Centinel System – Repair Manual – 016-006   Flywheel Housing

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Preparatory Steps

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 WARNING 

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

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

Some state and federal agencies have determined that used engine oil can be carcinogenic and cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged contact with used engine oil. If not reused, dispose of in accordance with local environmental regulations.
 WARNING 

To reduce the possibility of personal injury, avoid direct contact of hot oil with your skin.
 WARNING 

Adequately support the engine to prevent damage and personal injury.
  • Disconnect the batteries and air starter to prevent accidental engine starting.
  • Remove the transmission, clutch, and all related components. Refer to the equipment manufacturer’s instructions.
  • Remove the flywheel. Refer to Procedure 016-005.
  • Drain the oil. Refer to Procedure 007-037.
  • Remove the oil pan. Refer to Procedure 007-025.
  • Remove the rear crankshaft seal. Refer to Procedure 001-024.
  • Remove the starting motor. Refer to Procedure 013-020.
  • Remove the rear engine mounts from the flywheel housing.

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Remove

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Remove the two top exterior capscrews from the flywheel housing.

Install two guide studs.

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 WARNING 

This component weighs 23 kg [50 lb] or more. To avoid personal injury, use a hoist or get assistance.

Use a hoist and lifting sling. Install the lifting sling around both sides of the upper housing. Adjust the hoist until there is tension in the lifting sling. Remove the remaining capscrews.

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Use a mallet to tap the flywheel housing off the two locating dowels.

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Remove two capscrews, cover plate, and gasket. Discard the gasket.

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 CAUTION 

Immediately upon removal of the flywheel housing assembly, a plug must be inserted into the cylinder block oil passage drillings. Failure to insert the oil passage plug can result in a bearing failure, crankshaft failure, or both.

The reusable plug, Part Number 4918321, is included in Protective Plug Kit, Part Number 4918319. This plug is necessary to prevent debris from entering the lubrication system during the repair.

Plug the block oil passage with plug Part Number 4918321.

Firmly push plug into oil passage to prevent all debris from entering the lubricating system when cleaning the gasket surface.

 
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Clean and Inspect for Reuse

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 CAUTION 

Do not allow dirt or foreign material to enter oil passages in the cylinder block when cleaning the gasket sealing surfaces. Main or connecting rod bearing failures can be caused if debris is introduced into the lubrication system. Therefore, use of power tools combined with abrasive pads to clean gasket surfaces is not recommended.

Clean the gasket surfaces by hand with a gasket scraper or cleaning pad Part Number 3823258

If the residual gasket material can not be felt with a finger, the surface is ready to accept the new gasket.

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 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 avoid personal injury.
 WARNING 

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

Steam-clean or use solvent to clean the housing.

Dry with compressed air.

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Inspect all surfaces for nicks, burrs, or cracks.

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

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Inspect all threaded capscrew holes for damage.

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

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Install

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Remove the protective plug from the block oil passages. Make sure debris does not enter the lubrication system.

Use a clean shop towel to carefully wipe out the oil passage and inspect to make sure no debris is left in the passage.

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Install the cover plate and two capscrews. Tighten the capscrews.

Torque Value:  11  n.m  [97 in-lb]

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Install two guide studs into the cylinder block to help support and align the housing during installation.

Position the flywheel housing gasket to the rear of the engine block using the guide pins.

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Install the flywheel housing over the guide studs.

Lubricate the threads and underneath the heads of the capscrews with clean 15W-40 lubricating oil.

Install capscrews 1, 2, 3, and 4, and tighten in the sequence shown.

Torque Value:  7  n.m  [62 in-lb]

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The flywheel housing is located on the block by two ring dowels from the factory. If a flywheel housing is removed, it can be reinstalled with the ring dowels in place, but alignment must be checked with the following alignment procedure.

If the alignment does not meet specification, the ring dowels must be removed and the housing must be realigned without the ring dowels.

 
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 CAUTION 

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

Measure the flywheel housing alignment.

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Measure

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Bore Alignment


Attach a dial indicator to the crankshaft. Use mounting tool Part Number ST-1325 and indicator Part Number 3376050.

The dial indicator can be mounted by any method that holds the extension bar of the indicator rigid so it does not sag. If the bar sags or the indicator slips, the readings obtained will be inaccurate.

Position the indicator in the 6:00 o’clock position and the gauge at zero.

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Slowly rotate the crankshaft. Record the readings obtained at the 9:00 o’clock, 12:00 o’clock, and 3:00 o’clock positions as (a), (b), and (c) in the concentricity work sheet. Recheck zero at the 6:00 o’clock position.

The values for (a), (b), and (c) can be positive or negative. Refer to the accompanying figure to determine the correct sign when recording these values.

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 CAUTION 

Do not force the crankshaft beyond the point where the bearing clearance has been removed. Do not pry against the flywheel housing. These actions can cause false bearing clearance reading.

Rotate the crankshaft until the dial indicator is at the 12-o’clock position and zero the gauge.

Use a pry bar to raise the rear of the crankshaft to its upper limit. Record the value as (d) in the concentricity work sheet. This is the vertical bearing clearance adjustment and will always be positive.

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Use the concentricity work sheet (see the accompanying illustration) to determine the total vertical and horizontal values.

The total horizontal is equal to the 9:00 o’clock reading (1) minus the 3 :00 o’clock reading (c).

The total vertical is equal to the 12:00 o’clock reading (b) plus the bearing clearance (d).

Example:

6:00 o’clock = reference = 0
9:00 o’clock = [a ] = 0.004
12:00 o’clock = [b ] = 0.003
3:00 o’clock =[c] = -0.002.

Using the work sheet and the numbers from the example, the total horizontal value equals 0.006, and the total vertical value equals 0.005.

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Mark the total horizontal value on the horizontal side of the chart and the total vertical on the vertical side of the chart.

Use a straightedge to find the intersection point of the total horizontal and total vertical values. The intersection point must fall within the shaded area for the flywheel housing concentricity to be within specification.

Using the total horizontal and total vertical values from the previous example, the intersection point falls within the shaded area. Therefore, the flywheel housing concentricity is within specification.

Use the accompanying chart for SAE 1, 2, and 3 flywheel housings.

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Use the accompanying chart for SAE 0 and ½ flywheel housings.

 
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Use the accompanying chart for SAE 00 flywheel housings.

 
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If the intersection point falls outside the shaded area, the ring dowels must be removed and the housing repositioned.

The ring dowels are not required to maintain concentricity of the housing; the clamping force of the capscrews holds the housing in place.

After the ring dowels are discarded, install the flywheel housing on the engine.

To position the housing, tighten the capscrews enough to hold the flywheel housing in place, but loose enough to enable small movement when struck lightly with a mallet.

Recheck the concentricity. When concentricity is within specification, tighten the capscrews to the specified value.

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Face Alignment


 CAUTION 

The dial indicator tip must not enter the capscrew holes, or the gauge will be damaged.

Install a dial indicator as illustrated.

The extension bar for the indicator must be rigid for an accurate reading. It must not sag. Position the indicator at the 12:00 o’clock position. Adjust the dial until the needle points to zero.

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Slowly rotate the crankshaft. Record the readings at the 3:00 o’clock, 6:00 o’clock, and 9:00 o’clock positions.

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

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Continue to rotate the crankshaft until the indicator is at the 12:00 o’clock position. Check the indicator to make sure that the needle points to zero. If it does not, the readings will be incorrect.

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Determine the total indicator runout.

Total Indicator Runout (Example)
Position Runout
12:00 o’clock 0.00 mm [0.000 in]
3:00 o’clock +0.08 mm [+0.003 in]
6:00 o’clock -0.05 mm [-0.002 in]
9:00 o’clock +0.08 mm [+0.003 in]
Total Indicator Runout = 0.13 mm [0.005 in]

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The maximum allowable total indicator reading is determined by the diameter of the housing bore. If out of specifications, replace the housing.

SAE Number Bore Diameter Total Indicator Runout Maximum
00 787.40 to 787.65 mm [30.88 to 31.00 in] 0.30 mm [0.012 in]
0 647.70 to 647.95 mm [25.50 to 25.51 in] 0.25 mm [0.010 in]
½ 584.2 to 584.4 mm [23.000 to 23.008 in] 0.25 mm [0.010 in]
1 511.18 to 511.30 mm [20.125 to 20.130 in] 0.20 mm [0.008 in]
2 447.68 to 447.80 mm [17.652 to 17.630 in] 0.20 mm [0.008 in]
3 409.58 to 409.70 mm [16.125 to 16.130 in] 0.20 mm [0.008 in]

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Install the remaining capscrews. Tighten all capscrews in two steps using the sequence shown.

Torque Value: Step 1 100 n.m   [74 ft-lb]
  Step 2 197 n.m   [145 ft-lb]

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Finishing Steps

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 WARNING 

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

This component weighs 23 kg [50 lb] or more. To avoid personal injury, use a hoist or get assistance to lift the component.
  • Install the rear engine mounts on the flywheel housing.
  • Install the starting motor capscrews, starter, and spacer. Refer to Procedure 013-020.
  • Install the rear crankshaft seal. Refer to Procedure 001-024.
  • Install the oil pan. Refer to Procedure 007-025.
  • Fill the oil. Refer to Procedure 007-037.
  • Install the flywheel. Refer to Procedure 016-005.
  • Install the transmission, clutch, and all related components. Refer to the equipment manufacturer’s instructions.
  • Connect the batteries and air starter.

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Last Modified:  16-Mar-2005