0435504 JOHNSON GEARCASE., ASSY., Complete

START BY:a. remove oil pan 1. Check each main bearing cap for its location on the engine. Each cap has a number which gives the location of that cap. Make a note that the number on each cap is toward the front of the cylinder block.2. Remove the bolts and washers that hold main bearing cap (2) in place. Remove the bearing cap and the lower half of the main bearing. Use tool (C) to remove the bolts that hold the No. 1 main bearing cap in position.3. Remove bearing (1) from the bearing cap.
If the crankshaft is turned in the wrong direction, the tab of the bearing will be pushed between the crankshaft and the cylinder block. This will cause damage to the crankshaft and block.
4. Turn the crankshaft until tool (A) can be installed in the oil hole in the crankshaft in the direction which will push the upper main bearing out, tab end first. Install the bearings dry when the clearance checks are made. Put clean engine oil on the bearings for final assembly.
When bearing caps are installed, make sure the number on the side of the cap is next to and respective with the number on the engine block.
5. Install the lower bearing in the bearing caps. Install upper bearings (bearing with the oil hole) in the cylinder block with tool (A).If the serviceman wants to measure the bearing clearances, Plastigage is recommend. Lead wire, shim stock or use of a dial bore gauge can damage the bearing surface.The serviceman must be very careful to use Plastigage correctly. The following points must be remembered:...Make sure that the backs of the bearings and the bores are clean and dry....Make sure that the bearing locking tabs are properly seated in their slots....The crankshaft must be free of oil where the Plastigage touches it....If the main bearing clearances are checked with the engine upright or on its side, the crankshaft must be supported. Use a jack under an adjacent crankshaft counterweight and hold the crankshaft against the crown of the bearing. If the crankshaft is not supported, the weight of the crankshaft will cause incorrect readings....Put a piece of Plastigage on the crown of the bearing half that is in the cap. Do not allow the Plastigage to extend over the edge of the bearing....Install the bearing cap using the correct torque-turn specifications. Do not use an impact wrench. Be careful not to dislodge the bearing when the cap is installed....Do not turn the crankshaft with the Plastigage installed....Carefully remove the cap, but do not remove the Plastigage. Measure the width of the Plastigage while it is in the bearing cap or on the crankshaft journal. Do this by using the correct scale on the package. Record the measurements....Remove the Plastigage before reinstalling the cap.When using Plastigage, the readings can sometimes be unclear. For example, all parts of the Plastigage are not the same width. Measure the major widths to make sure that they are within the specification range. Also, experience has shown that when checking clearances tighter than 0.10 mm (.004") the readings may be low by 0.013 to 0.025 mm (.0005 to .0010"). Out-of-round journals can give faulty readings. Also, journal taper may be indicated when one end of the Plastigage is wider than the other.For complete details concerning measuring bearing clearances, see Engine Bearings And Crankshafts, Form No. SEBD0531. 6. Check the bearing clearance with tool (B) as follows: Put cap (3) in position, and install the bolts. Tighten bolt (5) to a torque of 40 4 N m (30 3 lb.ft.). Put a mark on both bolt heads and the bearing cap. Tighten bolt (4) 120° 5° more. Tighten bolt (5) 120° 5° more. 7. Remove the bearing cap, and measure the thickness of the Plastigage. The main bearing clearance must be 0.076 to 0.168 mm (.0030 to .0066 in.). The maximum permissible clearance is 0.18 mm (.007 in.). 8. Put 2P2506 Thread Lubricant on the bolt threads and washer faces. Put clean engine oil on the lower half of the main bearing. Put the bearing cap and lower half of the main bearing in position on the engine. Install the bolts. Tighten bolt (5) to a torque of 40 4 N m (30 3 lb.ft.). Tighten bolt (4) to a torque of 40 4 N m (30 3 lb.ft.). Put a mark on both heads and the cap. Tighten bolt (4) 120° 5° more. Tighten bolt (5) 120° 5° more.9. Do Steps 1 through 8 for the remainder of the bearings. 10. Check the crankshaft end play with tooling (D). The end play is controlled by the thrust bearing on No. 4 main bearing. The end play with new bearings must be 0.08 to 0.25 mm (.003 to .010 in.). The maximum permissible end play with used bearings is 0.36 mm (.014 in.).END BY:a. install oil pan