Page 343 - CTS - Mechanic Diesel - TP

MECHANIC DIESEL - CITS

v Gearbox
1 Remove the companion flange from the pinion shaft by removing the cap-screw holding the pinion shaft
retainer to the end of the pinion. Pull the companion the flange off the pinion.
2 Remove the outer hearing and seal retainers, and pinion shims.
3 Remove housing cover (hold the pinion shaft in the place while the cover is removed).
4 Remove the pinion shaft bearings and the pinion shft. Replace bearings or pinion shaft if severely pitted,
scored, or worn (apply low heat to the inner race to remove from the shaft).
5 Remove the crankshaft bearing snap ring and bearing.

6 Remove the gear snap ring.
7 Remove the gear with the puller holes provided. Inspect thegear for pitting, cracks and scoring and replace if
necessary.
8 If case is being repositioned, hammer out the freeze plugs.
9 Remove the socket head cap-screws that retain the gearbox housing to the pump frame.
10 Remove the gearbox from the power frame.
11 Throughly clean and inspect all parts prior to re-assembly.
12 Using a silicone seal, form a gasket around the outside of the sperical bearing adapter on the power end.
13 Install the gearbox housing onto the power frame in the correct orientation of socket head cap-screws.
14 If previously removed hammer in the freeze plugs with silicone sealer.
15 If new bull gear is being installed fit key to shaft and gear. Key must fit with 0.000 to 0.001 inches clearance
(slip fit). Do not drive key in with excessive force.
16 Coat the crankshaft extension with some light oil and install the gear with the long hub side inward.
17 Install the gear snap ring with snap ring pliers. Be sure snap ring is seated in groove.
18 Install the crankshaft bearing and snap ring. be sure snap ring is seated in groove.
19 Install the pinion bearings onto the pinion shaft. Heat the bearings to 250 degrees F in an oven or oil bath to
install on the pinion shaft.
20 Install the pinion shaft into the pinion bore of the gearbox housing
21 While holding the pinion shaft in place, install the gearbox housing cover. Use silicone seal as gasket material.
22 Install the pinion bearing races into the gearbox housing.
23 Install the pinion bearing retainer (off drive) and pinion bearing seal retainer (drive) without shims. Tighten the
retainers while moving the pinion back and forth. When the pinion begins to tighten and move with resistance,
stop tightening the retainers. Use the shims in the shim pack to measure the clearance between the housing
and retainer. Remove the retainers, add the measured shim pack between the retainer and the housing and
re-install the retainers. Recheck the movement in the pinion. If the pinion does not move, continue adding
shims until the pinion moves back and forth without resistance. The bull gear bearing retainer needs no shims
but needs silicone seal as a gasket.
24 Install the companion flange.
25 Install the pinion shaft end retainer using the cap screw to hold the companion flange in place.
vi Crankshaft
1 Remove the pump from the trailer and move it to a service area with an overhead lift, where the frame can
eventually be turned on its die.
2 Remove the gearbox, connecting rods, and cross heads.
3 Remove the rotary lube union.
4 Remove the crankshaft cover bolts from the off drive side.
5 Remove the four bolts from inside the frame, threaded into the crankshaft cover.

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CITS : Automotive - Mechanic Diesel - Exercise 18.5