0398183 JOHNSON GEARCASE ASSY., Complete

Table 1
Required Tools
Tool Part Number Part Description Qty
A 438-6765 Cap 2
B - Capping Kit 1 Start By:
Remove the flexible exhaust pipe. Refer to Disassembly and Assembly, "Flexible Exhaust Pipe - Remove and Install" for the correct procedure.
Remove the coolant tank for the DEF injector. Refer to Disassembly and Assembly, "Coolant Tank - Remove and Install" for the correct procedure.
Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Turn the battery disconnect switch to the OFF position.
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.
Remove the Original Equipment Manufacture (OEM) exhaust system from the Clean Emissions Module (CEM). Refer to the OEM for the correct procedure.
Illustration 1 g06389690
Typical example
Disconnect the harness assemblies from the soot antenna. Refer to Disassembly and Assembly, "Soot Antenna - Remove and Install" for the correct procedure.
Disconnect the wiring harness assembly from connection (3)
Disconnect the harness assembly from DEF injector connection (2). Use Tooling (A) to cap the harness connection and the DEF injector.
Attach a suitable lifting device to the CEM. The weight of CEM is approximately 129 kg (284 lb).
Illustration 2 g06389716
Typical example
Remove bolts (4).
Remove washers (5) and upper anti-vibration mounts (6) from CEM support (8).
Use the suitable lifting device to remove CEM assembly and CEM support (8) from brackets (10).
Remove lower anti-vibration mounts (9) and spacer (7).
Illustration 3 g06389720
Typical example
If necessary, remove bolts (11).
Use the suitable lifting device to remove CEM assembly (1) from CEM support (8).Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
C - Guide Studs M12 by 110 mm 4
D - Guide Studs M16 by 110 mm 4
Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are worn or damaged.
Illustration 4 g06389720
Typical example
Illustration 5 g06389716
Typical example
Attach a suitable lifting device to CEM (1). The weight of clean emissions module is approximately 129 kg (284 lb).
If necessary, install Tooling (C) to the base of the CEM. Position CEM support (8) onto Tooling (C) and install bolts (14) in the available locations hand tight. Remove Tooling (C) and install the remaining bolts.Tighten bolts (11) to a torque of 78 N m (58 lb ft).Note: Ensure that the CEM is installed in the original position on the CEM support.
Install Tooling (D) to front and rear bracket (10).
Position lower anti-vibration mounts (9) and spacers (7) onto the front bracket and the rear bracket. Ensure that the lower anti-vibration mounts are correctly orientated.
Use the suitable lifting device to install CEM assembly (1) onto lower anti-vibration mounts (9) and the front bracket and the rear bracket.
Remove Tooling (D) from the front bracket and the rear bracket.
Install upper anti-vibration mounts (6). Ensure that the upper anti-vibration mounts are correctly orientated.
Install washers (5) and bolts (4). Hand tighten the bolts.
Tighten bolts (4) to a torque of 177 N m (131 lb ft).
Remove the suitable lifting device from CEM assembly (1).
Illustration 6 g06389690
Typical example