N14 Base Engine Troubleshooting and Repair Manual – 016-006   Flywheel 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 this component.

Remove the transmission, the clutch, and all related components. Refer to the manufacturer’s instructions.

Remove the flywheel. Refer to Procedure 016-005.

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.

Use a portable lifting bracket, Part Number . 3823835, 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 capscrews (1) and (2), and install two 3/8-18 x 4 in guide studs, Part Number 3824462.

Remove the remaining capscrews.

Use a rubber hammer to loosen the housing from the dowels in the cylinder block.

On wet-type flywheel housings, remove the o-ring from the rear cover and the 11 rectangular sealing rings from the flywheel housing.

WARNING  When using a steam cleaner, wear safety glasses or a face shield, as well as protective clothing. 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 and protective clothing to reduce the possibility of personal injury.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

Steam clean or use solvent to clean the housing.

Dry with compressed air.

Inspect all surfaces for nicks, burrs, or cracks.

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

Inspect all threaded capscrew holes for damage.

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

Use the dowel pin extractor, Part Number ST-1134, or equivalent to remove the two dowel pins from the cylinder block.

Measure one of the dowel pins which was removed and replace it with the next oversize dowel.

Install the flywheel housing.

Tighten the capscrews.

Do not tighten the capscrews to the final torque value until the flywheel housing is aligned.

Use chalk to mark the housing at the 12:00 o’clock, 3:00 o’clock, 6:00 o’clock, and 9:00 o’clock positions.

Attach the dial indicator to the crankshaft.

Use the accessory drive to rotate the crankshaft until the dial indicator is at the 3:00 o’clock position.

Adjust the dial indicator until the needle points to “0” (zero).

Rotate the crankshaft until the indicator is at the 9:00 o’clock position.

Check the total indicator reading.

If the total indicator reading exceeds the limits use a mallet to horizontally move the housing one-half the distance of the total indicator reading.

Rotate the crankshaft until the indicator is at the 12:00 o’clock position.

Adjust the dial until the needle points to “0” (zero).

Rotate the crankshaft until the indicator is at the 6:00 o’clock position.

Check the total indicator reading.

If the total indicator reading exceeds the limits, use a mallet to vertically move the housing one-half the distance of the total indicator reading.

Rotate the crankshaft until the indicator is at the 12:00 o’clock position.

Adjust the dial until the needle points to “0” (zero).

Rotate the crankshaft, and record the indicator reading at the 3:00 o’clock, 6:00 o’clock, and 9:00 o’clock positions.

After the housing bore is aligned, check to make sure the surface of the housing is in alignment.

When the housing alignment is within the limits, tighten the capscrews. Tighten the capscrews in the sequence.

After the capscrews are tightened, check the housing bore and the surface alignment again before doweling the housing.

Use the appropriate size capscrews to attach plate, Part Number ST-1232-1, which is contained in drill ream fixture, Part Number ST-1232.

Do not tighten the capscrews so tightly that the plate will not move.

Use the locator pin, Part Number 3375052, to align the plate with the hole for the dowel pin.

Tighten the capscrews.

The taper on the pin must engage the dowel pin hole.

The locator pin must rotate easily after the capscrews are tightened.

Measure the dowel pins which are to be installed.

Obtain a reamer (1) that is 0.013 mm to 0.02 mm [0.0005 in to 0.001 in] smaller than the dowel.

The dowel must be long enough to protrude from the block one-half of the flywheel housing wall thickness but must not protrude past the housing wall.

There are three oversize dowel pins available from Cummins Inc.:

Install the appropriate drill bushings. The graphic shows the bushings available from Cummins Inc.

The drill bushing used must be the same size as the reamer (or the drill) which is used.

If the new dowel pins are more than 0.38 mm [0.015 in] larger than the old dowels, drill the hole to a size that is slightly smaller than the reamer.

The reamer will not have to remove an excessive amount of material.

CAUTION  Do not allow metal chips to enter the engine. Damage to the engine will result.

Ream the hole until the reamer touches the bottom of the hole in the block.

After reaming one hole, turn the plate and align it with the second dowel hole.

Repeat the procedure in the second hole.

Remove the plate from the crankshaft.

CAUTION  To avoid possible engine damage, make sure the dowel hole does not contain any metal chips.

Use a square nose drift. Drive each dowel in until it touches the bottom of the hole in the block.

After the dowels are installed, measure the bore and the surface alignment again.

CAUTION  If a new flywheel housing is being installed, the dowels must be removed from the cylinder block prior to installing the housing to prevent damage to the housing. The housing must be doweled with an oversize dowel after it has been aligned.

Install two 5/8 – 18 x 4 in guide studs, Part Number 3824462, into the cylinder block to help support and align the housing during installation.

If a wet-type flywheel housing is being installed, perform the following:

• Install a new o-ring onto the rear cover. Use 15W-40 oil to lubricate the o-ring.
• Install 11 rectangular sealing rings into the capscrew and dowel pin counterbores in the flywheel housing. Use gasket adhesive to fasten the sealing rings to the housing.

Install the flywheel housing over the guide studs.

Install the capscrews, and tighten in the sequence shown.

CAUTION  The flywheel housing bore and the surface must be in alignment with the crankshaft to prevent possible damage to the engine, the clutch, or the transmission.

Use chalk to mark the housing at the 12:00 o’clock, 3:00 o’clock, 6:00 o’clock, and 9 o’clock positions.

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

Use the accessory drive shaft to rotate the crankshaft.

Attach a dial indicator to the crankshaft as shown.

The indicator arm must be rigid for an accurate reading. It must not sag.

Put the indicator at the 12:00 o’clock position. Adjust the dial indicator until the needle points to “0” (zero).

Use the accessory drive to rotate the crankshaft in a clockwise direction (as viewed from the front of the engine).

Record the indicator reading at three different points: 3:00 o’clock, 6:00 o’clock, and 9:00 o’clock.

Continue rotating the crankshaft until the dial indicator is at the 12:00 o’clock position.

Check the dial indicator to make sure the needle still points to “0” (zero).

Determine the total indicator run out as follows:

The maximum allowable total indicator reading depends on the diameter of the housing bore. See the following chart:

If the bore alignment does not meet the specifications, loosen the housing capscrews.

Tighten the capscrews again, and measure the bore alignment again.

Flywheel housing misalignment can be confirmed if the dial indicator minimum and maximum readings are exactly 180 degrees apart.

Alignment can be corrected by repositioning the housing.

A flywheel housing bore “Out-of-Round” condition will produce dial indicator minimum and maximum readings in random locations.

If the alignment is not within specifications and the bore is round, the housing can be shifted.

If the alignment is not within specifications and the bore is not round, the housing must be replaced.

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

Put the tip of the dial indicator gauge against the flywheel housing surface.

Use the accessory drive to rotate the crankshaft until the dial indicator is at the 12:00 o’clock position.

Push the crankshaft toward the front of the engine.

Adjust the dial on the indicator until the needle points to “0” (zero).

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

Use the accessory drive to rotate the crankshaft in the clockwise direction.

Record the indicator reading at three different points: 3:00 o’clock, 6:00 o’clock, and 9:00 o’clock.

Continue rotating the crankshaft until the dial indicator is at the 12:00 o’clock position.

Check the dial indicator to make sure the needle still points to “0” (zero).

Determine the total indicator run out as follows:

The maximum allowable total indicator reading depends on the diameter of the housing bore. See the following chart:

If the alignment is not within specifications, remove the housing. Check for nicks, burrs, or foreign material between the block and the housing.

Check the alignment again. If the alignment is not within specifications, the block or the housing is not machined correctly.

Install the two rear engine mounts. Tighten the capscrews to the manufacturer’s specifications.

Remove the lifting fixture used to support the engine.

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.

Install the starting motor. Refer to Procedure 013-020.

Connect the battery cables.

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 this component.

Install the flywheel. Refer to Procedure 016-005.

Install the clutch, the transmission, and related components. Refer to the manufacturer’s instructions.