Bell Housing: Service and Repair

Flywheel Housing Replacement

Special Tools

J-37228 - Seal Cutter

For equivalent regional tools, refer to Special Tools Special Tools.

Removal Procedure

1. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill Gasoline) Cooling System Draining and Filling (Vac-N-Fill)Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Static Fill)Cooling System Draining and Filling (Static Fill LGH, LML) Cooling System Draining and Filling (Static Fill)Cooling System Draining and Filling (Vac-N-Fill Diesel) Cooling System Draining and Filling (Vac-N-Fill).

2. Remove the oil filter. Refer to Engine Oil and Oil Filter Replacement Service and Repair.

3. Remove the upper oil pan. Refer to Upper Oil Pan Replacement Upper Oil Pan Replacement.

4. Remove the crankshaft rear oil seal. Refer to Crankshaft Rear Oil Seal Replacement Service and Repair.

5. Remove the EGR cooler and pipe bolts and reposition the pipe. Refer to Exhaust Gas Recirculation Coolant Hoses/Pipes Replacement (Cooler to Cooler Hose-LML) Exhaust Gas Recirculation Coolant Hoses/Pipes Replacement (Cooler to Cooler Hose)Exhaust Gas Recirculation Coolant Hoses/Pipes Replacement (EGR Bypass Pipe-LML) Exhaust Gas Recirculation Coolant Hoses/Pipes Replacement (EGR Bypass Pipe)Exhaust Gas Recirculation Coolant Hoses/Pipes Replacement (Manifold Feed Pipe to Cooler Hose-LML) Exhaust Gas Recirculation Coolant Hoses/Pipes Replacement (Manifold Feed Pipe to Cooler Hose)Exhaust Gas Recirculation Coolant Hoses/Pipes Replacement (Manifold Feed Hose to Cooler-LML) Exhaust Gas Recirculation Coolant Hoses/Pipes Replacement (Manifold Feed Hose to Cooler).




6. Remove the turbocharger oil return pipe nuts from the top of the flywheel housing.

7. Remove the oil cooler adapter studs and nuts from the flywheel housing.




8. Remove the flywheel housing bolts, denoted by the black circles.

9. Separate the flywheel from the cylinder block using J-37228 - cutter.

10. Remove the flywheel housing.




11. Remove the turbocharger oil return pipe gasket from the flywheel housing.

12. Remove the oil cooler adapter bolts.

13. Remove the oil cooler adapter and gaskets.

14. If required, clean and inspect the flywheel housing. Refer to Flywheel Housing Cleaning and Inspection Flywheel Housing Cleaning and Inspection.

Installation Procedure




1. Install NEW O-ring seals to the flywheel housing, if necessary.




2. Apply a 2 mm (1/8 in) wide bead of sealant (3) to the flywheel housing sealing surfaces. Refer to Adhesives, Fluids, Lubricants, and Sealers Adhesives, Fluids, Lubricants, and Sealers for the correct part number.




3. Install a NEW oil cooler adapter gasket.

4. Install a NEW oil cooler adapter to flywheel housing gasket.

5. Install the oil cooler adapter to the flywheel housing.

Caution: Refer to Fastener Caution Fastener Caution.

6. Install the oil cooler adapter bolts and tighten to 25 Nm (18 lb ft).




7. Install the flywheel housing bolts, denoted by the black circles. Tighten the bolts to 95 Nm (70 lb ft).




8. Install the oil cooler adapter studs and nuts to the flywheel housing.

* Tighten the oil cooler adapter studs to 8 Nm (71 lb in).

* Tighten the oil cooler adapter nuts to 25 Nm (18 lb ft).

9. Install the EGR cooler and pipe bolts and reposition the pipe. Refer to Exhaust Gas Recirculation Coolant Hoses/Pipes Replacement (Cooler to Cooler Hose-LML) Exhaust Gas Recirculation Coolant Hoses/Pipes Replacement (Cooler to Cooler Hose)Exhaust Gas Recirculation Coolant Hoses/Pipes Replacement (EGR Bypass Pipe-LML) Exhaust Gas Recirculation Coolant Hoses/Pipes Replacement (EGR Bypass Pipe)Exhaust Gas Recirculation Coolant Hoses/Pipes Replacement (Manifold Feed Pipe to Cooler Hose-LML) Exhaust Gas Recirculation Coolant Hoses/Pipes Replacement (Manifold Feed Pipe to Cooler Hose)Exhaust Gas Recirculation Coolant Hoses/Pipes Replacement (Manifold Feed Hose to Cooler-LML) Exhaust Gas Recirculation Coolant Hoses/Pipes Replacement (Manifold Feed Hose to Cooler)




10. Install the oil filter (1). Refer to Engine Oil and Oil Filter Replacement Service and Repair.

11. Install the upper oil pan. Refer to Upper Oil Pan Replacement Upper Oil Pan Replacement.

12. Install a NEW gasket to the turbocharger oil return pipe.

13. Install the turbocharger oil return pipe to flywheel housing nuts and tighten to 25 Nm (18 lb ft).

14. Install the crankshaft rear oil seal. Refer to Crankshaft Rear Oil Seal Replacement Service and Repair.

15. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill Gasoline) Cooling System Draining and Filling (Vac-N-Fill)Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Static Fill)Cooling System Draining and Filling (Static Fill LGH, LML) Cooling System Draining and Filling (Static Fill)Cooling System Draining and Filling (Vac-N-Fill Diesel) Cooling System Draining and Filling (Vac-N-Fill).

16. Relearn the crankshaft position reluctor wheel. Refer to Crankshaft Position Reluctor Wheel Learn Testing and Inspection.