ISC, ISCe, QSC8.3, ISL, ISLe3, ISLe4 and QSL9 Engines – 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.

• Disconnect the battery. Refer to Procedure 013-009 in Section 13.
• Remove the transmission, clutch, and all related components (if equipped). Refer to the OEM service manual.
• Remove the flywheel/ring gear assembly. Refer to Procedure 016-005 in Section 16.
• Adequately support the engine to prevent damage.
• Remove the starting motor. Refer to Procedure 013-020 in Section 13.
• Remove both rear engine mounts. Refer to Procedure 016-003 in Section 16.

Remove the REPTO oil supply line.

Remove the oil seal capscrews, oil seal, and gasket.

To gain access to the housing capscrews, use a drift to drive the cup plugs straight through into the housing.

Retrieve the plugs from inside the housing.

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

Install two crankshaft locator studs, Part Number 3822784, into the crankshaft flywheel mounting flange, 180 degrees apart.

Remove the crankshaft drive gear.

CAUTION  The idler gear will fall when the shaft is removed.

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

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

Remove two of the capscrews and install two guide pins, Part Number 3376638, to support the housing during removal.

Use an offset wrench, Part Number 3823892, to remove the capscrews that are not visible.

WARNING  This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly.

Remove the remaining capscrews. Use a rubber hammer to loosen the housing.

Remove the housing.

Use gear locking tool, Part Number 3823891, to prevent the output shaft from turning when removing the retainer capscrew.

Remove the capscrew and washer that secures the output flange to the output shaft.

Use a rawhide hammer to remove the output flange and flat washer from the output shaft.

Use a dent puller to remove the seal. Do not damage the surface of the housing or seal bore.

When the housing is turned over, the bearing will fall out. Do not allow the bearing to be damaged.

Turn the housing over so the four cover plate capscrews are accessible. Be careful not to damage the output shaft.

Remove the capscrews and ribbed cover plate from the output gear housing.

Remove and discard the square cut o-ring.

Save the original shims for rebuild purposes. They will be used to set the proper end clearance on the output shaft and bearing assembly.

Turn the housing over and use a rawhide hammer to hit the end of the output shaft to remove the output shaft sub-assembly from the REPTO housing.

With the housing positioned so the cylinder block mating surface is down, use a hammer and brass punch to drive the bearing outer races out of the output shaft housing bore.

Support the housing in a press with the cylinder block mating surface down.

With a long mandrel, press out the idler shaft bushing.

Remove and discard the o-ring.

Use a hammer and brass drift to remove the two bearing outer races from the bore of the idler gear. Discard the outer races.

Remove the large spacer ring from the center groove of the gear. Discard the spacer ring.

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.

Use a steam cleaner to clean all areas of the idler gear.

Inspect the output shaft and bearings for wear.

Inspect the output gear for damage.

Inspect the output flange for damage or wear grooves from the oil seal.

Replace if necessary.

Inspect the REPTO housing for cracks at the rear engine mounting surfaces and the flywheel bore.

Replace the housing if cracked.

Inspect the idler shaft bushing for wear.

Replace the bushing if worn.

Inspect the bore, side faces, and teeth of the idler gear.

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

Install a new o-ring on the idler shaft bushing.

Use assembly lubricant, Part Number 3163087, or equivalent, to lubricate the o-ring.

Support the housing evenly with the engine mating surface up.

Press the new bushing into the housing until it is below the surface of the cylinder block mating surface.

Use assembly lubricant, Part Number 3163087, or equivalent, to lubricate the larger bearing race.

Use the larger end of the driver, Part Number 3823893, to press the bearing race to the shoulder in the housing.

Turn the housing over and support it evenly in the press.

Use assembly lubricant, Part Number 3163087, or equivalent, to lubricate the smaller bearing race.

Use the smaller end of the driver, Part Number 3893893, to press the bearing race to the shoulder in the housing.

Use assembly lubricant, Part Number 3163087, or equivalent, to lubricate the output shaft and larger bearing.

Install the larger bearing onto the output shaft.

Position the housing on the table so the cylinder block mating surface is up.

Install the output shaft assembly into the housing.

The correct end clearance (rolling resistance) is determined by the number and thickness of shims used between the two bearings.

When the shim thickness is increased, there is more shaft end clearance and less rolling resistance.

When the shim thickness is decreased, there is less shaft end clearance and more rolling resistance.

Turn the housing over with the engine mating surface down, while holding the output shaft and gear in place.

If the original thickness of shims is not available for reuse, a beginning thickness of 1.47 mm [0.058 in] can be used as a starting point.

Install the original thickness of shims.

Use assembly lubricant, Part Number 3163087, or equivalent, to lubricate the smaller bearing.

Install the smaller bearing onto the shaft.

Temporarily install the output flange before installing the oil seal.

Use clean 15W-40 engine oil to lubricate the splines.

Install the flat washer and capscrew. Use the gear locking tool, Part Number 3823891, to hold the output shaft while tightening the capscrew.

Measure the shaft end play.

Shaft End Play

Check the output shaft rolling resistance with a torque wrench.

If the rolling resistance is not within specification, remove the output flange and smaller bearing.

Add or subtract shims to obtain the correct rolling resistance.

Adding more shims will decrease the resistance and removing shims will increase resistance. Any combination of shims can be used.

Once the correct rolling resistance is obtained, remove the output flange and install a new oil seal.

Press the oil seal flush with the housing surface.

Apply pipe sealant, Part Number 3375066, to the output flange capscrew and under the washer.

Install the output flange flat washer and capscrew.

Tighten the capscrew.

Install a new o-ring on the bearing housing cover.

Use clean vegetable oil to lubricate the o-ring.

Install and tighten the cover and four capscrews.

Insert a new spacer ring into the bore of the idler gear.

Push until it snaps into place in the center groove.

Use assembly lubricant, Part Number 3163087, or equivalent, to lubricate the bearing outer races.

Press the two new bearing outer races into the bore of the idler gear.

The larger side of the taper must face toward the outside of the gear.

Do not interchange individual parts that make up the idler gear bearing assembly. Rebuild the idler gear with bearings that are packaged together.

Keep the two roller bearing assemblies and the spacer ring with the idler gear.

Install the rectangular seal on the rear seal carrier and lubricate with assembly lubricant, Part Number 3163087, or equivalent.

Apply a continuous bead of RTV sealant, Part Number 3164067, or equivalent, around all capscrew holes on the mounting surface of the flywheel housing.

WARNING  This component or assembly weighs greater than 23 kg {50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly.

Inspect the rear face of the cylinder block and flywheel housing mounting surface for cleanliness and nicks or burrs.

Install the flywheel housing over the two ring dowels.

Be sure the sealing ring is not damaged during installation.

Install the capscrews and tighten in the sequence shown. Use an offset wrench, Part Number 3823892, for capscrews hidden from view.

Before installing the idler gear, measure the flywheel housing bore and face alignment. Refer to Procedure 016-006 in Section 16.

Fabricate a sleeve from 38.10 mm [1.50 in] PVC (or equivalent) to the following dimensions:

Length: 25.4 mm [1.0 in]

Slot: 12.70 mm [0.50 in]

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

Apply a thin film of assembly lubricant, Part Number 3163087, or equivalent, on the outer races and bearings.

Install the bearing and spacer into the idler gear. Use the babricated PVC (or equivalent) sleeve to hold the bearing assembly together when installing the idler gear assembly.

Apply a thin film of assembly lubricant, Part Number 3163087, or equivalent, into the idler shaft bore of the housing and on the idler shaft.

NOTE: For idler scissor gears, loosen the screws in the scissor gear by turning counterclockwise until they will no longer turn. The screws will not come out of the gear

Install the idler gear assembly into the flywheel housing.

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

Use clean assembly lubricant, Part Number 3163087, or equivalent, to lubricate the idle shaft o-ring and install the o-ring into the shaft.

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

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

Apply assembly lubricant, Part Number 3163087, or equivalent, under the head of the idler shaft capscrew. Insert the capscrew through the idler shaft. Tighten the installation capscrew with a torque wrench.

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 is an indication of misalignment between the bore and the shaft. Remove the idler shaft and install it again.

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

Apply pipe sealant, Part Number 3375066, to the threads of the idler shaft capscrew. Apply assembly lubricant, Part Number 3163087, or equivalent, under the head of the capscrew and tighten to the final torque value.

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

Use a driver, Part Number 3823710, to install the cup plugs into the housing, as illustrated.

When installing cup plugs, make sure they are flush with the spot face on the flywheel housing and are not cocked.

Coat the flywheel housing drain plug with pipe sealant and install it in the hole in the bottom of the flywheel housing.

Tighten the plug. Refer to Procedure 017-007 in Section 17.

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 crankshaft locator studs, Part Number 3822784, into the crankshaft flywheel mounting flange 180 degrees apart.

Make sure the crankshaft and the crankshaft gear are clean.

Install the crankshaft gear in the locator studs.

Do not use any lubricant to install the seal. The oil seal must be installed with the crankshaft gear seal contact surface and the lip of the seal clean and dry to provide a proper oil sealing surface.

Install a new gasket (1) in the flywheel housing.

Install a new seal over the crankshaft gear seal contact surface.

Apply sealant, Part Number 3375066, to seal the retainer capscrews.

Install the capscrews and tighten in a star pattern.

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 in Section 13.
• Install the rear engine mounts. Refer to Procedure 016-003 in Section 16.
• Install the flywheel/ring gear assembly. Refer to Procedure 016-005 in Section 16.
• Install the flexplate, if installed. Refer to Procedure 016-004 in Section 16.
• Install the flywheel, if installed.Refer to Procedure 016-005 in Section 16.
• Install the transmission, clutch, and all related components (if equipped). Refer to the OEM service manual.
• Connect the battery. Refer to Procedure 013-009 in Section 13.
• Operate the engine and check for leaks.