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Interference Between Clutch Damper and Flywheel Bolts On 2003-2006 Caterpillar 3406E C-15 & C-16 Diesel Engines The AERA Technical Committee offers the following information regarding possible interference between the clutch damper and flywheel bolts on 2003-2006 Caterpillar 3406E, C-15 and C-16 diesel engines. Engines built or serviced with the VCT plus clutch damper, introduced in April 2003, have the possibility of the clutch damper interfering with the flywheel mounting bolts. This applies to the following clutch part numbers: 108009-32Y, 108925-20, 108925-25, 108926-20Y, 108926-25Y, 109701-20, 109701-25, 109705-20Y, 109705-25Y & 109706-32Y. Correction/Action: Any repair that has required the transmission to be removed from the truck, and the engine serial number is 5EK1 and up, 6TS1 and up, 1LW1 and up, 2WS1 and up, 6NZ1-92122, 7CZ1-04382, MBN1-21447, BXS1-00984, 5DS1 and up, or 1MM1 and up, requires checking the flywheel bolt washers. You must verify the 5mm washer has been replaced with the 3mm washer, Caterpillar Part Number 8D-5054. Failure to replace the washers could result in damper rivet interference. Torque the bolts to 270 Nm +/- 40 Nm (200 ft/lb +/- 30 ft/lb). It is also suggested that paint may be applied to bolt heads to show verification and completion identification.
Installation Instructions for CRF 150R and KX450F Steahly Flywheel Weight Warning: Improper instalation of this flywheel weight could result in engine damage or a serious crash. If you do not have the tools or the mechanical abilities take it to a professional. 1. Drain the engine oil or turn off the gas and lay the bike on its side. 2. Remove the shift lever. 3. Remove the ignition cover. Take care not to tear the gasket or have a new gasket on hand. Be carefull that you don’t lose the two dowel pins that are between the cover and the engine case. 4. Remove the flywheel nut. Use an air impact wrench or figure out a way to keep the flywheel from rotating while you remove the nut. A strap wrench or an automotive oil filter wrench may work as a holding tool or try putting the bike in high gear and holding the rear brake on. 5. Pull off the stock flywheel with the proper flywheel puller that has a crank end protection cap. Steahly part number E-63. Do not attempt removal with out the correct puller. Do not use claw type pullers. 6. Fit the flywheel weight on to the stock flywheel. Line up the two threaded holes in the weight with two holes in the stock flywheel. 7. Clean the threads of the two special bolts with contact cleaner. Put a big drop of red Loctite or other high strength thread locker on the threads of the 2 bolts. Install the two special bolts as shown in the picture and torque to 12 foot pounds. 8. Unless you plan to take the weight on and off a lot we highly recommend using a center punch and a hammer to flare out the threads at the end of the bolt (see pictures below). This will reduce the possibility of the bolt coming loose. 9. Clean up the flywheel and weight and remove any metal stuck to the magnets. 10. Install the flywheel with weight back onto the tapered crank shaft end making sure the key ways are lined up. Torque the stock nut to 42 ft- lbs.
Additional service information is available in the Detroit Diesel Series 60 Service Manual, 6SE483. The next revision to this manual will include the revised information. As a convenience to holders of the Series 60 Service Manual, information in service manual format is attached. The page(s) may be inserted into the manual. NOTE: Manual insert pages are numbered for insertion into the current Series 60 Service Manual dated January 2004. Service manuals are available from authorized Detroit Diesel distributors. If this bulletin was obtained from the Internet, service manual page(s) are available by returning to the screen “SIB Index”, selecting attachment pages, and printing the page(s). Detroit Diesel®, DDC®, Series 60® and the spinning arrows design are registered trademarks of Detroit Diesel Corporation. © Copyright 2004 Detroit Diesel Corporation. All rights reserved. Printed in U.S.A.
Please check the part-number(s) for your application against the part-number(s) listed on the instruction sheet. DO NOT USE ANY WASHERS with ARP Flywheel Bolts. They are designed to be installed without them. Note: ARP will NOT be responsible for any failures resulting from using a washer with this kit. Make sure there is an adequate chamfer around the bolt holes on the flywheel to clear the radius under the head of the bolt. Lubricate the threads of the bolt with LOCTITE 242 and the under head of the bolt with ARP ULTRATORQUE FASTENER ASSEMBLY LUBRICANT. Then install the flywheel onto the crankshaft and tighten the bolts hand tight. Using an alternating or criss cross pattern, torque the bolts to 95 ft lbs using the specified lubricants in Step 4. If you have any questions or need additional information please contact us at (805) 339-2200 or by FAX at (805) 650-0742 Flywheel Bolt without Washer- Installation
KENNEDY thoroughly recommends reading these instructions before using the trolley jack, even if you have used a trolley jack on a vehicle before. Reading these instructions carefully and understanding them fully will enable you to raise a vehicle correctly and will prevent injury to yourself or someone else as well as damage to the vehicle and equipment. Because this product is also used in conjunction with axle stands, please follow all relevant safety instructions regarding the lifting and supporting of vehicles. l Always take care to avoid injury when carrying or moving the jack. l Always check vehicle owner’s manual for correct vehicle weight. l Always use on specified jacking points, on a level surface and with a solid foundation. l Always check that jacking points are not corroded before use. l Always engage the handbrake before the vehicle is lifted and use wheel chocks at the end of the vehicle opposite the jack to guard against wheel movement. l Never use for manoeuvring vehicles. l Never use the jack if you suspect a fault. See the ‘Trouble Shooting’ section on page 6 for further information. l Never lift a car when somebody is under it, even with secure axle stands. l Never work under a vehicle only supported by a jack. After lifting the vehicle, support immediately with properly rated axle stands. l Never exceed the rated load capacity or tamper with the factory set overload valve. l Never lean against the raised vehicle. l Never modify the jack, it is not designed to support extensions or cradles and could become unsafe.
The steering system consists of solid steering shaft with a lower joint assembly. Stealth and 3000GT models are equipped with a Supplemental Restraint System (SRS) that includes an air bag and clockspring located in the steering column. WARNING: On Stealth and 3000GT, before doing any repairs, disconnect and shield battery ground. Disconnect SRS connector at control unit. Use caution when working around steering column (air bag could deploy). TROUBLE SHOOTING Refer to TROUBLE SHOOTING - BASIC PROCEDURES article in the GENERAL TROUBLE SHOOTING section. REMOVAL & INSTALLATION STEERING WHEEL & HORN PAD R & I Removal (All Models Except Stealth & 3000GT) 1) Remove horn pad. On Galant, push horn pad toward top of steering wheel for removal. On Precis, push and turn horn pad assembly to remove and disconnect horn button connector. On all other models, remove screws and/or pry horn pad from steering wheel. 2) On all models, place reference mark on steering wheel and steering column shaft for reassembly reference. Remove steering wheel retaining nut and washer. Using steering wheel puller, remove steering wheel. CAUTION: DO NOT hammer on steering wheel during removal, as it may damage steering column. Installation To install, reverse removal procedure. Ensure reference marks are aligned. Tighten steering wheel retaining nut to specification. See TORQUE SPECIFICATIONS table at end of article. Removal (Stealth & 3000GT) 1) Set front wheels in the straight-ahead position. Remove STEERING COLUMN
AUTOMATIC FWD MODELS REMOVAL 1) Remove battery and battery tray. On 3000GT, remove undercover(s). On Eclipse turbo, drain and remove intercooler. On all models, remove air cleaner and case. Raise and support vehicle. Remove wheels. Disconnect control cables at transaxle. Drain transaxle fluid. 2) On Mirage 1.6L, disconnect tension rod. On all models, disconnect neutral safety switch connector, oil cooler hoses and electrical connectors from transaxle. Disconnect speedometer cable and throttle control cable (if equipped). Remove starter motor. 3) On Galant models with electronically controlled suspension, remove air compressor and bracket. Disconnect front height sensor rod at lower control arm. 4) On all models, remove upper transaxle-to-engine bolts. Remove engine undercover (if equipped). On all models, remove drive axle shafts. See FWD AXLE SHAFTS article in DRIVE AXLES. Separate lower control arms from struts for access to axle shafts (if necessary). 5) Remove front exhaust pipe (if necessary). On Eclipse 4WD, Galant 4WD and 3000GT, remove right member and gusset. On 4WD models, separate transfer assembly from transaxle. Reference mark transfer assembly-to-drive shaft and remove transfer assembly. 6) On all models, remove transmission inspection (dust) cover. Place index mark on torque converter and drive plate for reassembly reference. Remove torque converter-to-drive plate bolts. Push torque converter away from engine into transaxle. 7) Support transaxle with jack. Remove transaxle mounts bolts, mounting brackets and remaining transaxle-to-engine bolts. Slide transaxle assembly to right and lower to remove. CAUTION: Ensure torque converter is fully seated in transaxle before installation. Always install new snap rings on inner constant velocity joints.
Power from transaxle is transferred to driving wheels by 2 axle shafts. Both axle shafts use Constant Velocity (CV) joints at inner and outer ends. CV joints are enclosed in CV boots, and connected by an intermediate shaft. Intermediate shaft is splined on both ends. Retaining rings retain intermediate shaft in the inner and outer CV joints. A retaining ring retains inner CV joint stub in differential side gear. Outer CV joint stub is splined into wheel hub, and secured by a spindle nut. Left axle has a dynamic damper to reduce vibration. The following are possible types of Constant Velocity (CV) joints used on axle shaft: Birfield Joint (BJ), Double Offset Joint (DOJ), Rzeppa Joint (RJ) and Tripod Joint (TJ). Determine type of CV joint used prior to disassembly. See AXLE SHAFT SPECIFICATIONS table under INSTALLATION. Note type of boot and location prior to removal. See BAND & BOOT APPLICATION. Install a NEW retaining ring each time axle shaft is removed from transaxle. Article Text (p. 3) 1992 Mitsubishi Mirage For Dan's Transmission Service 10 Jefferson Place Fort Walton Beach FL 32548 © 1997 Mitchell Repair Information Company, All Rights Reserved. Monday, April 01, 2002 09:00AM
Removal (Diamante) 1) Remove hood. Drain cooling system. Remove radiator. Release fuel system pressure. See FUEL PRESSURE RELEASE. Disconnect negative battery cable. Drain engine oil and transaxle oil. Remove front exhaust pipe. Remove transaxle assembly. See appropriate CLUTCHES or TRANSMISSION SERVICING article. 2) Disconnect accelerator cable, brake booster vacuum hose, fuel supply and return lines, and heater hoses. Disconnect EGR temperature sensor (if equipped). Unplug vacuum hose connector. Remove drive belts. Remove power steering pump and A/C compressor, leaving hoses attached. 3) Unplug all harness connectors. Remove bolt from body ground connection. Disconnect alternator wiring inside relay box. Remove relay box and engine wiring harness connection. On models with ABS, remove radiator overflow tank and bracket. 4) Attach engine hoist. Raise engine enough to take weight from mounts. Remove engine mount bracket. Remove damper. Remove rear roll stopper bracket mount bolt. Remove front roll stopper bracket mount bolt. Carefully lift engine from car. Installation (Diamante) To install, reverse removal procedure. Install engine mount bracket so that arrow points away from engine, toward body. Install new "O" rings on fuel lines. Install new exhaust gaskets and nuts. Adjust throttle cable. See TORQUE SPECIFICATIONS TABLE at the end of this article. Replenish fluids. CAUTION: DO NOT allow foreign material into turbocharger air intake hoses or pipes.
BRAKE BOOSTER REMOVAL OF BRAKE BOOSTER 1. REMOVE MASTER CYLINDER (See page BR–10) 2. DISCONNECT VACUUM HOSE FROM BRAKE BOOSTER 3. REMOVE PEDAL RETURN SPRING 4. REMOVE CLIP AND CLEVIS PIN 5. REMOVE BRAKE BOOSTER, GASKET AND CLEVIS BR–17 BRAKE SYSTEM – Brake Booster INSTALLATION OF BRAKE BOOSTER (See page BR–16) 1. ADJUST LENGTH OF BOOSTER PUSH ROD (a) Install the gasket on the master cylinder. (b) Set the SST on the gasket, and lower the pin until its tip slightly touches the piston. SST 09737–00010 (c) Turn the SST upside down, and set it on the booster. SST 09737–00010 (d) Measure the clearance between the booster push rod and pin head (SST). Clearance: 0 mm (0 in.) (e) Adjust the booster push rod length until the push rod lightly touches the pin head. 2. INSTALL BRAKE BOOSTER, GASKET AND CLEVIS (a) Install the booster and gasket. (b) Install the clevis. (c) Install and torque the booster mounting nuts. Torque: 13 N–m (130 kgf–cm, 9 ft–lbf ) 3. CONNECT CLEVIS TO BRAKE PEDAL Insert the clevis pin into the clevis and brake pedal and install the clip to the clevis pin. 4. INSTALL PEDAL RETURN SPRING 5. INSTALL MASTER CYLINDER (See page BR–15) 6. CONNECT HOSE TO BRAKE BOOSTER 7. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM (See page BR–8) 8. CHECK FOR FLUID LEAKAGE 9. CHECK AND ADJUST BRAKE PEDAL (See page BR–6) 10. PERFORM OPERATIONAL CHECK (See page BR–7)