Series 60

Section 10.2 Rear Engine Power Take-Off (REPTO) Assembly

Section 10.2
Rear Engine Power Take-Off (REPTO) Assembly

The REPTO (Rear Engine Power Take Off) is an aluminum SAE #1 flywheel housing mounted against the rear of the cylinder block, it takes the place of a standard flywheel housing. It provides a cover for the flywheel and serves as a support for the cranking motor and the transmission.‪

The aluminum flywheel housing has an internal idler gear that is driven off the rear of the crankshaft. Those gears drive an output yoke that faces the rear of the vehicle. The output yoke is located at the one o'clock position and has four different yoke configurations. It provides up to 300 hp intermittent and 240 hp continuous PTO power. ‪

A rear oil seal, which is pressed into the housing, may be removed or installed without removing the housing. Refer to "1.8.2 Removal of Front or Rear Crankshaft Oil Seal (Gear Case Cover or Flywheel Housing Removed)" .‪

The output yoke and its oil seals can be serviced. If there is any internal failure, the REPTO should be removed and replaced as an assembly. ‪

Section 10.2.1
Repair and Replacement for the Rear Engine Power Take-Off Assembly

The REPTO assembly currently is a nonserviceable component; if there are internal problems with the REPTO it must be replaced as an assembly.‪

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

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Figure 1. Flowchart for Repair or Replacement of REPTO Assembly

Section 10.2.2
Removal of Rear Engine Power Take-off Assembly

Remove the REPTO assembly as follows:‪

  1. Disconnect battery power.Refer to "9.3.2 Removal and Cleaning of Storage Battery" .
  2. Remove cranking motor from the REPTO flywheel housing.Refer to "9.4.2 Removal of Cranking Motor" .
  3. Remove transmission and PTO driveshaft and any other parts attached to the housing.
  4. Remove the flywheel as follows:
    1. Remove two adjacent flywheel bolts.
    2. Insert two flywheel guide studs (J–36235) into the crankshaft. See Figure "Flywheel Guide Studs" .
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      Figure 2. Flywheel Guide Studs

    4. Remove the remaining flywheel bolts.
  5. Drain oil pan housing by removing the plug at the bottom of the housing. Remove the oil line from the cooler.
  6. Remove three plugs to gain access to bolts securing the housing to the block. See Figure "Pipe Plugs on the Gear Set Cover Plate"
  7. Remove the three bolts being careful not to drop them into the housing.
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    Figure 3. Pipe Plugs on the Gear Set Cover Plate

    NOTICE:

    Do not drop the bolt or washer into the gear set. Engine or REPTO damage will occur.‪

  8. Remove the remaining eight bolts.
    danger

    FALLING COMPONENT

    To avoid injury from a falling component, ensure a proper lifting device is used.‪

  9. Attach a suitable sling or use a floor jack to support the flywheel housing, which weighs about 534 N (120 lbs). Gently tap the backside of the flywheel housing with a rubber mallet to loosen it from the block. Remove the housing.
  10. Remove Gasket Eliminator®, Kent-Moore® part number or equivalent PT 7276 from the flywheel housing and block at this time. See Figure "Removal of Gasket Eliminator®" .
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    Figure 4. Removal of Gasket Eliminator®

    cautions

    To avoid injury from flying sealant. Do not use an impact gun on plugs with white sealant.

  11. Remove all sealing material from the block and housing. Refer to Section on “Cleaning” in the “General Information Section”.

Section 10.2.3
Cleaning of Rear Engine Power Take-off Assembly

Clean the REPTO as follows:‪

  1. Clean any residue from the end of the crankshaft and inside wall of the REPTO mounting hub.
  2. Clean any residue from the yoke sealing surface, washer and nut.
Section 10.2.3.1
Inspection of Rear Engine Power Take-off Assembly

Inspect the REPTO assembly as follows:‪

  1. Inspect the flywheel. Refer to "1.16.2.1 Inspection of Flywheel" .
  2. Inspect flywheel housing for cracks and any other damage.
    1. If sealing surface is damaged, repair with emery cloth.
    2. If cracked, repair is not possible.
  3. Inspect the crankshaft where the rear oil seal makes contact.Refer to "1.8 Crankshaft Oil Seals" .
    1. Check for groove in crankshaft.
    2. If crankshaft is grooved, install a wear sleeve over the crankshaft end. An oversized I.D. rear oil seal must be used with the rear sleeve. Refer to "1.8.5 Installation of Front and Rear Crankshaft Oil Seal and Wear Sleeve" .
  4. Inspect the bottom of the yoke.
    1. If burrs are found on the surface of the yoke, replace the component.
    2. If no damage is found, reuse part.
  5. Inspect the rubber yoke seal.
    1. If any defects are found, replace the seal.
    2. If no damage is found, reuse the seal.

Section 10.2.4
Installation of Rear Engine Power Take-off Assembly

Install the REPTO as follows:‪

  1. Apply a lubricant like white grease to the end of the crankshaft and inside the wall of the REPTO mounting hub. See Figure "Application of Lubricant" .

    Note: If installing a new REPTO housing, ensure that all 11 plastic shipping plugs are removed from the housing.

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     1. Crankshaft‪

     .‪

    Figure 5. Application of Lubricant

  2. If installing a new REPTO housing:
    cautions

    To avoid injury from flying sealant. Do not use an impact gun on plugs with white sealant.

    1. Install the pipe plug above the cranking motor mount on the REPTO flywheel housing. See Figure "Installation of Pipe Plug Above Cranking Motor Mount" .
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      Figure 6. Installation of Pipe Plug Above Cranking Motor Mount

    2. Install the bottom pipe plug located in the 6 o'clock position on the REPTO flywheel housing. See Figure "Installation of Pipe Plug in the 6 o'clock Position" .
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      Figure 7. Installation of Pipe Plug in the 6 o'clock Position

    3. Install the pipe plug with a copper washer located in the 5 o'clock position on the REPTO flywheel housing. See Figure "Installation of Pipe Plug in the 5 o'clock Position" .
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      1. Copper Washer‪

      2. Pipe Plug‪

      Figure 8. Installation of Pipe Plug in the 5 o'clock Position

      Note: Do not install any plugs in the two holes below the crankshaft on the back lower face (even though they are threaded), they are oil drain holes back to sump. See Figure "No Pipe Plug in these Two Threaded Holes" .

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      Figure 9. No Pipe Plug in these Two Threaded Holes

  3. Apply Gasket Eliminator®, Kent-Moore® part number or equivalent PT 7276 , to sealing surface of the flywheel housing or the block whichever is easier. See Figure "Application of Gasket Eliminator®" .
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    Figure 10. Application of Gasket Eliminator®

  4. Install oil fitting on back of flywheel housing. See Figure "Installation of Oil Fitting" .
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     1. Oil Fitting‪

     .‪

    Figure 11. Installation of Oil Fitting

  5. Insert two flywheel guide studs (J–36235) into the crankshaft. See Figure "Flywheel Guide Studs" .
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    Figure 12. Flywheel Guide Studs

    danger

    FALLING COMPONENT

    To avoid injury from a falling component, ensure a proper lifting device is used.‪

  6. Use a hoist to carefully slide the REPTO flywheel housing into position onto the guide studs. See Figure "Installation of REPTO Flywheel Housing" .
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    1. Crankshaft‪

    2. Guide Studs J-36235‪

    Figure 13. Installation of REPTO Flywheel Housing

    NOTICE:

    Do not drop the bolt or washer into the gear set. Engine or REPTO damage will occur.‪

  7. Using a magnetic socket, install and torque all eleven flywheel housing mounting bolts in sequence to 112–126 N·m (83–93 lb·ft.) for 12 mm bolts or 160–200 N·m (118–148 lb·ft.) for 14 mm bolts. See Figure "Flywheel Housing Bolt Location and Torque Sequence" .

    Note: Ensure that the three bolts behind plugs are not overlooked in this step.

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    Figure 14. Flywheel Housing Bolt Location and Torque Sequence

  8. Install the two pipe plugs located on the gear set cover plate and plug next to the cranking motor. See Figure "Pipe Plugs on the Gear Set Cover Plate" .
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    Figure 15. Pipe Plugs on the Gear Set Cover Plate

  9. Set crankshaft endplay as follows:

    NOTICE:

    Setting crankshaft end play must be done whenever the REPTO housing is installed to prevent crankshaft from damaging crankshaft thrust washers upon initial engine startup.‪

    1. Bolt the flywheel to the unit using six flywheel bolts.
    2. Torque the flywheel bolts to 102 N·m (77 ft·lb).
    3. Remove the flywheel. (This is necessary to remove the gap between the crankshaft and REPTO drive hub.)
    4. Attach driver handle (J–8092) onto the setting tool(J–42722–1) . See Figure "Installation of Shims" .
    5. Stack approximately 0.100 in. of shims, (J–42722–4) onto the nose of the setting tool. See Figure "Installation of Shims" .
    6. Add or remove shims until 0.005 in. gap is measured at four points (90 degrees apart) with a feeler gage. See Figure "Installation of Shims" .
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      Figure 16. Installation of Shims

    7. Note: Tool must be held firmly in place and perpendicular to the housing.

    8. Hold the setting tool firmly against the drive hub; with a large hammer, hit the driver handle two to four times to set the gap between the crank and thrust washer. See Figure "Installation of Shims" .
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      Figure 17. Installation of Shims

    9. Remove the tool, ensuring no shims remain stuck to the hub.
  10. Bar the engine over from the front of the crankshaft. It should turn slightly harder than without the REPTO housing installed.
  11. Install flywheel and torque bolts.Refer to "1.16.3 Installation of Flywheel" .
  12. Install cranking motor assembly.Refer to "9.4.3 Installation of Cranking Motor" .

    Note: Crankshaft endplay is set and there is no further need to check if this procedure was done correctly.

  13. Install oil supply line.

    Note: Ensure the oil supply line is connected to the port next to the turbo oil supply line and not to the oil cooler assembly.

  14. Test for REPTO Flywheel Housing Bore Concentricity as follows:
    1. Attach the base post onto the crankshaft palm.
    2. Assemble the dial indicators onto the base post.
    3. Position the dial indicator square with the flywheel housing inside bore of the bell. Ensure the indicator has adequate travel in each direction. See Figure "Measuring Flywheel Housing Bore Concentricity " .
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      Figure 18. Measuring Flywheel Housing Bore Concentricity

    4. Adjust each dial indicator to read zero at the twelve o'clock position.
    5. Bar the engine and rotate the crankshaft one complete revolution, taking readings at 90 degree intervals (four readings each for the bore). See Figure "Flywheel Housing" .
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      Figure 19. Flywheel Housing

    6. Remove the wrench or cranking bar before recording each reading to ensure accuracy.

      Note: The maximum total indicator reading must not exceed 0.33 mm (0.013 in.).

    7. If the run-out exceeds the maximum limits, check for dirt of foreign material between the flywheel housing and the cylinder block or oil pan.
    8. Clean the mating surfaces once again. Refer to section "General Information, Cleaning" in the beginning of this manual.
    9. Install REPTO Flywheel Housing.Refer to "10.2.4 Installation of Rear Engine Power Take-off Assembly" .
    10. Check run-out again.
  15. Install transmission. Refer to OEM.
  16. Apply lube to the yoke seal surface and slide it onto the PTO spline. See Figure "Apply Lube to Yoke Seal and Loctite® 565 to Both Sides of Washers" .
  17. Apply Loctite® 565 or equivalent to both sides of the large washer and hand start nut. See Figure "Apply Lube to Yoke Seal and Loctite® 565 to Both Sides of Washers" .
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     1. Yoke‪

     2. Washer‪

    Figure 20. Apply Lube to Yoke Seal and Loctite® 565 to Both Sides of Washers

  18. Insert a 3/4 in. drive wrench in the front pulley to stop crank from turning.
  19. Install the nut to the spline and torque to 474–542 N·m (350–400 ft lbs).

    Note: All cranking motors assembled to the REPTO housings should be installed with a new gasket.

  20. Install cranking motor. Refer to "9.4.3 Installation of Cranking Motor" .

    NOTICE:

    Do not connect to the wrong port. Connecting to the wrong port will allow coolant to be fed to the gears and the engine will fail.‪

  21. Install the oil supply line to the brass fitting on the housing and the opened port.
  22. Install oil pan. Refer to "3.11.4 Installation of Oil Pan" .
  23. Fill engine with clean lube oil. Refer to "5.2 Lubricating Oil (Diesel)" .
  24. Install engine into vehicle.
  25. Start and run engine for verification of proper engine operation.


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

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