Cummins ISX11.9 CM2250 – Service Manual 001-093   Rear PTO Idler Gear

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  To reduce the possibility of personal injury, avoid direct contact of hot oil with your skin.

WARNING  Some state and federal agencies have determined that used engine oil can be carcinogenic and cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged contact with used engine oil. If not reused, dispose of in accordance with local environmental regulations.

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. 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 the OEM service manual.
• 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.
• Remove the gear housing. Refer to Procedure 001-034 in Section 1.

NOTE: The rear engine power take-off (REPTO) idler gear must be removed with the rear gear housing as an assembly. Once the rear gear housing has been removed, the REPTO idler gear can be removed from the gear housing.

Remove the REPTO idler gear as an assembly. Leave the snap ring on the shaft and remove the capscrew.

Disassemble the idler gear assembly. The components are listed below.

1. Inner thrust bearing
2. Idler gear
3. Outer thrust bearing
4. Inner snap ring
5. Idler gear shaft
6. Outer snap ring
7. Capscrew.

Mark or tag the individual pieces of the idler gear assembly and attach them together.

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.

Clean the parts with solvent.

Dry with compressed air.

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

Use a bristle brush to clean the oil drillings in the idler gear shaft.

Blow out the oil drillings with compressed air.

Use a straightedge to inspect the retaining capscrews for necking. If necking is observed, do not reuse the capscrews. The capscrews must be replaced.

Inspect the idler gear for chipped, broken, or cracked teeth.

Replace the idler gear if damage is found.

Measure the inside diameter of the idler gear bushing bore.

Camshaft Idler Gear Bushing Bore Inside Diameter

Measure the outside diameter of the idler gear shaft.

Camshaft Idler Gear Shaft Outside Diameter

Measure the outside diameter of the REPTO idler shaft dowel rod.

REPTO Idler Ring Dowel Outside Diameter

Measure the thrust washer thickness in three places 120-degrees apart.

Camshaft Idler Thrust Washer Thickness

Flex the thrust washers approximately 3 to 6 mm [1/8 to 1/4 in] and inspect the surfaces for cracks.

NOTE: The idler gear and shaft must be installed onto the gear housing as an assembly.

• Install the inner snap ring into the groove on the rear of the idler shaft.
• Install the inner thrust bearing on to the idler shaft with the larger thrust face facing the gear.
• Lubricate the inner diameter of the idler gear with Lubriplate™ 105, or equivalent.
• Install the idler gear over the shaft.
• Install the outer thrust bearing on to the idler shaft with a larger thrust face facing the gear.
• Install the outer snap ring into the groove on the front of the idler shaft.

• Install the idler gear assembly on to the gear housing. Align the idler shaft ring dowel with the oil feed hole in the gear housing.
• Install the capscrew through the shaft and into the gear housing.

Tighten the capscrew.

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 gear housing. Refer to Procedure 001-034 in Section 1.
• Install the rear camshaft gear. Refer to Procedure 001-085 in Section 1.
• Install the rear camshaft idler gear. Refer to Procedure 001-115 in Section 1.
• Install the flywheel housing. Refer to Procedure 016-006 in Section 16.
• If equipped, install the flexplate. Refer to Procedure 016-004 in Section 16.
• If equipped, install the flywheel. 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 the OEM service manual.
• 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 normal operating temperature and check for leaks and proper operation.