Series 60

Section 1.10 Gear Case Cover Pre-Exhaust Gas Recirculation (EGR)

Section 1.10
Gear Case Cover Pre-Exhaust Gas Recirculation (EGR)

The gear case cover and gear case housing bolt together at the front of the engine to form a sealed compartment for the engine gear train. See Figure "Engine Gear Case and Cover" .‪

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Figure 1. Engine Gear Case and Cover

The gear case cover also serves as a retainer for the crankshaft front oil seal. See Figure "Crankshaft Front Oil Seal" . ‪

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Figure 2. Crankshaft Front Oil Seal

Several components that are mounted to the gear case cover include the water pump (pre-1991 engines only), accessory drive assembly, and fan support bracket See Figure "Gear Case Cover-mounted Components" . ‪

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Figure 3. Gear Case Cover-mounted Components

The front engine support is bolted to the front of the gear case cover, directly behind the crankshaft pulley and vibration damper. See Figure "Typical Front Engine Support"

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Figure 4. Typical Front Engine Support

Several access covers are provided on the gear case cover for service of the engine without removing the gear case cover. Removal of the camshaft drive gear access cover will allow the removal of the camshaft drive gear-to-camshaft bolt for camshaft and cylinder head removal without removing the gear case cover. See Figure "Camshaft Drive Gear Access Cover" . ‪

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Figure 5. Camshaft Drive Gear Access Cover

The fan support bracket includes the access cover for the adjustable idler gear. See Figure "Fan Support Bracket" .‪

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Figure 6. Fan Support Bracket

With the fan support bracket and the camshaft drive gear access cover removed, the gear lash between the adjustable idler gear and the camshaft drive gear can be measured and adjusted Refer to "1.24.2.1 Check Engine Timing" .‪

On vehicles without power steering, an access cover is provided for inspection of the air compressor drive gear. See Figure "Air Compressor Drive Gear Access Cover" .‪

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Figure 7. Air Compressor Drive Gear Access Cover

On some vehicles equipped with power steering, the power steering hydraulic pump is mounted to the gear case cover in the place of the access cover, and is driven by a short coupling that fits in the splined hole in the center of the air compressor drive gear. The pump is installed with a gasket.‪

Section 1.10.1
Repair or Replacement of Gear Case Cover

To determine if repair is possible or replacement is necessary, perform the following procedure. See Figure "Flowchart for Repair or Replacement of Gear Case Cover" .‪

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Figure 8. Flowchart for Repair or Replacement of Gear Case Cover

Section 1.10.2
Removal of Engine Gear Case Cover

With the engine mounted on an overhaul stand. Remove the gear case cover as follows:‪

NOTICE:

Do not hit the face of the damper to loosen it. Damage to the internal components may result. The oil pan cannot be used to support the front of the engine in a vehicle, as its thermoplastic construction will not support the weight.‪

  1. Drain the engine oil and remove the engine oil pan. Refer to "14.6.1 Lubricating Oil" , for oil draining and refer to "3.11.2 Removal of Oil Pan" .
  2. Loosen the fan hub mounting bolts. Loosen the fan adjusting bolt. Back the adjuster off far enough to remove the drive belts. Remove the fan and fan hub assembly. Refer to "4.6.2 Removal of Engine Cooling Fan" .
  3. Loosen the alternator mounting bolts. Remove the alternator drive belts, alternator, and mounting brackets (if so equipped). Refer to "9.2.2 Removal of Alternator" . See Figure "Alternator and Related Parts" .
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    Figure 9. Alternator and Related Parts

  4. Loosen the air conditioner compressor and mounting brackets (if so equipped). Refer to OEM guidelines.
  5. Remove the five fan support bolts. See Figure "Fan Support Bolt Location" .
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    Figure 10. Fan Support Bolt Location

  6. Remove the water pump assembly. Refer to "4.3.2 Draining and Removal of Front Mounted Water Pump" for front mounted water pump. Refer to "4.2.2 Draining and Removal of Water Pump (GCM)" for gear case mounted.
  7. Remove the power steering pump (if so equipped). Refer to OEM guidelines.
  8. Remove the crankshaft pulley. Refer to "1.15.2 Removal and Cleaning Crankshaft Pulley" .
  9. Remove the vibration damper. Refer to "1.14.2 Cleaning and Removal of Crankshaft Vibration Damper" .
  10. Remove the front engine mount by removing the four bolts securing the front engine mount to the gear case cover.
  11. Loosen and remove the five bolts that secure the accessory drive assembly to the gear case cover. See Figure "Accessory Drive Assembly" .
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    Figure 11. Accessory Drive Assembly

  12. Remove the accessory drive assembly by pulling it straight out of the gear case cover to avoid damaging the rubber O-ring. See Figure "Accessory Drive Assembly" .
  13. There are a total of 34 bolts that secure the gear case cover to the gear case. Bolts 17, 18, 19 and 20 were removed with the front engine mount. Bolts F1 through F5 were removed in a previous step; refer to step 12 . Loosen and remove bolts 1 through 16, 21, 22 (see note).
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    Figure 12. Gear Case Cover Bolt Arrangement (Front)

    Note: Bolts 21 and 22 are rear bolts on pre-1991 engines.

    1. Remove the SRS. Refer to "2.30.2 Removal of Synchronous Reference Sensor" .
    2. Remove the air compressor drive assembly by removing the six bolts on the back of the gear case on the intake side of the engine located around the air compressor drive assembly. See Figure "Gear Case Cover Bolt Arrangement (Left Rear)" .
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      Figure 13. Gear Case Cover Bolt Arrangement (Left Rear)

    4. Remove the bolts on the back of the gear case on the water pump (right) side of the engine. See Figure "Gear Case Cover Bolt Arrangement (Right Rear)" .
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      Figure 14. Gear Case Cover Bolt Arrangement (Right Rear)

  14. Support the gear case cover with a suitable lifting device, using the front engine lift bracket. See Figure "Engine Gear Case Cover Support" .
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    1. Engine Lifter Bracket‪

    3. Gear Case Housing‪

    2. Gear Case Cover‪

    Figure 15. Engine Gear Case Cover Support

    Note: There is a rubber O-ring installed between the center of the bull gear hub and the gear case cover. The O-ring may adhere to the cover when it is removed. Be sure the O-ring is not lost. See Figure "Bull Gear O-ring" .

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    Figure 16. Bull Gear O-ring

  15. Tap the gear case cover with a fiber mallet or plastic hammer to loosen it from the gear case. Remove the engine gear case cover.
Section 1.10.2.1
Inspection of Gear Case Cover

Inspect the gear case cover as follows:‪

  1. Clean all of the old gasket sealer from the mating surfaces of the gear case and gear case cover. Refer to General Information "General Information" , "Cleaning".
  2. Clean the gasket material from the mating surfaces of any components or access covers that were removed from the gear case cover, and the gear case cover itself.
    warning

    EYE INJURY

    To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 276 kPa (40 psi) air pressure.‪

  3. Clean all of the removed parts except the electrical components with clean fuel oil and dry with compressed air.

    Note: Any time the gear case cover is removed, the crankcase oil seal must be replaced. Install the new front oil seal after the gear case cover has been installed to the engine.

  4. If necessary, remove the crankshaft front oil seal at this time. Refer to "1.8.2 Removal of Front or Rear Crankshaft Oil Seal (Gear Case Cover or Flywheel Housing Removed)" . Inspect the gear case cover for stress cracks or breaks in the casting. Refer to "1.10.2.1 Inspection of Gear Case Cover" . Repair or replace as necessary. Refer to "1.12.3 Installation of Gear Case" .
  5. Inspect all O-rings for signs of dryness or splitting. Replace as necessary.

Section 1.10.3
Installation of Gear Case Cover

Perform the following steps for gear case installation:‪

  1. Apply a continuous 1/16 in. bead of Gasket Eliminator PT-7276 (Loctite® 518) or equivalent to the mating surface of the gear case.

    Note: Gasket eliminator cures with the absence of air. The length of time between gear case cover installation and torquing the bolts that secure the gear case cover to the gear case should be kept to a minimum.

  2. Install two guide studs (J–36107) to the gear case. See Figure "Gear Case Cover Guide Stud Location" .
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    1. Front Gear Case Cover‪

    4. Locating Dowel (Round)‪

    2. Front Engine Lift Bracket‪

    5. Locating Dowel (Diamond)‪

    3. Front Gear Case Housing‪

    Figure 17. Gear Case Cover Guide Stud Location

  3. Support the gear case cover with a suitable lifting device, using the front engine lift bracket. See Figure "Engine Gear Case Cover Support" .
  4. Position the gear case cover on the guide studs and slide it forward. Index the two dowels in the gear case. See Figure "Gear Case Cover Guide Stud Location" .
  5. There are 34 bolts that secure the gear case cover to the gear case (including five for the fan support bracket). Install them as follows:

    NOTICE:

    With gasketless parts such as the gear case cover; the torque values and tightening sequences are critical to prevent parts warpage.‪

    1. Install the shorter bolts, No. 1 through 16, 21, 22 (see note), in various locations at the front of the gear case cover. Finger-tighten them. Remove the guide studs when installing bolts 7 and 14. See Figure "Gear Case Cover Bolt Torque Sequence (Front)" .
    2. Note: Bolts 21 and 22 are rear bolts on pre-1991 engines.

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      Figure 18. Gear Case Cover Bolt Torque Sequence (Front)

    3. Torque bolts 1 through 16, 21, 22 (see note), to 58-73 N·m (43-54 lb·ft).
    4. Install the front engine mount to the gear case cover. Install the four, longer, front engine mount-to-gear case cover bolts, finger-tight.
    5. Torque bolts 17, 18, 19 and 20 to 160-200 N·m (118-148 lb·ft). See Figure "Gear Case Cover Bolt Torque Sequence (Front)" .
    6. Bolts F1 through F5 are fan support bracket bolts. Install the fan support bracket and torque bolts F1, F2 and F3 to 58-73 N·m (43-54 lb·ft). Torque bolts F4 and F5 to 160-200 N·m (118-148 lb·ft).
    7. Install the six bolts on the intake (left) side of the engine around the air compressor drive. Torque the bolts to 58-73 N·m (43-54 lb·ft), using the sequence. See Figure "Air Compressor Drive Torque Sequence" .
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      Figure 19. Air Compressor Drive Torque Sequence

    9. Install the SRS to the gear case; refer to "2.30.3 Installation of Synchronous Reference Sensor" .
    10. Install the two rear mounted bolts (pre - 1991 engines only) bolts on the exhaust (right) side of the engine. Torque the number 2 and 3 bolts to 58-73 N·m (43-54 lb·ft) torque. See Figure "Gear Case Cover Bolt Torque Sequence (Right Rear)" .
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      Figure 20. Gear Case Cover Bolt Torque Sequence (Right Rear)

  6. Install a new crankshaft front oil seal. Refer to "1.8.5 Installation of Front and Rear Crankshaft Oil Seal and Wear Sleeve" .
  7. Install the accessory drive assembly to the gear case. Refer to "1.35.5 Installation of the Accessory Drive" .
  8. Install the vibration damper to the crankshaft. Refer to "1.14.3 Installation of Crankshaft Vibration Damper" .
  9. Install the crankshaft pulley to the end of the crankshaft. Refer to "1.15.3 Installation of Crankshaft Pulley" .
  10. Install the water pump assembly. Refer to "4.2.8 Installation of Water Pump (GCM)" for gear case mounted. Refer to "4.3.7 Installation of Front Mounted Water Pump" for front mounted.
  11. Install a new gasket between the power steering pump cover and the gear case (if so equipped).
  12. Install the power steering pump cover to the gear case cover with the six bolts. Tighten the bolts progressively in a star-shaped pattern to draw the power steering pump in evenly. Torque the bolts to 30-38 N·m (22-28 lb·ft), using a star-shaped pattern.
  13. Insert a new gasket between the camshaft drive gear access cover and the gear case cover.
  14. Install the camshaft drive gear access cover to the gear case cover. Torque the bolts to 30-38 N·m (22-28 lb·ft), using the tightening sequence. See Figure "Access Cover Bolt Torque Sequences" .
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    Figure 21. Access Cover Bolt Torque Sequences

  15. Install the air conditioner compressor and brackets. Install the air conditioner compressor drive belt. Refer to OEM guidelines.
  16. Install the alternator and brackets. Refer to "9.2.3 Installation of Alternator" . Install the alternator drive belts. Refer to "14.6.9 Drive Belts" .
  17. Adjust the alternator and air conditioner compressor drive belts to the specifications. Refer to "14.6.9 Drive Belts" .
  18. Install the engine oil pan. Refer to "3.11.4 Installation of Oil Pan" . Fill the crankcase with recommended lubricating oil. Refer to "14.6.1 Lubricating Oil" .


Series 60 Service Manual - 6SE483
Generated on 10-13-2008

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