Gear Case Cover Replacement

TM 9-2320-363-34-1 · Chapter 3 — Power Package Maintenance

This task covers: a. Removal b. Cleaning c. Inspection d. Installation

Tools and Special Equipment:                      Equipment Condition (Cont):
Shop Equipment, SC 4910-95-CL-A31                 Reference                Condition Description
Tool Kit, SC 5180-90-CL-N05                                                .          .
Guide Stud (2), J36107                            Page 3-126               Accessory Drive
                                                                           Removed
Materials/Parts:
                                                  Page 3-92                Air Compressor Drive
Ring, Seal              P/N 5141452                                        Removed
Eliminator,             Appendix B, Item 18       TM 9-2320-363-20         Water Pump Removed
Gasket
                                                  Page 3-56                Fan Drive Supporl
Oil, Lubricating        Appendix B, Item 37                                Removed
References:                                       Page 3-220               Oil Pan Removed
TM 9-2320-363-20                                  Page 3-46                Front Engine Mount
                                                                           Adapter Removed
Equipment Condition:
                                                  General Safety Instructions:
Reference               Condition Description
TM 9-2320-363-20        Alternator Removed                          WARNING
Page 7-2                Power Steering Pump                 Gear case cover weighs 89
                        Removed                            lb (40 kg). Attach suitable
                                                           lifting device prior to removal
TM 9-2320-363-20        Tachometer Drive                   or installation to prevent
                        Removed                            possible injury to personnel.
                                                            Be careful not to slide gear
                                                           case cover off guide studs.
                                                           To do so could result in injury
                                                           to personnel or equipment
                                                           damage.

                                        CAUTION
          Use wood blocks on jack stands to protect oil pan flange.

1.    INSTALL JACK STAND UNDER EACH SIDE OF OIL PAN FLANGE. REMOVE PREVIOUSLY
      INSTALLED SUPPORT.

2. REMOVE TWO NUTS (1) AND TWO BOLTS (2) SECURING ALTERNATOR MOUNTING BRACKET (3) ON GEAR CASE COVER (4) AND GEAR HOUSING (5).

3. REMOVE AND DISCARD TIE STRAPS (6) SECURING FAN CLUTCH SOLENOID AIR LINE (7) AND MOVE AIR LINE AWAY FROM GEAR CASE COVER (4) AND GEAR HOUSING (5).

4. REMOVE BOLT (8) FROM STANDOFF BRACKET (9) AND GEAR CASE COVER (4). MOVE STANDOFF BRACKET (9) AWAY FROM GEAR CASE COVER (4).

5. REMOVE NUT (1O), BOLT (11), AND STANDOFF BRACKET (12) FROM GEAR CASE COVER (4). MOVE STANDOFF BRACKET (12) AWAY FROM GEAR CASE COVER (4).

6. REMOVE TWO BOLTS (13) FROM OPPOSITE SIDES OF GEAR CASE COVER (4). REPLACE TWO BOLTS (13) WITH TWO GUIDE STUDS (14).

7. REMOVE 14 BOLTS (15).

8. MOVE GEAR CASE COVER (4) AWAY FROM GEAR HOUSING (5) AND POSITION NYLON ROPE THRU TACHOMETER DRIVE COVER OPENING ON GEAR CASE COVER (4).

9. SECURE NYLON ROPE TO SUITABLE LIFTING DEVICE, SLIDE GEAR CASE COVER (4) OFF TWO GUIDE STUDS (14).

10. REMOVE AND DISCARD SEAL RING (16) BETWEEN BULL/IDLER GEAR HUB RECESS (17) AND GEAR CASE COVER (4).

11. REMOVE TWO GUIDE STUDS (14).

12. REMOVE ALL OLD GASKET ELIMINATOR FROM MATING SURFACES OF GEAR CASE COVER (4) AND GEAR HOUSING (5).

13. REMOVE FRONT OIL SEAL (18) FROM GEAR CASE COVER (4). DISCARD OIL SEAL.

Use general cleaning methods to clean all parts (page 2-30).

1. lNSPECT VISIBLE AREA OF CRANKSHAFT OIL SEAL CONTACT AREA CAREFULLY FOR DAMAGE WHENEVER GEAR CASE COVER IS REMOVED.

2. INSPECT ALL PARTS FOR WEAR OR DAMAGE.

1. POSITION NYLON ROPE THRU TACHOMETER DRIVE COVER OPENING OF GEAR CASE COVER (1) AND SECURE ROPE TO SUITABLE LIFTING DEVICE.

Gasket eliminator cures in presence of air. Keep time to minimum between gear case cover installation and tightening gear case cover mounting bolts.

2. APPLY CONTINUOUS 1/16-lN. BEAD OF GASKET ELIMINATOR TO MATING SURFACES OF GEAR HOUSING (2).

3. INSTALL TWO GUIDE STUDS (3) IN BOLT HOLES ON OPPOSITE SIDES OF GEAR HOUSING (2).

4. INSTALL NEW SEAL RING (4) IN BULL/IDLER GEAR HUB RECESS (5) USING ENGINE LUBRICATING OIL TO HOLD SEAL RING IN PLACE.

5. POSITION GEAR CASE COVER (1) ON TWO GUIDE STUDS (3) AND REMOVE NYLON ROPE AND LIFTING DEVICE.

6. INSTALL GEAR CASE COVER (1) AGAINST GEAR HOUSING (2).

7. INSTALL 10 SHORT BOLTS (6).

8. INSTALL FOUR LONG BOLTS (7).

9. REMOVE TWO GUIDE STUDS (3) AND INSTALL TWO BOLTS (8).

10. INSTALL STANDOFF BRACKET (9) AND BOLT (1 O) TO GEAR CASE COVER (1).

11. INSTALL STANDOFF BRACKET (11), BOLT (12), AND NUT (13) ON GEAR CASE COVER (1).

12. SECURE FAN CLUTCH SOLENOID AIR LINE (14) TO GEAR CASE COVER (1) AND GEAR HOUSING (2) WITH NEW TIE STRAPS (15).

13. TIGHTEN BOLTS TO 43-54 LB-FT (58-73 N.m) IN SEQUENCE SHOWN.

14. POSITION ALTERNATOR MOUNTING BRACKET (16) ON GEAR CASE COVER (1) AND GEAR HOUSING ASSEMBLY (2). INSTALL TWO BOLTS (17) AND TWO NUTS (18). HOLD TWO NUTS AND TIGHTEN TWO BOLTS TO 43-54 LB-FT (58-73 N.m).

Install crankshaft front oil seal (page 3-227 or 3-231). Install water pump (TM 9-2320-363-20). Install air compressor drive (page 3-92). Install accessory drive (page 3-126). Install tachometer drive (TM 9-2320-363-20). Install power steering pump (page 7-2). Install alternator (TM 9-2320-363-20). Install fan drive support (page 3-56). Install front engine mount adapter (page 3-46). Install oil pan (page 3-220).