880686T59 Mercury GEAR HOUSING ASSEMBLY, Complete

Table 1
Dimensions for Acceptable Cylinder Liner Projection with the 362-8264 Cylinder Head Gasket
Part Dimension Value
454-9920 Cylinder Liner flange 12.650 0.020 mm (0.4980 0.0008 inch) Z
519-7297 Spacer Plate 12.338 to 12.388 mm (0.48575 to 0.4877 inch) X
144-5692 Plate Gasket 0.170 to 0.230 mm (0.0067 to 0.0091 inch) Y
Allowable projection 0.050 to 0.120 mm (0.0020 to 0.0047 inch)
Table 2
Dimensions for Acceptable Cylinder Liner Projection with the 110-6991 Cylinder Head Gasket(1)
Part Dimension Value
211-7826 Cylinder Liner flange 12.650 0.020 mm (0.498 0.0008 inch) Z
110-6994 Spacer Plate 12.310 0.030 mm (0.4846 0.0012 inch) X
362-9677 Spacer Plate 12.330 0.030 mm (0.4854 0.0012 inch) X
144-5692 Plate Gasket 0.210 0.030 mm (0.008 0.0010 inch) Y
Allowable projection 0.060 mm (0.0020 inch) to 0.200 mm (0.0080 inch)
(1) The 110-6991 Cylinder Head Gasket is ONLY used on commercial engines.Introduction
Use this procedure to check the cylinder liner projection out of the cylinder block and installed in the cylinder block.Reference: Refer to Reuse And Salvage Guidelines, "Procedure to Salvage Top Decks of Cylinder Blocks of 3500 Engines" for additional information about reuse and/or salvage of the cylinder block.Required Tools
Table 3
Required Tools
Part Number Part Name Qty
1U-9895 Crossblock 1
3H-0465 Push-Puller Plate 2
8F-6123 Bolt (3/4-16 thread, 139.7 mm (5.5.50 inch) long 2
3B-1925 Washer (COPPER) 4
1A-0075 Bolt (3/4-16 thread, 44.45 mm (1.750 inch) long 4
8T-0455 Liner Projection Tool Group 1
6V-7059 Micrometer 1 Preparation
For checking the cylinder liner projection with the liner out of the cylinder block, ensure that the following surfaces are clean prior to measuring:
Cylinder liner flanges
Spacer plate
Spacer plate gasketFor checking the installed cylinder liner projection, ensure that the following surfaces are clean prior to measuring:
Top surface of the cylinder block
Cylinder liner bores
Cylinder liner flanges
Spacer plates
Spacer plate gasketCylinder Liner out of the Cylinder Block - Check
Illustration 1 g02247495
Use the 6V-7059 Micrometer to measure the thickness of the following items:
(X) Spacer Plate
(Y) Spacer Plate Gasket
(Z) Cylinder Liner FlangeThe cylinder liner projection depends on which spacer plate is used. Refer to Table 1 or to Table 2.Note: To determine the cylinder liner projection, subtract the thickness of the spacer plate and gasket from the thickness of the cylinder liner flange.
Refer to Table 1 or to Table 2 for the correct value of your cylinder liner projection.Cylinder Liner Installed in the Cylinder Block - Check
Illustration 2 g01192749
Measuring the cylinder liner projection
(1) 3H-0465 Push-Puller Plate
(2) 1P-2403 Dial Indicator
(3) 1P-2402 Gauge Body
(4) 1A-0075 Bolt and 3B-1925 Washer (COPPER)
(5) Spacer plate
(6) 1U-9895 Crossblock
Install a new gasket and spacer plate (5) on the cylinder block.
Install the cylinder liner in the cylinder block without seals or bands.
Hold spacer plate (5) and the cylinder liner in position according to the following procedure:
Install four 3B-1925 Washers (COPPER) and four 1A-0075 Bolts (4) around spacer plate (5). Tighten the bolts evenly to a torque of 95 N m (70 lb ft).
Install the following components: 1U-9895 Crossblock (6), two 3H-0465 Push-Puller Plates (1) and two 8F-6123 Bolts. Ensure that 1U-9895 Crossblock (6) is in position at the center of the cylinder liner. Ensure that the surface of the cylinder liner is clean. Tighten the bolts evenly to a torque of 70 N m (50 lb ft).
Check the distance from the bottom edge of 1U-9895 Crossblock (6) to the top edge of spacer plate (5). The vertical distance from both ends of the 1U-9895 Crossblo