0378994 JOHNSON GEARCASE ASSY.

Table 1
Required Tools
Tool Part Number Part Description Qty
A(1) 9U-6198 Crankshaft Turning Tool 1
A(2) 5P-7306 Shaft Housing 1
5P-7305 Engine Turning Tool 1
B 136-4632 Timing Pin 1
C 1P-2320 Combination Puller 1
(1) The Crankshaft Turning Tool is used on the front pulley.
(2) This Tool is used in the aperture for the electric starting motor.Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Dispose of all fluids according to local regulations and mandates.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: Put identification marks on all hoses, on all hose assemblies and on all tube assemblies for installation purposes. Plug all hose assemblies and tube assemblies. Plugging all hose assemblies and tube assemblies helps to prevent fluid loss and also helps to keep contaminants from entering the system.
Do not disconnect the air lines until the air pressure in the system is at zero. If hose is disconnected under pressure it can cause personal injury.
Release the pressure from the air system. Refer to the Original Equipment Manufacture (OEM) for the correct procedure.
Drain the coolant from the cooling system into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct draining procedure.
If the engine is equipped with a hydraulic pump on the rear of the air compressor, remove the hydraulic pump. Refer to the OEM for the correct procedure.
Use Tooling (A) in order to rotate the crankshaft so that number one piston is at the top center position on the compression stroke. Refer to Systems Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston" for the correct procedure. Note: The air compressor must be timed with the engine in order to minimize engine vibration.
Illustration 1 g01966313
Typical example
Remove plug (2) from the cylinder block. Remove O-ring seal (1) from the plug.
Install Tooling (B) into Hole (X) in the cylinder block. Use Tooling (B) in order to lock the crankshaft in the correct position. Note: Do not use excessive force to install Tooling (B). Do not use Tooling (B) to hold the crankshaft during repairs.
Illustration 2 g01969655
Typical example
Illustration 3 g02022020
Illustration 4 g01969454
Typical example
Slide hose clamps along coolant hose (3) and coolant hose (4). Disconnect coolant hose (3) and coolant hose (4) from air compressor (6).
Disconnect the air line from port (5) (not shown) and air line from port (7). Ref to the OEM for the correct procedure.
Remove banjo bolt (10) and remove sealing washers (11) (not shown).
Remove bolt (13) and bolt (15) from support bracket (14). Remove support bracket (14) from compressor (6) and the cylinder block.
Support air compressor (6). Remove nuts (18) and remove the air compressor from front housing (9). Note: Note the position of tube assembly (12) before removal.
If necessary, disconnect nut (8) (not shown) and remove tube assembly (12) from the union on the cylinder block.
If necessary, remove studs (17) from front housing (9).
If necessary, remove bolts (20) and remove plate (19). Remove O-ring seal (16) from plate (19). Refer to Illustration 4.
Illustration 5 g01969515
Typical example
Remove O-ring seal (24) from air compressor (6).
If necessary, follow Step 16.a through Step 16.b in order to remove gear (21) from the crankshaft of the air compressor.