0337774 JOHNSON SHIFTER, Clutch dog

At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Drain the coolant only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand. Remove the fill cap from the radiator slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.
1. Release the pressure in the cooling system. Drain the coolant from the engine. The capacity of the cooling system is 71 L (19 gal).
Belt tightener (3) is under heavy spring tension. To prevent personal injury, release slowly and carefully the belt tightener after belts (4) have been removed from the pulleys.
2. Use a pry bar on belt tightener (3) to release the pressure on three belts (4) and remove the belts. After the removal of the belts, slowly and carefully release the belt tightener.3. Remove clevis pin (2) and disconnect the spring from belt tightener (3). Remove four bolts (1) and remove belt tightener (3).4. Remove bolt (6) and the washer from the hose clip. Disconnect hose (5). 5. Disconnect wire harness (10) and remove wire clip (11).6. Disconnect hoses (18) and elbow (7).7. Loosen hose clamp (15) and disconnect hose (14).8. Remove two bolts (12) and disconnect bonnet (13).9. Remove four bolts (8) and remove cover (9).10. Remove four remaining long bolts (16) and remove water pump (17). Install the water pump in the reverse order of the removal. After installation of the water pump, fill the cooling system with coolant to the correct level. See the Operation And Maintenance Manual.End By:a. install alternator and mounting group.Disassemble Water Pump
Start By:a. remove water pump The water pump seal can be replaced without removing the water pump from the engine.An intermittent leakage of a small amount of coolant from the hole in the water pump housing is not an indication of a water pump seal failure. This is required to provide lubrication for the seal. Replace the water pump seal only if a large amount of leakage or a constant flow of coolant is observed draining from the water pump housing.1. Remove O-ring seal (1) from the adapter.2. Remove adapter (2) from the housing. Remove the O-ring seal from the outside diameter of the adapter.3. Remove bolt (3) and the retainer that hold the impeller on the shaft. 4. Use tooling (A) to remove impeller (4) from the shaft. 5. Remove the spring and seal (5) from the shaft. 6. Remove four bolts (7) from retainer (6) that hold the shaft assembly to the pump housing.7. Remove O-ring seal (8) from the housing. 8. Remove gear and shaft assembly (10) from the housing.9. Remove bolt (9) and the retainer from the shaft assembly. 10. Use a press to remove the shaft assembly from gear (11). Remove the retainer from the shaft assembly. 11. Remove bearing (13), spacer (14) and bearing (12) from the shaft. 12. Remove lip-type seal (15) from the housing.13. Turn the housing over, and remove ceramic ring (16) and the seal.Assemble Water Pump
1. Use 6V1541 Quick Cure Primer and clean shaft (8) and the seal counterbore in the pump housing.2. Install bearing (4), spacer (3) and bearing (2) on shaft (8).3. Put retainer (1) and gear (7) in position on the shaft assembly. Install retainer (6) and bolt (5). 4. Use tooling (A) to install the lip seal in the housing as shown. Put a small amount of clean SAE 30 oil on the lip of the seal. 5. Install a new O-ring seal (10) on the housing.6. Put shaft assembly (9) in position in the housing. Install the bolts that hold the retainer to the housing.
Clean water only is permitted for use as a lubricant for assistance at installation. Do not damage or put hands on the wear surface of the carbon ring or the ceramic ring. Install the ceramic ring with the smoothest face of the ring toward the carbon seal assembly.
7. Put ceramic ring (12) in position in rubber seal (11). Use hand pressure and tool (B) to install the ceramic ring in the housing.
Avoid contaminating the seal faces with grease or oil. Also, avoid stretching the rubber seal during installation.
The carbon seal assembly must rotate with the water pump shaft after installation.8. Remove the spring from seal assembly (13). Use hand pressure and tool (B) to install the seal assembly. Push the seal assembly on the shaft until the seal faces make light contact. 9. Install spring (15) on the shaft.10. Put impeller (14) in position on the shaft. Install the washer and bolt that holds it. Tighten the bolt to a torque of 39 3 N m (29 2 lb.ft.). 11. Install O-ring seal (17) on the outside diameter of the adapter. Put a small amount of clean SAE 30 oil on the O-ring seal.12. Install O-ring seal (18) on the adapter.13. Put adapter (16) in position on the housing.End By:a. install water pump