5005394 JOHNSON ENGINE COVER Assy

Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-0520 Driver Group 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure that all components of the rear power take-off (RPTO) are clean and free from wear and damage.
Illustration 1 g02070454
Illustration 2 g02069024
If necessary, follow Steps 2.a through Steps 2.c in order to install the sleeve bearings from the flywheel housing.
Accurately align oil Holes (X) in sleeve bearing (20) with the oil holes in flywheel housing (9).
Use Tooling (A) in order to install sleeve bearing (20) into flywheel housing (9). Note: Ensure that the oil holes are correctly aligned. If the oil holes are not correctly aligned, the sleeve bearing should be removed.
Repeat Step 2.a through Steps 2.b in order to install sleeve bearing (21) to flywheel housing (9).
Illustration 3 g02070455
If necessary, follow Steps 3.a through Steps 4 in order to install the sleeve bearing to the gears.
Place gear (17) onto suitable support.
Accurately align Grooves (Z) in sleeve bearing (19) with Grooves (Y) in gear (17).
Use Tooling (A) and a suitable press in order to install sleeve bearing (19) into gear (17).
Illustration 4 g03453500
Repeat Steps 3.a through Step 3.c in order to install the sleeve bearing to gear (18).
Place gear (18) onto suitable support.
Accurately align Grooves (Z) in sleeve bearing (19a) with Grooves (Y) in gear (18).
Use Tooling (A) and a suitable press in order to install sleeve bearing (19a) into gear (18).
Illustration 5 g02069021
Lubricate idler hub (15) and gear (17) with clean oil. Install idler hub (15) to gear (17). Note: Ensure that the gear and the idler hub are correctly oriented.
Install gear (17) and idler hub (15) assembly to flywheel housing (9). Note: Ensure that the oil hole in the idler hub is correctly positioned.
Install bolts (13) to idler hub (15) and hand tighten bolts. Note: Ensure that the idler hub is correctly aligned to the flywheel housing.
Repeat Steps 5 through Step 7 in order to install gear (18), idler hub (16) and bolts (14) to flywheel housing (9).
Tighten bolts (13) and bolts (14) to a torque of 100 N m (74 lb ft).
Ensure that there is tactile backlash between gear (17) and gear (18). Ensure that there is end play between the idler hubs and the gears.
Illustration 6 g02069020
install gear assembly (11) and gear assembly (12) to flywheel housing (9).
Illustration 7 g02069019
Illustration 8 g02070473
If necessary, follow Steps 12.a through Steps 12.c in order to install the sleeve bearings to the adapters.
Place adapter (2) onto suitable support.
Use Tooling (A) and a suitable press in order to install sleeve bearing (10) into adapter (2).
Repeat Steps 12.a through Step 12.b in order to install the sleeve bearing into adapter (5).
Install a new O-ring seal (3) (not shown) to adapter (2).
Install adapter (2) to flywheel housing (9). Note: Ensure correct orientation of the adapter.
Install bolts (1) and tighten the bolts to a torque of 55 N m (41 lb ft).
Install a new O-ring seal (6) (not shown) to adapter (5).
Install adapter (5) to flywheel housing (9). Note: Ensure correct orientation of the adapter.
Install bolts (4) and tighten the bolts to a torque of 55 N m (41 lb ft).
Ensure that there is tactile backlash between the gears. Ensure that there is end play between the gears and the flywheel housing and the adapters.
Install gear (7) to crankshaft (8).
If necessary, install the OEM equipment to the rear power take-off (RPTO). End By:
Install the flywheel. Refer to Disassembly and Assembly, "Flywheel - Install" for the correct procedure.