Cummins ISX11.9 CM2250 – Service Manual 001-034   Gear Housing, Rear

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

WARNING  This component or assembly weighs greater than 23 kg [50 lb]. To reduce the possibility of serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly.

WARNING  Support the rear of the engine using the rear support attached to the rear of the cylinder block. Failure to support the engine can cause personal injury.

• Disconnect the batteries. Refer to the OEM service manual.
• Drain the lubricating oil system. Refer to Procedure 007-037 in Section 7.
• Remove the fuel pump. Refer to Procedure 005-016 in Section 5.
• Remove the starting motor. Refer to Procedure 013-020 in Section 13.
• Disconnect the engine speed sensor. Refer to Procedure 019-363 in Section 19.
• If equipped, remove the rear power take-off. Refer to Procedure 009-022 in Section 9.
• Support the rear of the engine and remove the transmission. Refer to the OEM service manual.
• If equipped, remove the flywheel. Refer to Procedure 016-005 in Section 16.
• If equipped, remove the flexplate. Refer to Procedure 016-004 in Section 16.
• Remove the flywheel housing. Refer to Procedure 016-006 in Section 16.
• Remove the rear camshaft idler gear. Refer to Procedure 001-115 in Section 1.
• Remove the rear camshaft gear. Refer to Procedure 001-085 in Section 1.

Suspend the oil pan by loosening the oil pan mounting capscrews on the perimeter of the oil pan. Suspend the oil pan approximately 6 mm [0.25 in].

Remove the four oil pan mounting capscrews from the rear gear housing.

NOTE: This section is for removing the non-REPTO rear gear housing option.

Remove all of the mounting capscrews, the rear gear housing, and the steel gasket.

Discard the gasket.

NOTE: This section is for removing the REPTO rear gear housing option.

DO NOT remove the REPTO idler gear at this time. Remove the REPTO idler gear and rear gear housing as a complete assembly.

Remove all of the mounting capscrews, the rear gear housing, and the steel gasket.

Discard the gasket.

Remove and discard the press in place gasket between the rear gear housing and flywheel housing.

NOTE: This section applies to the REPTO rear gear housing option only.

Remove the REPTO ider gear assembly from the gear housing by removing the mounting capscrew in the center of the idler shaft, then lifting and removing the REPTO idler gear assembly from under the flange of the rear gear housing. Refer to Procedure 001-093 in Section 1.

WARNING  When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

CAUTION  Do not damage the fuel pump mounting stud pressed into the gear housing. Replacement of the gear housing can result if damaged.

Clean the rear gear housing with solvent.

Dry with compressed air.

Inspect the rear gear housing for signs of leakage or any other damage.

Replace the housing if damaged.

NOTE: This section applies to the non-REPTO rear gear housing option.

Make sure the fuel pump mounting stud is installed in the rear gear housing.

Install locating dowels into the cylinder block.

Position the rear gear housing gasket onto the locating dowel pins and install.

Install the rear gear housing onto the cylinder block.

NOTE: There are two dowels pressed through the gear housing to align the gear housing to the cylinder block.

Install and hand tighten the 11 shorter capscrews (1) into the rear gear housing and cylinder block. The shorter capscrews go into the holes above the center line of the crankshaft.

Install and snug the two longer capscrews (2) into the rear gear housing and cylinder block. The longer capscrews go into the holes near the cylinder block pan rail.

Tighten the mounting capscrews in the same pattern as illustrated.

Check for protrusion on each side of the rear gear housing relative to cylinder block pain rail.

If the protrusion of either side is out of limit, loosen the mounting capscrews. Tighten the mounting capscrews until it falls within limits.

After tightening the capscrews, if the gear housing protrusion is still out of specification, replace the gear housing

NOTE: This section applies to the REPTO rear gear housing option.

NOTE: The REPTO idler gear assembly must be installed to the rear gear housing before the rear gear housing is installed.

If removed, install the REPTO idler gear assembly to the rear gear housing by inserting the REPTO idler gear assembly under flange of the rear gear housing and into position. Refer to Procedure 001-093 in Section 1.

Make sure the fuel pump mounting stud is installed in the rear gear housing.

Install locating dowels into the cylinder block.

Position the rear gear housing gasket and gear housing onto the locating dowel pins and install.

Install the rear gear housing onto the cylinder block.

NOTE: There are two dowels pressed through the gear housing to align the gear housing to the cylinder block.

Install and hand tighten the eleven shorter capscrews (1) into the rear gear housing and cylinder block. The shorter capscrews go into the holes above the center line of the crankshaft.

Install and snug the two longer capscrews (2) into the rear gear housing and cylinder block. The longer capscrews go into the holes near the cylinder block pan rail.

Tighten the mounting capscrews in the same pattern as illustrated.

Check for protrusion on each side of the rear gear housing relative to cylinder block pan rail.

If protrusion of either side is out of range, loosen the mounting capscrews.

Tighten the mounting capscrews until it is within limit.

After tightening the capscrews, if it is still out of specification, replace the gear housing.

NOTE: This section applies to both non-REPTO and REPTO rear gear housing options.

Inspect the oil pan gasket for damage.

NOTE: The engine is equipped with a rubber oil pan gasket. If the gasket is found to be damaged, the oil pan must be removed and the entire oil pan gasket replaced. Refer to Procedure 007-025 in Section 7.

NOTE: The oil pan must be installed within 10 minutes of applying the sealant.

Clean the sealing surfaces.

Apply a bead of RTV sealant, Part Number 3164076, at the intersecting joint of the cylinder block, oil pan, and gear housing. There are two joints, one joint on either side of the crankshaft.

Loosely install the four oil pan mounting capscrews into the rear gear housing.

Tighten the oil pan mounting capscrews. Refer to Procedure 007-025 in Section 7.

WARNING  Support the rear of the engine using the rear support attached to the rear of the cylinder block. Failure to support the engine can cause personal injury.

WARNING  This component or assembly weighs greater than 23 kg [50 lb]. To reduce the possibility of serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

• Install the rear camshaft gear. Refer to Procedure 001-085 in Section 1.
• Install the rear idler gear. Refer to Procedure 001-115 in Section 1.
• Install the flywheel housing. Refer to Procedure 016-006 in Section 16.
• Install the flexplate, if applicable. Refer to Procedure 016-004 in Section 16.
• Install the flywheel, if applicable. Refer to Procedure 016-005 in Section 16.
• Install the transmission. Refer to the OEM service manual.
• Install the rear support brackets. Refer to Procedure 016-003 in Section 16.
• Remove the rear engine support.
• If equipped, install the rear power take-off. Refer to Procedure 009-022 in Section 9.
• Install the starting motor. Refer to Procedure 013-020 in Section 13.
• Install the fuel pump. Refer to Procedure 005-016 in Section 5.
• Connect the engine speed sensor. Refer to Procedure 019-363 in Section 19.
• Fill the lubricating oil system. Refer to Procedure 007-037 in Section 7.
• Connect the batteries. Refer to the OEM service manual.
• Operate the engine to operating temperature and check for leaks.