0435475 JOHNSON GEARCASE ASSY., Complete

Start By:a. remove engineb. remove air starterc. remove oil pan, (rear half only)d. remove crankshaft rear seal and wear sleevee. remove flywheel housing adapter
Typical Example 1. Remove the covers and gaskets over camshaft gears (3).2. Remove cover (1) from the top of the flywheel housing.3. Remove bolts (2) and the plate and adapter that fasten the camshaft gears to the camshaft.4. Put the three washers from tooling (A) behind plate (5) and install the bolt and plate (5).
Do not apply more than 51675 kPa (7500 psi) pressure to 1P820 Hydraulic Puller. 8B7559 adapters are rated at 6 1/2 ton each and 1P820 Hydraulic Puller is rated at 17 ton at 68900 kPa (10000 psi). If to much pressure is applied, the gear may be damaged.
5. Install tooling (A) on camshaft drive gear (3). Apply 51,675 kPa (7500 psi) to the puller and hit the screw part of the puller with a hammer until the gear is free of the camshaft taper. Remove tooling (A) and gears (3).6. Put stands or blocks under the rear of the engine block. The weight of the engine is approximately 7430 kg (16,400 lb).7. Install tooling (B) on the top of the flywheel housing and attach a hoist.8. Remove all bolts that fasten the flywheel housing to the engine block. Be aware that there are two bolts below cover (1), and the two bolts that pass through shaft (4) must also be removed.9. Remove the flywheel housing from the engine. The weight of the flywheel housing is 210 kg (454 lb). The following steps are for installation of the flywheel housing.10. Use 6V1541 Quick Cure Primer to clean the mating surfaces of the flywheel housing and the cylinder block. Put 6V6640 Gasket Maker on the surfaces of the flywheel housing that make contact with the cylinder block.11. Install tooling (B) on the top of the flywheel housing. Fasten a hoist and put the flywheel housing in position on the cylinder block. 12. Install the bolts in their respective locations. See the Installation Chart. Tighten the 1/2" - NC bolts to a torque of 135 15 N m (100 11 lb ft). Tighten the 5/8" NC bolts to a torque of 270 25 N m (200 18 lb ft). 13. Put the camshaft timing pins in position and put the timing bolt in the flywheel with Number 1 piston at the compression stroke. See the topic, Install Camshafts in this module. Be sure gear backlash is removed. For correct timing, all gear clearance (backlash) must be removed. Turn camshaft drive gears (3) in the same direction as the crankshaft rotation and hold this position.14. Install camshaft gears (3), tach drive adapter (4), plate (5) and bolts (2). Tighten bolts (2) as follows:a. Tighten bolts (2) to a torque of 360 50 N m (265 35 lb ft).b. Hit bolts (2) with a soft hammer to seat the gear on the camshaft.c. Tighten bolts (2) again to a torque of 360 50 N m (265 35 lb ft).d. Repeat Steps b and c until the torque does not change.15. Remove the timing pins from the camshafts and the flywheel.16. Install the cover on the top of the flywheel housing and the covers over both camshaft drive gears. Two bolts, that fasten each camshaft gear cover to the flywheel housing, are longer and must be installed at locations (X).End By:a. install crankshaft rear seal and wear sleeveb. install oil pan, (rear half only)c. install air starterd. install enginee. install flywheel housing adapter