0439979 JOHNSON GEARCASE ASSY., Complete

Table 1
Required Tools
Tool Part Number Part Description Qty
A - Loctite 5900 -
B - Loctite 243 -
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Do not turn the crankshaft or the camshaft while the camshaft gear is removed. If the front gear group is not correctly timed during installation, interference can occur between the pistons and the valves, resulting in damage to the engine.
Illustration 1 g01047263
Apply Tooling (B) to the serrations of studs (18). Install the studs in plate (16).
Install the integral seal on the dowel pins on the cylinder block. Note: Apply Tooling (A) to the bottom of the integral seal in order to fill the space at the cylinder block, the front housing, and the engine oil pan.
Install plate (16) on the dowel pins on the cylinder block. Install new locking bolts (17) (Marked "X") in order to fasten the front plate to the cylinder block. Tighten the locking bolts to a torque of 55 N m (41 lb ft). Note: Apply Tooling (B) to the bolts.
Illustration 2 g01056102
Install stub shaft (15). Apply Tooling (B) to the studs and the bolt for stub shaft (15). Tighten nuts (14) and the bolt to a torque of 55 10 N m (41 7 lb ft).
Install shaft assembly (13). Do not tighten nuts (12) and the bolt for the shaft assembly at this time. The nuts and the bolt for shaft assembly (13) will need to be tightened when the backlash is adjusted.
Adjust the backlash between the camshaft gear and the adjustable idler gear assembly. The backlash should be 0.356 0.254 mm (0.014 0.010 inch). Refer to Testing and Adjusting, "Gear Group (Front) - Time" for the backlash adjustment procedure. Tighten nuts (12) and the bolt to a torque of 55 10 N m (41 7 lb ft).
Install stub shaft (10). Apply Tooling (B) to bolts (11). Install bolts (11) and tighten to a torque of 55 10 N m (41 7 lb ft) in sequence. (1, 3, 4, 5, 2, 1, 2, 3, 4, 5, 1). Note: Mark bolts (11) in clockwise order from one to five. These will be the numbers for the torque sequence in step 6.
Illustration 3 g01047231
Position cluster gear assembly (1) on the stub shaft. Ensure that the timing marks are aligned on the cluster gear assembly and the crankshaft gear.
Apply Tooling (B) to bolts (3). Position plate (2) with the oil groove toward the gear face. Install bolts (3).
Position idler gear (7) on the shaft assembly.
Apply Tooling (B) to bolts (9). Position plate (8) with the oil groove toward the gear face. Install bolts (9). Note: Skip Step 12 if the shaft assembly is removed. The backlash for the camshaft gear and the adjustable idler gear will need to be readjusted. Refer to Testing and Adjusting, "Gear Group (Front) - Time".
Position adjustable idler gear (4) on the shaft assembly.
Apply Tooling (B) to bolts (6). Position plate (5) with the oil groove toward the gear face. Install bolts (6).
Adjust the backlash for the camshaft gear and the adjustable idler gear, if necessary. Refer to Testing and Adjusting, "Gear Group (Front) - Time". Note: The camshaft gear must be installed and the adjustable idler gear must be removed in order to perform the backlash adjustment procedure.End By:
Install the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Install".