0385386 JOHNSON GEARCASE ASSY., Std

The ends of the bellows are very sharp. Injury could occur if the bellows are not handled properly. Handle the bellows by the convolutions.
The bellows must be supported at all times when the bellows are not installed in the application. Failure to support the bellows adequately could result in the failure of the bellows. Do not use power tools in order to disassemble or assemble any part of the flexible exhaust system.The alignment of the bellows is important. Incorrect alignment may lead to premature failure of the bellows. Misalignment can be identified by visually inspecting the uniformity of the spacing between the convolutions on the bellows.Inspect the bellows for damage prior to installation. If there is any damage to the convolutions, discard the bellows. If there is any difficulty in installation after the repair, discard the bellows.
Illustration 1 g02354623
The lateral alignment of the bellows is critical. All the components must be assembled in the same alignment as prior to disassembly. The components that require correct lateral alignment are shown at Positions (A, B, and C).
Illustration 2 g02354616
Follow Steps 2.a through Step 2.d in order to remove the flexible exhaust as an assembly from the Clean Emission Module (CEM) and the turbocharger.
Use suitable material in order to encase flexible exhaust pipe (3). Encasing the flexible exhaust pipe will prevent damage of the bellows. Encase bellows for the flexible exhaust pipe (3) between Position (D) and Position (E). Use cable straps in order to retain the suitable material. Note: Ensure that the flexible exhaust pipe is supported at all times.
Loosen ball clamp (2) from the flexible exhaust pipe assembly.
Loosen the bolt for V-band clamp (4). Note: If V-band clamp (4) remain tight on the flanges, apply releasing fluid on the V-band clamp. Lightly tap the bolt on the V-band clamp with a soft faced hammer in order to assist removal. Do not use a prybar in order to remove V-band clamp.
Remove the assembly of the flexible exhaust pipe from the CEM (1) and the turbocharger (5). Note: Ensure that the assembly of the flexible exhaust pipe is supported as the clamps are removed.Disassembly Procedure for the Flexible Exhaust Pipe Assembly
If any part of the flexible exhaust pipe assembly is damaged. Refer to Special Instruction, REHS5014, "Reuse Guideline for the Flexible Exhaust Pipe Group on Tier 4 Engines" for more information.
Illustration 3 g02354617
If necessary, follow Step 2.a through Step 2.d in order to disassemble the flexible exhaust pipe assembly.
Make temporary marks in Position (F) on all components of the bellows (3) and tube assembly (6) in order to show correct orientation and alignment. Note: Do not scribe the components in order to mark the position of the flexible exhaust pipe assembly.
Loosen clamp (7) and remove tube assembly (6) from bellows (3).
Loosen ball clamp (8) and remove the ball clamp. Discard the ball clamp.
Remove bellows (3) from the elbow (9). Note: Ensure that the flexible exhaust pipe bellows are not subjected to any undue stress.Assembly Procedure for the Flexible Exhaust Pipe Assembly
Ensure that all components of the flexible exhaust pipe assembly are clean and free from wear and damage. If necessary, replace any components of the flexible exhaust pipe assembly that are worn or damaged. Refer to Special Instruction, REHS5014, "Reuse Guideline for the Flexible Exhaust Pipe Group on Tier 4 Engines" for more information.
Illustration 4 g02354618
If the flexible exhaust pipe assembly was previously disassembled. Follow Step 2.a through Step 2.i in order to assemble the flexible exhaust pipe assembly.
Use the correct personal protective equipment when removing the clamp.
If original bellows are to be reinstalled, place the internal area in Position (G) of the bellows on a suitable support. Use a 3 mm (0.118 inch) in order to drill a pilot hole through the spot weld in Position (H) on clamp (7). Note: Do not center punch the spot weld on clamp (7).
Use a 6.5 mm (0.256 inch) in order to drill out spot weld in Position (H) on clamp (7). Remove clamp (7) from the bellows.
Remove all burrs from the internal and external areas of bellows (3). Ensure that debris does not enter bellows.
Illustration 5 g02354619
Position a new clamp (7) onto bellows (3). Hand tighten clamp (7). Ensure that the center of the clamp is central to Slots (J) on the bellows. The clamp must be flush with the end of the bellows (3). Note: Ensure that the bellows are not subjected to any undue stress.
If new bellows (3) are installed, clamp (7) will be pre-installed to the bellows. Note: Ensure that the bellows are not subjected to any undue stress.
Position a new ball clamp (8) onto elbow (9).
Position bellows (3) onto elbow (9). Align the bellows and the elbow with temporary marks.
Tighten ball clamp (8) hand tight. Note: Ensure that the bellows are not subjected to any undue stress.
Install tube assembly (6), align the tube assembly with the temporary marks on the bellows. Tighten clamp (7) hand tight. Installation Procedure for the Flexible Exhaust Pipe as an Assembly
Inspect the bellows for damage prior to installation. If there is any damage to the co