0394625 JOHNSON GEARCASE ASSY., Complete

Wear goggles, gloves, protective clothing, and a National Institute for Occupational Safety and Health (NIOSH) approved P95 or N95 half-face respirator when handling a used Diesel Particulate Filter or Catalytic Converter Muffler. Failure to do so could result in personal injury.
The muffler, catalytic converter/muffler, and diesel particulate filter will become extremely hot during engine operation. A hot muffler, catalytic converter/muffler and diesel particulate filter can cause serious burns. Allow adequate cooling time before working on or near the muffler, catalytic converter/muffler and diesel particulate filter.
Do not strike any part of the assembly of the Diesel Particulate Filter (DPF). Do not allow any object to contact the internal element of the DPF. If the internal element of the DPF becomes damaged, the assembly must be replaced.Do not use power tools in order to disassemble or assemble any part of the Diesel Oxidation Catalyst (DOC), Diesel Particulate Filter (DPF), or the outlet section.
Refer to Operation and Maintenance Manual, "Diesel Particulate Filter - Clean" before starting any maintenance procedures on the assembly of the Diesel Particulate Filter (DPF).
Illustration 1 g02330913
In certain applications, it will be necessary to remove the assembly of the Diesel Oxidation Catalyst (DOC), Diesel Particulate Filter (DPF), and the outlet section as an assembly in order to allow the removal of the DPF.
Follow Step 3.a through Step 3.i in order to remove the DOC, DPF, and outlet section as an assembly (1).
Remove the Original Equipment Manufacturers (OEM) exhaust system from outlet cannister (4).
Remove the tube assemblies for the pressure sensor from the DPF assembly and outlet section (4). Refer to Disassembly and Assembly, "Pressure Sensor (DPF) - Remove and Install" for the correct procedure.
Remove the soot antennas from the DPF assembly and outlet section (4). Refer to Disassembly and Assembly, "Soot Antenna - Remove and Install" for the correct procedure.
Remove the temperature sensors from the DPF assembly. Refer to Disassembly and Assembly, "Temperature Sensor (DPF) - Remove and Install" for the correct procedure.
Loosen the bolt on ball clamp (5) in order to allow the removal of DPF assembly (1).
Remove the nuts on clamp (2) and clamp (3). Position clamp (2) and clamp (3) away from DPF assembly (1).
Attach a suitable lifting device to DPF assembly (1). The weight of the DPF assembly is approximately 66 kg (145 lb).
Use the suitable lifting device to remove DPF assembly (1) from the bracket for clean emission module (6).
Remove the DPF. Refer to Disassembly and Assembly, "Diesel Particulate Filter - Disassemble" for the correct procedure. Alternative Removal Procedure for the Diesel Particulate Filter
Wear goggles, gloves, protective clothing, and a National Institute for Occupational Safety and Health (NIOSH) approved P95 or N95 half-face respirator when handling a used Diesel Particulate Filter or Catalytic Converter Muffler. Failure to do so could result in personal injury.
The muffler, catalytic converter/muffler, and diesel particulate filter will become extremely hot during engine operation. A hot muffler, catalytic converter/muffler and diesel particulate filter can cause serious burns. Allow adequate cooling time before working on or near the muffler, catalytic converter/muffler and diesel particulate filter.
Refer to Operation and Maintenance Manual, "Diesel Particulate Filter - Clean" before starting any maintenance procedures on the assembly of the Diesel Particulate Filter (DPF).
Illustration 2 g02331135
Illustration 3 g02332653
In certain applications, it will be necessary to remove outlet section (4) or the Diesel Oxidation Catalyst (DOC) (8) from the Diesel Particulate Filter (DPF) in order to allow the removal of the DPF.
If necessary, remove DOC (8). Refer to Disassembly and Assembly, "Catalyst (Diesel Oxidation Catalyst) - Remove and Install" for the correct procedure.
Remove the DPF. Refer to Disassembly and Assembly, "Diesel Particulate Filter - Disassemble" for the correct procedure.
If necessary, remove the OEM exhaust tube assembly from outlet section (4).
Remove the tube assembly for the pressure sensor from outlet section (4). Refer to Disassembly and Assembly, "Pressure Sensor (DPF) - Remove and Install" for the correct procedure.
Remove the soot antenna from outlet section (4). Refer to Disassembly and Assembly, "Soot Antenna - Remove and Install" for the correct procedure.
Make temporary alignment marks on Torca clamp (7) in Position (A). Loosen the nuts on Torca clamp (7).
Slide Torca clamp along the DPF into Position (B).
Sufficiently loosen the nuts on clamp (3) in order to allow removal of outlet section (4).
Rotate the outlet section (4) in a counter clockwise direction in order to disengage the pins and slots (10).
Attach a suitable lifting device to outlet section (4). The weight of the outlet section is approximately 15 kg (33 lb).
Use the suitable lifting device to remove outlet section (4) from the DPF.
Remove Torca clamp (7) from the DPF.
Remove the DPF. Refer to Disassembly and Assembly, "Diesel Particulate Filter - Disassemble" for the correct procedure.