N14 Base Engine Troubleshooting and Repair Manual – 016-005   Flywheel

• Disconnect the batteries to prevent accidental engine starting.
• Ensure vehicle is immobilized and safe to work on. Refer to the end-user procedures.
• Remove the vehicle driveline and the transmission. Refer to the manufacturer’s instructions.

Install two 1/2 – 13 x 1 1/2 puller capscrews which have a minimum of 1 1/4-inch threaded area at points (1) and (2).

Remove capscrews (3) and (4), and install two 5/8 – 18 x 6-inch guide studs, Part No. 3824462.

NOTE: For Rail Applications the flywheel mounting capscrews must
be discarded and replaced.

Determine the capscrew thread size, and install two “T-handles”, Part No. 3824463, into the flywheel at points (4) and (5).

Remove the remaining four flywheel mounting capscrews.

NOTE: For Rail Applications the flywheel mounting capscrews must
be discarded and replaced.

WARNING  Because this part weighs more than 23 kg [50 lb], two people or a hoist will be required to lift the flywheel to avoid personal injury.

Tighten capscrews (1) and (2) in alternating sequence to loosen the flywheel.

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.

WARNING  When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles, as well as protective clothing, to reduce the possibility of personal injury.

WARNING  Compressed air used for cleaning should not exceed 207 kPa [30 psi]. Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

Use a wire brush to clean the crankshaft pilot bore.

Steam clean or use a solvent, and dry with compressed air.

Visually inspect for nicks or burrs.

Use a fine crocus cloth to remove small nicks and burrs.

WARNING  Do not use a cracked or resurfaced flywheel. These can break, causing serious personal injury or property damage.

Use the crack detection kit, Part No. 3375432, to check for cracks in the flywheel. Follow the instructions provided with the kit.

Inspect the flywheel ring gear teeth for cracks and chips.

NOTE: If the ring gear teeth are cracked or broken, the ring gear must be replaced.

NOTE: If an “old” style flywheel is fitted, it must be replaced with a “new” style flywheel. The “new” style flywheel ensures greater integrity of the crankshaft/flywheel bolted joint.

CAUTION  “Old” style flywheels must be scrapped and not reused. “Old” style flywheels are not compatible for use with the spacer/clamping ring.

Check the flywheel mating face of the crankshaft for signs of pitting, fretting or corrosion. Refer to Procedure 001-016.

Use the dial indicator gauge (1), Part No. 3376050, or its equivalent and dial gauge attachment (2), Part No. ST-1325, to inspect the flywheel bore (3) and the surface (4) runout.

Install the attachment to the flywheel housing.

Install the gauge on the attachment.

Install the contact tip of the indicator against the inside diameter of the flywheel bore, and set the dial indicator at “0” (zero).

Use the accessory drive shaft to rotate the crankshaft one complete revolution.

NOTE: The total indicator reading (TIR) must not
exceed 0.127 mm [0.0050-inch].

NOTE: If the TIR is greater than the specification, do the following:

• Remove the flywheel.

• Inspect the flywheel mounting surface for dirt, paint, or damage.

• Inspect the crankshaft for dirt or damage.

NOTE: If the crankshaft is found to be damaged, replace the crankshaft.

• Install the flywheel, and inspect the bore runout.

• Replace the flywheel if the runout does
  not meet specifications.

Install the contact tip of the indicator against the flywheel face, as close to the outside diameter as possible, to inspect the face (4) runout.

Push the flywheel forward to remove the crankshaft end clearance. Adjust the dial on the indicator until the needle points to “0”
(zero).

Use the accessory drive shaft to rotate the crankshaft one complete revolution. Measure the flywheel runout at four equal points on the flywheel.

NOTE: The flywheel must be pushed toward the front of the engine to remove the crankshaft end clearance each time a point is measured.

The total indicator reading (TIR) must not
exceed the following specifications:

If the flywheel face runout is not within specifications, remove the flywheel. Check for nicks, burrs, or foreign material between the flywheel mounting surface and the crankshaft flange.

Inspect the flywheel for any deformation, bending, or cracking that can contribute to excessive face run-out. Replace if necessary.

Install the clutch discs, the pressure plate, the transmission, and the driveline (if equipped) in reverse order of removal. Refer to the manufacturer’s instructions.

NOTE: Align the universal joints on each end of the drive shaft to prevent vibration. Refer to the manufacturer’s instructions.

NOTE: Use a new pilot bearing when installing a new or rebuilt clutch.

Use a mandrel and a hammer to remove the pilot bearing.

Use a 240 grit emery cloth to clean the pilot bore.

Use a mandrel and a hammer to install the pilot bearing.

NOTE: The pilot bearing must be installed flush with the pilot bore surface.

Install two 5/8 – 18 x 6-inch guide studs, Part No. 3824462, into the crankshaft flange.

WARNING  Because this part weighs more than 23 kg [50 lb], two people or a hoist will be required to lift the part to avoid personal injury.

Install the flywheel onto the guide stud.

Lubricate the threads of the capscrews and the surface of the washers with 15W-40 lubricating oil.

Install the four capscrews.

Remove the “T-handles”, Part No. 3824463, and the guide studs, Part No. 3824462.

Install the remaining two capscrews into the holes from which the guide studs were removed.

Tighten the capscrews in a star pattern.

Install the spacer/clamping ring, Part Number, 3287628.

WARNING  Do not reuse the existing capscrews. Replace all used flywheel capscrews with new capscrews. Do not replace or reuse the existing washers.

Lubricate the threads of the capscrews and the underhead area of the capscrews with clean 15W-40 lubricating oil.

Install the four new capscrews, Part Number, 3287753.

Remove the “T-handles”, Part No. 3824463, and the guide studs, Part No. 3824462.

Install the remaining two capscrews into the holes from which the guide studs were removed.

Tighten the capscrews in the sequence shown.

• Install vehicle driveline and transmission. Refer to the manufacturer’s instructions.
• Connect batteries.
• Mobilize vehicle. Refer to the end-user procedures.