RETIRO DE LA DEMANDA

3-35.1. Removal.

a. Remove starter, refer to paragraph 3-12.2.

WARNING

Flywheel is heavy. Provide adequate lifting device to support weight. Failure to follow this procedure could result in personal injury.

b. Remove two capscrews (1, FIGURE 3-125) and washers (2). Replace these with two guide studs.

c. Remove other two capscrews (1) and washers (2). Install these two capscrews in threaded holes of flywheel (3). d. Use two capscrews in step b to jack flywheel (3). off crankshaft.

e. Remove flywheel (3) and two capscrews (1). 3-35.2. Repair.

a. If ring gear (4, FIGURE 3-125) is damaged, place the flywheel (3) on a solid flat surface. b. Drive ring gear (4) off with a brass drift and hammer.

WARNING

Oil fumes or oil can ignite above 380° F (193°C). Use a thermometer and do not exceed 360°F (182°C). Do not allow a flame or heating element to be in direct contact with oil. Heat oil in a well ventilated area. Plan a safe handling procedure to avoid bums.

WARNING

Wear protective gloves to help prevent burns from handling hot ring gear (4).

CAUTION

If flame heat is used, be sure gear is heated uniformly around circumference. Do not overheat. Overheating may also destroy original heat treatment of gear.

c. Heat new ring gear (4) to 300°F (148°C) using either heated oil, oven heat, or flame heat. d. Turn gear so side with chamfer is toward engine with flywheel installed.

e. Install ring gear (4) against shoulder of flywheel. 3-35.3. Installation.

WARNING

Flywheel is heavy. Provide adequate lifting device to support weight. Failure to follow this procedure could result in personal injury.

NOTE

Flywheel must be clean and free of any oil, grease, or debris. a. Apply adhesive (LOCTITE 242) to threads of four new capscrews (1, FIGURE 3-125).

b. Install two guide studs in crankshaft capscrew threaded holes. Place flywheel (3) on studs and slide into position against crankshaft.

ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5

FIGURE 3-125. Flywheel and Housing Assembly

c. Start two capscrews (1) and washers (2) in crankshaft. Do not tighten until guide studs are removed and other two capscrews (1) and washers (2) are started.

d. Install timing pin (JDE-81-4) to hold flywheel in place while tightening capscrews. e. Tighten capscrews (1) to 120 ft-lbs (163 Nm).

f. Install starter, refer to paragraph 1-12.7.

3-36. REAR CRANKSHAFT OIL SEAL/WEAR SLEEVE ASSEMBLY. 3-36.1. Removal.

a. Remove flywheel, refer to paragraph 3-35.1.

b. Drill a small hole through seal casing at three locations (equally spaced).

c. Use a slide hammer/puller and a sheet metal screw to pull seal (5, FIGURE 3-125) from housing. Discard seal.

CAUTION

Do not gouge flange of crankshaft with chisel. Nicks or burrs should be removed with a medium grit stone or polishing cloth (180 grit or finer).

d. Carefully cut wear sleeve off crankshaft flange using a small cold chisel. WARNING

Cleaning solvent is flammable and toxic to eyes, skin, and respiratory tract. Skin/eye protection required. Avoid repeated/prolonged contact. Good general ventilation is normally adequate.

NOTE

The unitized design will not allow the seal to be separated from the wear sleeve without destroying the sleeve.

e. Clean OD of crankshaft flange with cleaning solvent P-D-680 to remove sealant from flange.

f. Look for nicks or burrs on wear ring surface and bore in flywheel housing. If necessary, use polishing cloth. g. Finish cleaning by wiping flange with a clean rag.

3-36.2. Installation.

WARNING

Cleaning solvent is flammable and toxic to eyes, skin, and respiratory tract. Skin/eye protection required. Avoid repeated/prolonged contact. Good general ventilation is normally adequate.

a. For proper adhesion and sealing, clean OD of crankshaft flange and ID of wear ring with cleaning solvent just prior to application of sealant. Make sure that OD of crankshaft flange and ID of seal housing bore are free from nicks or burrs.

b. Apply a light coating of sealing compound (MIL-R-46082) retaining sealant completely around the leading edge of crankshaft flange. Wipe away any sealant that may have gotten on seal housing bore.

c. Install pilot from tool set (JT30040) on end of crankshaft using two capscrews. Tighten both capscrews securely. Make sure tool contacts face of crankshaft.

d. Carefully start oil seal/wear sleeve over pilot and crankshaft flange with open side of seal toward engine.

e. Attach driver and thrust washer to guide plate with capscrew. Tighten the capscrew until driver bottoms on pilot. f. Remove capscrew thrust washer, driver, two capscrews, and guide plate.

g. Install flywheel, refer to paragraph 3-35.3. 3-37. FLYWHEEL HOUSING.

ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 a. Remove flywheel, refer to paragraph 3-35.1.

b. Remove oil seal/wear sleeve (5, FIGURE 3-125), refer to paragraph 3-36.1.

c. Support weight of flywheel housing (8) and remove eight 3/8-inch capscrews (6) and four 5/8-inch capscrews (7) securing housing to engine block; remove housing (8) and gasket (9). Discard gasket (9).

3-37.2. Inspect and Measure.

a. Inspect flywheel housing for cracks or other damage.

b. Remove all traces of gasket from mating surfaces of flywheel housing and engine block. c. Inspect dowel pins (10, FIGURE 3-125) for damage. Replace if damaged.

d. Remove and inspect bolt (11) and washer (12) for damage. Replace if damaged. Otherwise, install bolt (11) and washer (12).

e. Remove and inspect plug (13) and performed packing (14) for damage. Replace if damaged. Otherwise, install performed packing (14) and plug (13).

f. Remove and inspect bolt (15) for damage. Replace if damaged. Otherwise, install bolt (15). g. Check Total Indicator Reading (TIR) of flywheel housing seal bore ID.

(1) Attach magnetic base of dial indicator to flywheel end of crankshaft. (2) Position dial indicator against ID of seal bore in flywheel housing.

(3) Turn crankshaft 360 degrees at front of engine, using center bolt on harmonic balancer. Maximum permissible TIR is 0.006 inch (0.152 mm). If run-out exceeds limit, replace flywheel housing.

3-37.3. Installation.

CAUTION

Flywheel housing gasket must contain a silicone bead. If no bead is present, apply a thin bead of sealing compound (LOCTITE 77BR) to gasket to prevent oil leakage.

a. Install new silicone bead/gasket (9, FIGURE 3-125) on block. Gasket should be a silicone bead. NOTE

Dip threads of capscrews (6 and 7) in clean engine lubricating oil (MIL-L-2104). b. Position flywheel housing (8) on engine block.

c. Install eight 3/8-inch capscrews (6) and four 5/8-inch capscrews (7). Torque 3/8-inch capscrews (6) to 22 ft-lbs (30 Nm) initially and retorque to 35 ft-lbs (47 Nm). Torque 5/8-inch capscrews (7) to 170 ft-lbs (230 Nm).

d. Install crankshaft rear oil seal/wear sleeve (5), refer to paragraph 3-36.2. e. Install flywheel, refer to paragraph 3-35.3.

f. Service engine lubrication system, refer to end item maintenance manual.

Section XI. CRANKSHAFT PULLEY AND TIMING GEAR COVER