78438 5 Mercury STUD, (.375-16/.375-24 x 6.870) (6-3/4 IN.)

Table 1
Required Tools
Tool Part Number Part Description Qty
A - M12x1.75mm by 100 mm Guide Studs 2
B - M8x1.25mm by 50 mm Set Screw 4 Start By:
Remove the crankshaft position sensor. Refer to Disassembly and Assembly, Crankshaft Position Sensor - Remove and Install for the correct procedure.
Remove the electric starting motor. Refer to Disassembly and Assembly, Electric Starting Motor - Remove and Install for the correct procedure.
Remove the flywheel. Refer to Disassembly and Assembly, Flywheel - Remove for the correct procedure.
Remove the crankshaft rear seal. Refer to Disassembly and Assembly, Crankshaft Rear Seal - Remove and Install for the correct procedure.
Remove the engine oil pan. Refer to Disassembly and Assembly, Engine Oil Pan - Remove and Install for the correct procedure.
If necessary, remove the bracket for the Clean Emissions Module (CEM) for (Diesel Oxidation Catalyst (DOC) and Diesel Particulate Filter (DPF). Refer to Disassembly and Assembly, Clean Emissions Module (Diesel Oxidation Catalyst (DOC) and Diesel Particulate Filter (DPF) - Remove and Install for the correct procedure.
If necessary, remove the bracket for the Selective Catalyst Reduction (SCR). Refer to Disassembly and Assembly, Support and Mounting - Remove and Install (Selective Catalyst Reduction (SCR)) for the correct procedure.
Illustration 1 g06186236
Bolt (2) "M8 x 1.25"
Bolts (3) "M12 x 1.75"
Illustration 2 g06480554
Attach a suitable lifting device to flywheel housing (1). The weight of the flywheel housing is approximately 40 kg (88 lb).
Remove bolt (2) from flywheel housing (1).
Remove bolts (3) from Positions (W).
Install Tooling (A) in Positions (W).
Remove remaining bolts (3) from flywheel housing (1).
All jacking points in flywheel housing (1) must be used. Failure to use all the jacking points in the flywheel housing could result in damage to the flywheel housing.
Install Tooling (B) in the jacking points in Positions (X) in flywheel housing (1).Note: The flywheel housing will have three or four jacking points, use all the jacking points available.
Evenly apply a half turn on each of Tooling (B) in a clockwise rotation to jack flywheel housing (1) from the dowels. Failure to apply an even turning motions to all the jacking points in the flywheel housing could result in damage to the flywheel housing.
Use the suitable lifting device to remove flywheel housing (1). Ensure that the crankshaft is not damaged as the flywheel housing is removed.Note: The engine stand must not be rotated when the flywheel housing has been removed from the engine, this prevents the camshaft from being displaced.
Remove Tooling (B) from flywheel housing (1).
Illustration 3 g06154512
Do not remove the dowel (4) or dowel (5) unless the dowels are damaged.
If necessary, remove dowel (5) and ring dowel (4) from the cylinder block. Do not replace the dowels unless the dowels are damaged.Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
A - M12x1.75mm by 100 mm Guide Studs 2
C - Loctite 5900 1
D - P-80 Emulsion Rubber Assembly Lubricant 1
Ensure that all components are free from wear or damage. If necessary, replace any component that is worn and damaged.
Clean the gasket surfaces of the flywheel housing and the cylinder block.
Illustration 4 g06186239
Sealant path for Tooling (C)
Illustration 5 g06154512
Apply Tooling (C) in Positions (Z) as shown in Illustration 4.
If necessary, install dowel (5) and ring dowel (4) to the cylinder block. Do not replace the dowels unless the dowels are damaged.Flywheel housings that have an accessory drive installed, will not have ring dowel (5) installed. The hub for the accessory drive has a spigot and the spigot is used as the alignment dowel.
Illustration 6 g06387390
Illustration 7 g06186236
Bolt (2) "M8 x 1.25"
Bolts (3) "M12 x 1.75"