Section 1.13
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" .‪

Figure 1. Gear Case and Gear Train Assembly

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" ).‪

Figure 2. Water Pump Assembly and Related Parts

Figure 3. Air Compressor

Figure 4. Adjustable Idler Gear and Related Parts

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" .‪

Figure 5. Bull Gear and Spindle Location

The Timing Reference Sensor/Crankshaft Position Sensor (TRS/CKP) is an electronic component that is bolted to the side of the gear case on the intake (left) side of the engine just above the oil pan. See Figure "Timing Reference Sensor (TRS)" .‪

Figure 6. Timing Reference Sensor (TRS)

There is a drilled oil passage in the gear case casting for lubrication of the air compressor. See Figure "Air Compressor Lubrication Gallery (EGR Model)" .‪

Note: Do not use the oil plug location for an oil supply or for checking oil pressure.

Figure 7. Air Compressor Lubrication Gallery (EGR Model)

To determine if repair is possible or replacement is necessary, perform the following procedure. See Figure "Flowchart for Repair or Replacement of Gear Case" .‪

Figure 8. Flowchart for Repair or Replacement of Gear Case

Section 1.13.1
Removal of Gear Case EGR Model

Perform the following steps to remove gear case:‪

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" .
   

   Figure 9. Gear Case Mounting Bolt Locations EGR Model

8. Using a leather or cloth-wrapped strap, to support the gear case.
9. Use a rubber hammer or plastic mallet to loosen the gear case from the cylinder block. See Figure "Gear Case Removal EGR Model" .
   

   Figure 10. Gear Case Removal EGR Model

Section 1.13.1.1
Inspection of Gear Case EGR Model

Inspect the gear case as follows:‪

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.‪

Inspect the gear case as follows:‪

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

Install the gear case as follows:‪

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" .
   

   1. O-ring Installation Location‪

   2. 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
   2. Guide Studs‪

   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

5. Remove the guide studs from cylinder block.
6. Inspect the bull gear, spindle and adjustable idler gear access opening in the gear case and remove any foreign material.
7. Rotate engine until cylinder No.1 is at TDC.
8. Install the spindle, torque the four bolts to 58-73 N·m (43-54 lb·ft)
9. Install adjustable idler gear.Refer to "1.31.3 Installation of Adjustable Idler Gear Assembly" .
10. Install bull gear.Refer to "1.32.3 Installation of Bull Gear and Camshaft Idler Gear Assembly" .
11. Install the gear case cover.Refer to "1.11.3 Installation of Gear Case Cover EGR Model"