multi-purpose lubricant, or equivalent, to lubricate the idler shaft o-ring and install the o-ring onto the idler shaft.

NOTE: The anti-backlash gear assembly must be installed with the snap ring facing the installer.

Install the backlash gear assembly into the REPTO housing.

Hold the backlash gear assembly in place and remove the fabricated sleeve.

CAUTION  Do not use a hammer when installing the idler shaft and capscrew. The part can be damaged.

Apply a thin film of Lubriplate™ multi-purpose lubricant, or equivalent, into the idler shaft bore of the housing and on the idler shaft.

Hold the backlash gear assembly in place and insert the idler shaft through the housing and the backlash gear assembly.

Apply Lubriplate® 105 multi-purpose lubricant under the head of the idler shaft capscrew. Insert the capscrew through the idler shaft. Tighten the installation capscrew with a torque wrench.

NOTE: The torque needed to draw the idler shaft in place must not exceed 88 N•m [65 ft-lb]. If installation torque exceeds this amount, it indicates misalignment between the bore and the shaft. Remove the idler shaft and install it again.

CAUTION  Do not use a hammer when installing the idler shaft and capscrew. The part can be damaged.

After the idler shaft has been seated, remove the capscrew.

Apply pipe sealant to the threads of the idler shaft capscrew. Apply Lubriplate™ 105 multi-purpose lubricant under the head of the capscrew. Install the capscrew and tighten to its final torque value.

Rotate the engine crankshaft until a set screw is accessible through a tapped hole on the engine side of the REPTO housing.

CAUTION  These two set screws must be completely retracted into the thick gear so that the anti-backlash system will operate properly. If they protrude out of the thick gear, the anti-backlash system will be damaged.

Use a 7/32 inch Allen wrench to back the set screw away from the thin gear.

Rotate the engine crankshaft until the other set screw is accessible.

Back the set screw away from the thin gear.

Inspect the gears to make sure that the backlash has been activated.

Install a threaded plug into the access hole.

Install the access hole cover and gasket onto the REPTO housing.

Apply a film of cup plug sealant, Part Number 3375068, to the outside diameter of a new cup plug.

Use driver, Part Number 3823710, to install the cup plug into the housing as shown.

Turn the output flange so that the flat sides are on the top and bottom. This prevents any interference when the transmission is installed onto the housing.

Install two guide pins into the crankshaft flywheel mounting flange 180 degrees apart.

Make sure the crankshaft and crankshaft gear are clean.

Install the crankshaft gear on the guide pins.

Install the rear crankshaft oil seal. Refer to Procedure 001-024.

Install the four oil pan rear mounting capscrews.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

CAUTION  Place a wooden block, the width of the oil pan, between the floor jack and oil pan to prevent damage to the engine.

• Install the starting motor. Refer to Procedure 013-020.
• Install the battery cables.
• Use a floor jack or a suitable lifting fixture to support the rear of the engine.
• Install the flywheel. Refer to Procedure to 016-005.
• Install the transmission, clutch, and all related components, if equipped. Consult the manufacturer’s instructions.