REMOVING THE CRANKSHAFT ASSEMBLY

1. Pilot Bearing Removal

Before removing the crankshaft from the engine, remove the clutch pilot bearing and the flywheel from the crankshaft. The pilot bearing is removed at this time because it has to be removed with a slide hammer puller, and the block provides a rigid base.

Clutch pilot bearing puller.

The puller is inserted into the hole located in the center of the pilot bearing and spread to form a firm fit inside the bearing using the thumbscrew. When a firm fit is obtained, slide the

slide hammer to the rear with force until the bearing is forced completely out of the crankshaft.

Removing the clutch pilot bearing.

2. Flywheel Test

On vehicles equipped with a standard transmission, perform a runout test before removing the flywheel. A warped flywheel will cause the clutch to engage unevenly and the clutch pedal will "bounce." Figure 4-13 illustrates the use of a dial indicator with a "C" clamp. Again, the dial is set at zero and the flywheel is turned one complete rotation. Note that the plunger is placed near the friction surface edge. Record the highest reading. If the runout is excessive according to the TM, the flywheel must be replaced, or if facilities are available, you may grind it.

Measuring flywheel runout.

3. Flywheel Removal

Now, remove the flywheel. Remove the bolts or nuts from the area around the center of the flywheel and carefully lift the flywheel from the crankshaft. Be careful so that you DO NOT drop the flywheel. This may cause damage to the ring gear. When the flywheel is removed, check the ring gear for chipped or missing teeth. If these conditions exist, the ring gear must be replaced, either by installing a new ring gear on the flywheel or by replacing the entire flywheel. With the flywheel removed, perform the crankshaft end play test.

4. Crankshaft End Play

The crankshaft end play test is done by placing the dial indicator at either end of the engine block. Use the end which is most convenient. Attach the dial indicator on the engine block and place the dial indicator plunger on the crankshaft as in figure below. Reset the dial indicator to zero. Pry the crankshaft in the direction of the dial indicator by placing a pry bar between the crankshaft journal and a main bearing cap. Record the reading. If the reading is greater than the TM allows, the crankshaft thrust bearing will have to be replaced

during the repair phase. Now that all necessary checks have been made, you are ready to remove the crankshaft. During removal, remember there are many bearings and bearing surfaces. Extreme care must be exercised so that you DO NOT "nick" or scratch any bearing surfaces or drop any of these components.

Checking crankshaft end play.

5. Removing the Crankshaft

First, loosen ALL bearing cap retaining bolts and leave them in place. Next remove each main bearing cap and identify it by marking its bearing number on the side. Be sure to mark the same side of ALL bearing caps and bearings. This will help ensure that the bearings are reinstalled in their proper place and position when the engine is reassembled. Place the bearing caps in order on the workbench with the bearing and bolts installed. Lift the crankshaft out of the crankcase very carefully and stand it on end, or hang it in a rack.

Caution: If you lean the crankshaft against another object in an upright position, IT

WILL WARP.