SECTION C Engine 6.0L Diesel

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1 303-01C-i Engine 6.0L Diesel C-i SECTION C Engine 6.0L Diesel CONTENTS PAGE IN-VEHICLE REPAIR Crankshaft Rear Seal C-2

2 303-01C-2 Engine 6.0L Diesel C-2 IN-VEHICLE REPAIR Crankshaft Rear Seal Special Tool(s) Installer, Crankshaft Rear Seal and Wear Ring Remover, Crankshaft Rear Wear Ring Slide Hammer Material Threadlock 262 TA-26 Item Specification WSK-M2G351-A6 Item Part Number Description Crankshaft rear seal Removal 1. Remove the transmission. For additional information, refer to Section for automatic transmissions or Section for manual transmissions. Vehicles with manual transmission 2. Remove the clutch disc and pressure plate. For additional information, refer to Section

3 303-01C-3 Engine 6.0L Diesel C-3 3. Remove the 10 bolts and flexplate or flywheel. Discard the bolts. 4. NOTICE: Use extreme care when removing the flywheel front adapter to prevent damage to the alignment dowel pin. Remove the flywheel front adapter. 5. NOTICE: To prevent engine damage, do not remove the rear primary crankshaft flange bolts under any circumstances. If the flange is removed and reinstalled, it will result in engine vibration and premature transmission component wear. NOTICE: Drill only deep enough to penetrate the seal. Engine damage will occur if the seal is drilled too deep. NOTE: On original service seals, if equipped, the wear ring will be removed separately. Using a center punch, mark a location for 2 holes 180 degrees apart, 9.53 mm (0.375 in) from the outer diameter of the crankshaft flange. Using a drill bit of the appropriate size for the Slide Hammer being used, drill a hole on each side of the crankshaft rear seal as shown. Drill the holes to a depth of 8.76 mm (0.344 in) to capture the metal case of the crankshaft rear seal as well as the wear ring. 6. Using the 2 drilled holes, the Slide Hammer and a commercially available body dent puller attachment, walk the seal out of the rear cover by alternating from side to side to remove the crankshaft rear seal. Discard the crankshaft rear seal.

4 303-01C-4 Engine 6.0L Diesel C-4 Vehicles with an original service seal 7. NOTE: Original equipment seals will not have a wear ring. If a service part has previously been installed, it will have a wear ring. If the service part was a redesigned seal, the wear ring will have been removed with the seal in the previous step. If the service part was an original service seal, the wear ring will remain in the engine after the seal has been removed. If the wear ring remained in the engine after removing the seal, use the Crankshaft Rear Wear Ring Remover to remove and discard the crankshaft rear seal wear ring. 8. Clean and inspect the crankshaft sealing surface. Installation Vehicles with an original service seal 1. NOTICE: The crankshaft rear seal and wear ring are a one-piece design and need to be installed as an assembly. Do not separate the wear ring from the crankshaft rear seal or damage to the seal may occur. NOTE: An original service seal will have a wear ring without a flange and pre-applied threadlock. NOTE: Apply a bead of threadlock around the circumference of the outer rear edge of the secondary crankshaft flange.

5 303-01C-5 Engine 6.0L Diesel C-5 NOTE: Lubricate the outer diameter of the rubber seal with a solution of dish soap and water (approximately 50/50 mix) prior to assembly. Do not use any other type of lubricant. Lubricate the outer diameter of the rubber seal with a solution of dish soap and water. 2. Using the Crankshaft Rear Seal and Wear Ring Installer, install the new crankshaft rear seal and wear ring assembly. Vehicles with a redesigned seal 3. NOTE: A redesigned seal will have a flanged wear ring and pre-applied threadlock. Remove the new crankshaft rear seal and wear ring assembly and plastic step-up tool from the packing. Separate the plastic step-up tool (if installed on the crankcase rear seal) from the crankcase rear seal and wear ring assembly. 4. NOTICE: The crankshaft rear seal and wear ring are a one-piece design and need to be installed as an assembly. Do not separate the wear ring from the crankshaft rear seal or damage to the seal may occur. Identify the metal face of the wear ring. This face must be installed so it is on the outside of the engine (facing the transmission).

6 303-01C-6 Engine 6.0L Diesel C-6 5. NOTE: Lubricate the outer diameter of the rubber seal with a solution of dish soap and water (approximately 50/50 mix) prior to assembly. Do not use any other type of lubricant. Lubricate the outer diameter of the rubber seal with a solution of dish soap and water. 6. NOTICE: Make sure the crankshaft alignment dowel fits in the dowel recess hole in the Crankshaft Rear Seal and Wear Ring Installer base or engine damage may occur. Install the Crankshaft Rear Seal and Wear Ring Installer base and 2 bolts to the crankshaft flange. 7. NOTE: When positioning the crankshaft rear seal and wear ring assembly on the Crankshaft Rear Seal and Wear Ring Installer base, align it to the opening on the engine rear cover and manually start the crankcase rear seal installation. Position the crankshaft rear seal and wear ring assembly on the Crankshaft Rear Seal and Wear Ring Installer base.

7 303-01C-7 Engine 6.0L Diesel C-7 8. NOTICE: The plastic step-up tool increases the flat surface area of the Crankshaft Rear Seal and Wear Ring Installer. Failure to use the plastic step-up tool during installation will result in damage to the crankshaft rear seal and wear ring assembly. Insert the plastic step-up tool into the Crankshaft Rear Seal and Wear Ring Installer with the step-edge toward the installer. 9. NOTICE: The crankshaft rear seal face and the wear ring must be flush with the rear engine cover or damage to the crankshaft rear seal or wear ring may occur. NOTICE: Do not allow the engine to rotate during the installation of the crankshaft rear seal and wear ring assembly or damage to the crankshaft rear seal or wear ring may occur. Using the Crankshaft Rear Seal and Wear Ring Installer, install the new crankshaft rear seal and wear ring assembly until the installation tool contacts the rear engine cover. 10. Install the flywheel front adapter.

8 303-01C-8 Engine 6.0L Diesel C Install the flexplate or flywheel and the 10 new bolts. Tighten the bolts in 2 stages, in the sequence shown. Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten to 94 Nm (69 lb-ft). Vehicles with manual transmission 12. Install the clutch disc and pressure plate. For additional information, refer to Section Install the transmission. For additional information, refer to Section for automatic transmissions or Section for manual transmissions.

DISASSEMBLY AND ASSEMBLY

205-02B-1 DISASSEMBLY AND ASSEMBLY Differential Case and Ring Gear Material Item Specification 205-02B-1 Special Tool(s) Additive Friction Modifier EST-M2C118-A XL-3 2-Jaw Puller 205-D072 (D97L-4221-A)