Section 1.13 Gear Case Exhaust Gas Recirculation (EGR) Model
Section 1.13 Gear Case Exhaust Gas Recirculation (EGR) Model
Section 1.13 Gear Case Exhaust Gas Recirculation (EGR) Model
13
Gear Case Exhaust Gas Recirculation (EGR) Model
The gear case housing is constructed of cast iron, with machined mating surfaces, and is
bolted to the front of the engine cylinder block. The gear case and gear case cover are
bolted together to provide a sealed compartment for the engine gear train. See Figure
"Gear Case and Gear Train Assembly" .
1. Water Pump Drive 5. Air Compressor/Power Steering Pump Drive
Gear Gear
The components that are mounted to the gear case include the water pump assembly,
(see Figure "Water Pump Assembly and Related Parts" ), air compressor drive assembly
(see Figure "Air Compressor" ) and the adjustable idler gear assembly. (See Figure
"Adjustable Idler Gear and Related Parts" ).
1. Water Pump Assembly 3. Seal
2. Bolt
To eliminate the possibility of oil leakage at the adjustable idler gear stud
location, Detroit Diesel recommends the following:
When rebuilding a Series 60 engine, or if the gear case is removed for any
reason, the three original adjustable idler gear studs should be removed and
replaced with new studs.
Before pressing studs into the gear case, coat the shanks and underside of the
stud heads with Loctite® No. 242 Sealant. This will prevent any oil leakage
around the studs during engine operation.
An opening is provided in the center of the gear case for the installation of the spindle
and bull gear. See Figure "Bull Gear and Spindle Location" .
1. Bull Gear 2. Spindle
Note: Do not use the oil plug location for an oil supply or for checking oil pressure.
1. Remove gear case cover. Refer to "1.11.2 Removal of Gear Case Cover" .
2. Remove Timing Reference Sensor/Crankshaft Position Sensor (TRS/CKP).
Refer to "2.32.2 Removal of Timing Reference Sensor" .
3. Remove fuel pump.Refer to "2.6 N3 Fuel Injector Tube" .
4. Remove air compressor. Refer to "11.1.2 Cleaning and Removal of Adaptorless
Air Compressor" .
5. Remove water pump from gear case.Refer to "4.2.2 Draining and Removal of
Water Pump (GCM)" .
6. Remove bull gear, spindle and idler gear.Refer to "1.33.2 Removal of Bull Gear
and Camshaft Idler Gear Assembly" .
7. Remove fourteen bolts that secure gear case to engine block. See Figure "Gear
Case Mounting Bolt Locations EGR Model" .
Section 1.13.1.1
Inspection of Gear Case EGR Model
EYE INJURY
To avoid injury from flying debris when using compressed air, wear adequate eye
protection (face shield or safety goggles) and do not exceed 276 kPa (40 psi) air
pressure.
1. Clean all of the old gasket sealer from the mating surfaces of the gear case, gear
case cover, and engine block. Refer to "Gasket Eliminator Removal," in the
"GENERAL INFORMATION" Section at the beginning of this manual.
2. Clean the gasket material from the mating surfaces of any components or access
covers that were removed from the gear case cover or gear case. Clean all of the
parts with clean fuel oil and dry with compressed air.
3. Remove the oil gallery plug at the top of the gear case.
4. Use compressed air to ensure the oil gallery is completely free of blockage. If
necessary, use a wire brush to clean the gear case oil gallery.
5. Inspect the gear case for stress cracks, breaks, or other damage. Repair or
replace as necessary.
6. Inspect the adjustable idler gear studs for signs of galling or scoring. Replace as
necessary.
7. Inspect all the individual components as outlined under the appropriate section.
Section 1.13.2
Installation of Gear Case EGR Model
1. Apply a thin coat of Loctite® 518 or equivalent to the rear side of the of the gear
case and install a new O-ring on rear side of gear case near air compressor drive
opening. See Figure "Gear Case O-ring Installation Location and Loctite
Application" .
Figure 11. Gear Case O-ring Installation Location and Loctite Application
2. Install two guide studs into the front of the cylinder block. See Figure "Cylinder
Block Diamond Dowel and Guide Stud Location" .
3. Using a suitable lifting sling made of leather or cloth, install the gear case onto
the guide studs; index the holes in the gear case mating surface with the diamond
dowels located at the lower left corner and top center of the engine block. See
Figure "Cylinder Block Diamond Dowel and Guide Stud Location" .
1. Diamond Dowel Location 3. Diamond Dowel Location
Figure 12. Cylinder Block Diamond Dowel and Guide Stud Location
4. Install the 14 gear case to cylinder block bolts. See Figure "Gear Case Torque
and Torque Sequence" for the bolt torque and torque sequence.
Figure 13. Gear Case Torque and Torque Sequence
Generated on 09-07-2010