A1 - DDCSN
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1. 41287 Figure 9 10 Application of Gasket Eliminator All information subject to change without notice 9 14 From Bulletin 4 50 02 6SE50 0006 Copyright 2002 DETROIT DIESEL CORPORATION SERIES 50 SERVICE MANUAL 4 Install oil fitting on back of flywheel housing See Figure 9 11 41288 1 Oil Fitting Figure 9 11 Installation of Oil Fitting 5 Insert two flywheel guide studs J 36235 into the crankshaft See Figure 9 12 J 36235 41910 Figure 9 12 Flywheel Guide Studs All information subject to change without notice 6SE50 0006 Copyright 2002 DETROIT DIESEL CORPORATION From Bulletin 4 50 02 9 15 9 1 REAR ENGINE POWER TAKE OFF REPTO ASSEMBLY To avoid injury from a falling component while using a lifting device never stand beneath a suspended load 6 Use a hoist to carefully slide the REPTO flywheel housing into position onto the guide studs See Figure 9 13 41290 1 Crankshaft 2 Guide Studs J 36235 Figure 9 13 Installation of REPTO Flywheel Housing All information subject to change without notice 9 16 From Bulletin 4 50 02 6SE50 0006 Copyright 2002 DETROIT DIESEL CORPORATION SERIES 50 SERVICE MANUAL NOTICE Do not drop the bolt or washer into the gear set Engine or REPTO damage will occur 7 Using a magnetic socket install and torque all eleven flywheel housing mounting bolts in sequence to 12. change without notice 6SE50 0006 Copyright 2002 DETROIT DIESEL CORPORATION From Bulletin 4 50 02 9 27 9 2 9 28 FRONT MOUNTED POWER TAKE OFF If removed install flywheel locking tool J 36375 A through the inspection plug hole in the bottom of the flywheel housing See Figure 9 22 Install the crankshaft pulley Refer to Section 1 13 3 Install the PTO hub assembly inside of the crankshaft pulley making sure the slot on the backside of the hub fits over the dowel in the pulley Install the PTO hub assembly attaching bolt and retainer after coating the bolts threads and underside of the bolt head with INTERNATIONAL COMPOUND 2 or equivalent Torque the bolt to 610 N m 450 lb ft All information subject to change without notice From Bulletin 4 50 02 6SE50 0006 Copyright 2002 DETROIT DIESEL CORPORATION
3. o clock position on the REPTO flywheel housing See Figure 9 7 if pO ie 6 O CLOCK POSITION 41861 Figure 9 7 Installation of Pipe Plug in the 6 o clock Position All information subject to change without notice 6SE50 0006 Copyright 2002 DETROIT DIESEL CORPORATION From Bulletin 4 50 02 9 11 9 1 REAR ENGINE POWER TAKE OFF REPTO ASSEMBLY c Install the pipe plug with a copper washer located in the 5 o clock position on the REPTO flywheel housing See Figure 9 8 1 5 O CLOCK POSITION 41911 1 Copper Washer 2 Pipe Plug Figure 9 8 Installation of Pipe Plug in the 5 o clock Position All information subject to change without notice 9 12 From Bulletin 4 50 02 6SE50 0006 Copyright 2002 DETROIT DIESEL CORPORATION SERIES 50 SERVICE MANUAL NOTE Do not install any plugs in the two holes below the crankshaft on the back lower face even though they are threaded they are oil drain holes back to sump See Figure 9 9 41262 Figure 9 9 No Pipe Plug in these Two Threaded Holes All information subject to change without notice 6SE50 0006 Copyright 2002 DETROIT DIESEL CORPORATION From Bulletin 4 50 02 9 13 9 1 REAR ENGINE POWER TAKE OFF REPTO ASSEMBLY 3 Apply Gasket Eliminator Kent Moore part number or equivalent PT 7276 to sealing surface of the flywheel housing or the block whichever is easier See Figure 9 10
4. 12 126 N m 83 93 lb ft for 12 mm bolts or 160 200 N m 118 148 lb ft for 14 mm bolts See Figure 9 14 NOTE Ensure that the three bolts behind plugs are not overlooked in this step 41291 Figure 9 14 Flywheel Housing Bolt Location and Torque Sequence All information subject to change without notice 6SE50 0006 Copyright 2002 DETROIT DIESEL CORPORATION From Bulletin 4 50 02 9 17 9 1 REAR ENGINE POWER TAKE OFF REPTO ASSEMBLY Install the two pipe plugs located on the gear set cover plate and plug next to the cranking 8 j motor See Figure 9 15 Figure 9 15 9 18 From Bulletin 4 50 02 41860 Pipe Plugs on the Gear Set Cover Plate All information subject to change without notice 6SE50 0006 Copyright 2002 DETROIT DIESEL CORPORATION SERIES 50 SERVICE MANUAL 9 Set crankshaft endplay as follows NOTICE Setting crankshaft end play must be done whenever the REPTO housing is installed to prevent crankshaft from damaging crankshaft thrust washers upon initial engine startup a Bolt the flywheel to the unit using six flywheel bolts b Torque the flywheel bolts to 102 N m 75 ft lb c Remove the flywheel This is necessary to remove the gap between the crankshaft and REPTO drive hub d Attach driver handle J 8092 onto the setting tool J 42722 1 See Figure 9 16 e Stack approximately 0 100 in of shims J 427224 onto the nose of the setting tool
5. 9 POWER TAKE OFF Section 9 1 REAR ENGINE POWER TAKE OFF REPTO ASSEMBLY cscs 9 2 FRONT MOUNTED POWER TAKE OFF 9 2 From Bulletin 4 50 02 All information subject to change without notice 6SE50 0006 Copyright 2002 DETROIT DIESEL CORPORATION SERIES 50 SERVICE MANUAL 9 1 REAR ENGINE POWER TAKE OFF REPTO ASSEMBLY The REPTO Rear Engine Power Take Off is an aluminum SAE 1 flywheel housing mounted against the rear of the cylinder block it takes the place of a standard flywheel housing It provides a cover for the flywheel and serves as a support for the cranking motor and the transmission The aluminum flywheel housing has an internal idler gear that is driven off the rear of the crankshaft Those gears drive an output yoke that faces the rear of the vehicle The output yoke is located at the one o clock position and has four different yoke configurations It provides up to 300 hp intermittent and 240 hp continuous PTO power A rear oil seal which is pressed into the housing may be removed or installed without removing the housing Refer to section 1 8 The output yoke and its oil seals can be serviced If there is any internal failure the REPTO should be removed and replaced as an assembly 9 1 1 Repair and Replacement for the Rear Engine Power Take Off Assembly The REPTO assembly currently is a nonserviceable component if there are internal problems with the REPTO it must be replaced as an assembly All i
6. See Figure 9 16 f Add or remove shims until 0 005 in gap is measured at four points 90 degrees apart with a feeler gage See Figure 9 16 J 8092 J 42722 4 FEELER J 42722 1 41912 Figure 9 16 Installation of Shims All information subject to change without notice 6SE50 0006 Copyright 2002 DETROIT DIESEL CORPORATION From Bulletin 4 50 02 9 19 9 1 REAR ENGINE POWER TAKE OFF REPTO ASSEMBLY NOTE Tool must be held firmly in place and perpendicular to the housing g Hold the setting tool firmly against the drive hub with a large hammer hit the driver handle two to four times to set the gap between the crank and thrust washer See Figure 9 17 W x A 41296 Figure 9 17 Installation of Shims h Remove the tool ensuring no shims remain stuck to the hub 10 Bar the engine over from the front of the crankshaft It should turn slightly harder than without the REPTO housing installed 11 Install flywheel and torque bolts Refer to section 1 14 3 NOTE Crankshaft endplay is set and there is no further need to check if this procedure was done correctly NOTE l All cranking motors assembled to the REPTO housings should be installed with a new gasket 12 Install cranking motor Refer to section 8 5 3 All information subject to change without notice 9 20 From Bulletin 4 50 02 6SE50 0006 Copyright 2002 DETROIT DIESEL CORPORATION SERIES 50 SERVICE MANUAL NO
7. TICE Do not connect to the wrong port Connecting to the wrong port will allow coolant to be fed to the gears and the engine will fail sade the oil supply line is connected to the port next to the turbo oil supply line and not to the oil cooler assembly 13 Install the oil supply line to the brass fitting on the housing and the opened port 14 Test for REPTO Flywheel Housing Bore Concentricity as follows a Attach the base post onto the crankshaft palm b Assemble the dial indicators onto the base post c Position the dial indicator square with the flywheel housing inside bore of the bell Ensure the indicator has adequate travel in each direction See Figure 9 18 FLYWHEEL HOUSING Figure 9 18 Measuring Flywheel Housing Bore Concentricity d Adjust each dial indicator to read zero at the twelve o clock position All information subject to change without notice 6SE50 0006 Copyright 2002 DETROIT DIESEL CORPORATION From Bulletin 4 50 02 9 21 9 1 REAR ENGINE POWER TAKE OFF REPTO ASSEMBLY e Bar the engine and rotate the crankshaft one complete revolution taking readings at 90 degree intervals four readings each for the bore See Figure 9 19 Figure 9 19 Flywheel Housing f Remove the wrench or cranking bar before recording each reading to ensure accuracy NOTE The maximum total indicator reading must not exceed 0 33 mm 0 013 in g Ifthe run out exceeds the maximum limits
8. air and Replacement of the Front Mounted Power Take off Assembly The front mounted power take off assembly is a nonserviceable component tag for remanufacture 9 2 2 Removal of the Front Mounted Power Take off Perform the following steps to remove the PTO assembly All information subject to change without notice 9 26 From Bulletin 4 50 02 6SE50 0006 Copyright 2002 DETROIT DIESEL CORPORATION SERIES 50 SERVICE MANUAL 1 Remove the inspection plug in the bottom of the flywheel housing and install the flywheel lock tool J 36375 A See Figure 9 22 INSPECTION FLYWHEEL PLUG HOLE J 36375 Figure 9 22 Flywheel Lock 2 Thread the center screw of the flywheel lock J 36375 A into the flywheel housing until the tip of the tool rests between two teeth of the flywheel ring gear Tighten the knurled knob finger tight See Figure 9 22 NOTE It may be necessary to bar the engine over so that the tool center screw is exactly between two teeth 3 Remove the PTO hub assembly attaching bolt and retainer 4 Remove the PTO hub assembly 5 Remove the crankshaft pulley Refer to Section 1 13 2 9 2 2 1 Inspection of the Front Mounted Power Take off Visually inspect the PTO hub contact surfaces for galling or burrs To correct surfaces that have damage smooth these surfaces with emery cloth or a stone 9 2 3 Installation of the Front Mounted Power Take off Install the PTO assembly as follows All information subject to
9. check for dirt of foreign material between the flywheel housing and the cylinder block or oil pan h Clean the mating surfaces once again Refer to section General Information Cleaning in the beginning of this manual i Install REPTO Flywheel Housing Refer to section 9 1 4 j Check run out again All information subject to change without notice 9 22 From Bulletin 4 50 02 6SE50 0006 Copyright 2002 DETROIT DIESEL CORPORATION 15 16 17 Install transmission Refer to OEM Apply lube to the yoke seal surface and slide it onto the PTO spline See Figure 9 20 Apply Loctite 565 or equivalent to both sides of the large washer and hand start nut See Figure 9 20 SERIES 50 SERVICE MANUAL 41299 1 Yoke 2 Washer Figure 9 20 Apply Lube to Yoke Seal and Loctite 565 to Both Sides of Washers 18 Inserta 3 4 in drive wrench in the front pulley or use J 36375 A flywheel lock tool in the 19 20 21 22 flywheel housing to stop crank from turning Install the nut to the spline and torque to 474 542 N m 350 400 ft lbs Install oil pan Refer to section 3 9 3 Fill engine with clean lube oil Refer to section 5 2 Install engine into vehicle All information subject to change without notice 6SE50 0006 Copyright 2002 DETROIT DIESEL CORPORATION From Bulletin 4 50 02 9 23 9 1 REAR ENGINE POWER TAKE OFF REPTO ASSEMBLY A CAUTION Diesel engine exhaust and some of its constituen
10. ct the rubber yoke seal a If any defects are found replace the seal b Ifno damage is found reuse the seal All information subject to change without notice 9 8 From Bulletin 4 50 02 6SE50 0006 Copyright 2002 DETROIT DIESEL CORPORATION SERIES 50 SERVICE MANUAL 9 1 4 Installation of Rear Engine Power Take off Assembly Install the REPTO as follows 1 Apply a lubricant like white grease to the end of the crankshaft and inside the wall of the REPTO mounting hub See Figure 9 5 NOTE If installing a new REPTO housing ensure that all 11 plastic shipping plugs are removed from the housing 41348 1 Crankshaft Figure 9 5 Application of Lubricant All information subject to change without notice 6SE50 0006 Copyright 2002 DETROIT DIESEL CORPORATION From Bulletin 4 50 02 9 9 9 1 REAR ENGINE POWER TAKE OFF REPTO ASSEMBLY 2 If installing a new REPTO housing To avoid injury from flying sealant Do not use an impact gun on plugs with white sealant a Install the pipe plug above the cranking motor mount on the REPTO flywheel housing See Figure 9 6 41285 Figure 9 6 Installation of Pipe Plug Above Cranking Motor Mount All information subject to change without notice 9 10 From Bulletin 4 50 02 6SE50 0006 Copyright 2002 DETROIT DIESEL CORPORATION SERIES 50 SERVICE MANUAL b Install the bottom pipe plug located in the 6
11. e remaining flywheel bolts 5 Drain oil pan housing by removing the plug at the bottom of the housing Remove the oil line from the cooler All information subject to change without notice 6SE50 0006 Copyright 2002 DETROIT DIESEL CORPORATION From Bulletin 4 50 02 9 5 9 1 REAR ENGINE POWER TAKE OFF REPTO ASSEMBLY 6 Remove three plugs to gain access to bolts securing the housing to the block See Figure 9 3 7 Remove the three bolts being careful not to drop them into the housing 41860 Figure 9 3 Pipe Plugs on the Gear Set Cover Plate All information subject to change without notice 9 6 From Bulletin 4 50 02 6SE50 0006 Copyright 2002 DETROIT DIESEL CORPORATION SERIES 50 SERVICE MANUAL NOTICE Do not drop the bolt or washer into the gear set Engine or REPTO damage will occur 8 Remove the remaining eight bolts A CAUTION To avoid injury from a falling component while using a lifting device never stand beneath a suspended load 9 Attach a suitable sling or use a floor jack to support the flywheel housing which weighs l about 120 lbs Gently tap the backside of the flywheel housing with a rubber mallet to loosen it from the block Remove the housing 10 Remove any gasket material from the flywheel housing and block at this time See Figure 9 4 41287 Figure 9 4 Removal of Gasket Mate
12. in 261 7 N m 193 Ib ft 57 4 kW 77 hp Spicer 1350 2100 r min 253 6 N m 187 Ib ft 56 0 kW 75 hp Table 9 1 Torque and Horsepower for the Front Mounted Power Take off Assemblies NOTE These torque and horsepower values are the maximum available taken at three degrees shaft angle Any increase in the shaft angle has a direct negative effect on the amount of available torque and horsepower as well as shaft life Also any new application must have a Torsional Analysis performed by the DDC Engineering Department The PTO drive shaft must be purchased through Spicer Universal Joint Division Dana Corporation If a PTO adaptor kit is to be installed on an engine that has been in service it will be necessary to remove the standard pulley configuration and replace it with one of the PTO adaptor kits Perform the following steps to install the new PTO assembly 1 Remove the six bolts that retain the standard crankshaft pulley refer to Section 2 Install the new PTO pulley refer to Section 9 2 3 Be certain to use the new bolts and washer provided with the PTO adaptor kit 3 Install the new hub insulator assembly inside the new pulley assembly making certain that the slot on the backside of the hub fits over the dowel in the pulley 4 Install the new 1 in 14 x 3 50 in bolt and retainer after coating the bolt threads and underside of the bolt head with INTERNATIONAL COMPOUND 2 Torque the bolt to 610 N m 450 lb ft 9 2 1 Rep
13. nformation subject to change without notice 6SE50 0006 Copyright 2002 DETROIT DIESEL CORPORATION From Bulletin 4 50 02 9 3 9 1 REAR ENGINE POWER TAKE OFF REPTO ASSEMBLY To determine if repair is possible or replacement is necessary perform the following procedure See Figure 9 1 REMOVE INSPECT YOKE DOES IT TURN INDEPENDENTLY OF THE ENGINE IS THERE EXCESSIVE BACK amp FORTH PLAY REMOVE YOKE AND INSPECT YOKE INSPECT INSPECT HOES THE OUTPUT YOKE WORN SHAFT picasa ioe IS IT WORN EXIST REPLACE REPLACE YOKE REPTO AND SEALS ASSEMBLY Figure 9 1 Flowchart for Repair or Replacement of REPTO Assembly All information subject to change without notice 9 4 From Bulletin 4 50 02 6SE50 0006 Copyright 2002 DETROIT DIESEL CORPORATION SERIES 50 SERVICE MANUAL 9 1 2 Removal of Rear Engine Power Take off Assembly Remove the REPTO assembly as follows 1 Disconnect battery power Refer to section 8 3 2 2 Remove cranking motor from the REPTO flywheel housing Refer to section 8 5 2 3 Remove transmission and PTO driveshaft and any other parts attached to the housing 4 Remove the flywheel as follows a Remove two adjacent flywheel bolts b Insert two flywheel guide studs J 36235 into the crankshaft See Figure 9 2 CRANKSHAFT J 36235 41909 Figure 9 2 Flywheel Guide Studs c Remove th
14. rial All information subject to change without notice 6SE50 0006 Copyright 2002 DETROIT DIESEL CORPORATION From Bulletin 4 50 02 9 7 9 1 REAR ENGINE POWER TAKE OFF REPTO ASSEMBLY To avoid injury from flying sealant Do not use an impact gun on plugs with white sealant 11 Remove all sealing material from the block and housing Refer to Section on Cleaning in the General Information Section 9 1 3 Cleaning of Rear Engine Power Take off Assembly Clean the REPTO as follows i 1 Clean any residue from the end of the crankshaft and inside wall of the REPTO mounting hub 2 Clean any residue from the yoke sealing surface washer and nut 9 1 3 1 Inspection of Rear Engine Power Take off Assembly f Inspect the REPTO assembly as follows 1 Inspect the flywheel Refer to section1 14 2 1 2 Inspect flywheel housing for cracks and any other damage a If sealing surface is damaged repair with emery cloth b If cracked repair is not possible 3 Inspect the crankshaft where the rear oil seal makes contact Refer to section 1 8 a Check for groove in crankshaft b If crankshaft is grooved install a wear sleeve over the crankshaft end An oversized I D rear oil seal must be used with the rear sleeve Refer to section 1 8 7 4 _ Inspect the bottom of the yoke a Ifburrs are found on the surface of the yoke replace the component b Ifno damage is found reuse part 5 Inspe
15. ts are known to the State of California to cause cancer birth defects and other reproductive harm Always start and operate an engine in a well ventilated area If operating an engine in an enclosed area vent the exhaust to the outside Do not modify or tamper with the exhaust system or emission control system 23 Start and run engine for verification of proper engine operation i All information subject to change without notice 9 24 From Bulletin 4 50 02 6SE50 0006 Copyright 2002 DETROIT DIESEL CORPORATION SERIES 50 SERVICE MANUAL 9 2 FRONT MOUNTED POWER TAKE OFF Detroit Diesel Corporation DDC has a front mounted PTO for use on the Series 50 engines See Figure 9 21 vw 1 Retainer 4 Pulley Assembly 2 Bolt 5 Crankshaft 3 Hub Assembly Figure 9 21 Front Mounted Power Take off Components All information subject to change without notice 6SE50 0006 Copyright 2002 DETROIT DIESEL CORPORATION From Bulletin 4 50 02 9 25 9 2 FRONT MOUNTED POWER TAKE OFF This PTO is available in two different models adaptable to Spicer 1310 and Spicer 1350 drive shafts depending on the torque and horsepower requirements Maximum torque and horsepower for the PTO assemblies are listed in Table 9 1 Power Take off Models Engine Speed Torque Horsepower Spicer 1310 1800 r min 162 7 N m 120 lb ft 30 6 kW 41 hp Spicer 1310 2100 r min 158 7 N m 117 lb ft 29 8 kW 40 hp Spicer 1350 1800 r m
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