2. Install two guide studs, J 36107, to the gear case. See Figure

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1 SERIES 60 SERVICE MANUAL 2. Install two guide studs, J 36107, to the gear case. See Figure Front Gear Case Cover 4. Locating Dowel (Round) 2. Front Engine Lift Bracket 5. Locating Dowel (Diamond) 3. Front Gear Case Housing Figure Gear Case Cover Guide Stud Location 6SE Copyright 2002 DETROIT DIESEL CORPORATION From Bulletin

2 1.10 GEAR CASE COVER 3. Support the gear case cover with a suitable lifting device, using the front engine lift bracket. See Figure Position the gear case cover on the guide studs and slide it forward. Index the two dowels in the gear case. See Figure For Series Engines there are 21 bolts that secure gear case cover to to gear case. Torque bolts No.1 through 19 to 65 N m (48 lb ft). Torque bolts 20 and 21 to 113 N m (83 lb ft). See Figure 1-174a Figure 1-174a Gear Case Cover Bolt Torque Sequence Series Engine 6. There are 34 bolts that secure the gear case cover to the gear case (including five for the fan support bracket). Install them as follows: From Bulletin SE Copyright 2002 DETROIT DIESEL CORPORATION

3 SERIES 60 SERVICE MANUAL NOTICE: With gasketless parts such as the gear case cover; the torque values and tightening sequences are critical to prevent parts warpage. [a] Install the shorter bolts, No. 1 through 16, 21, 22 (see note), in various locations at the front of the gear case cover. Finger-tighten them. Remove the guide studs when installing bolts 7 and 14. See Figure NOTE: Bolts 21 and 22 are rear bolts on pre-1991 engines. Figure Gear Case Cover Bolt Torque Sequence (Front) [b] Torque bolts 1 through 16, 21, 22 (see note), to N m (43-54 lb ft). 6SE Copyright 2002 DETROIT DIESEL CORPORATION From Bulletin

4 1.10 GEAR CASE COVER [c] Install the front engine mount to the gear case cover. Install the four, longer, front engine mount-to-gear case cover bolts, finger-tight. [d] Torque bolts 17, 18, 19 and 20 to N m ( lb ft). See Figure [e] Bolts F1 through F5 are fan support bracket bolts. Install the fan support bracket and torque bolts F1, F2 and F3 to N m (43-54 lb ft). Torque bolts F4 and F5 to N m ( lb ft). [f] Install the six bolts on the intake (left) side of the engine around the air compressor drive. Torque the bolts to N m (43-54 lb ft), using the sequence. See Figure Figure Air Compressor Drive Torque Sequence [g] Install the SRS to the gear case; refer to section From Bulletin SE Copyright 2002 DETROIT DIESEL CORPORATION

5 SERIES 60 SERVICE MANUAL [h] Install the two rear mounted bolts (pre engines only) bolts on the exhaust (right) side of the engine. Torque the number 2 and 3 bolts to N m (43-54 lb ft) torque. See Figure Figure Gear Case Cover Bolt Torque Sequence (Right Rear) 7. Install a new crankshaft front oil seal. Refer to section Install the accessory drive assembly to the gear case. Refer to section Install the vibration damper to the crankshaft. Refer to section Install the crankshaft pulley to the end of the crankshaft. Refer to section Install the water pump assembly. Refer to section for gear case mounted. Refer to section for front mounted. 12. Install a new gasket between the power steering pump cover and the gear case (if so equipped). 13. Install the power steering pump cover to the gear case cover with the six bolts. Tighten the bolts progressively in a star-shaped pattern to draw the power steering pump in evenly. Torque the bolts to N m (22-28 lb ft), using a star-shaped pattern. 14. Insert a new gasket between the camshaft drive gear access cover and the gear case cover. 6SE Copyright 2002 DETROIT DIESEL CORPORATION From Bulletin

6 1.10 GEAR CASE COVER 15. Install the camshaft drive gear access cover to the gear case cover. Torque the bolts to N m (22-28 lb ft), using the tightening sequence. See Figure Figure Access Cover Bolt Torque Sequences 16. Install the air conditioner compressor and brackets. Install the air conditioner compressor drive belt. Refer to OEM guidelines. 17. Install the alternator and brackets. Refer to section Install the alternator drive belts. Refer to section Adjust the alternator and air conditioner compressor drive belts to the specifications. Refer to section Install the engine oil pan. Refer to section Fill the crankcase with recommended lubricating oil. Refer to section a From Bulletin SE Copyright 2002 DETROIT DIESEL CORPORATION

7 SERIES 60 SERVICE MANUAL This page intentionally left blank. 6SE Copyright 2002 DETROIT DIESEL CORPORATION From Bulletin b

8 1.10 GEAR CASE COVER Installation of Acoustical Gear Case Covers Install acoustical covers as outlined below. See Figure 1-179, and see Figure 1-180, for Group A installations with accessory drive. See Figure and see Figure 1-182for installation on Group B without accessory drive. See Figure and see Figure 1-184for typical Group C installations. See Figure and see Figure 1-186for Group D installations. 1. Using required fasteners, install front gear case acoustical cover and accessory drive acoustical cover. Tighten bolts and nut(s) to the torque values: listed in Table Using required fasteners and clips, install right rear and left rear covers. Tighten bolts and nut(s) to the torque values listed in Table 1-4. Bolt or Nut Size M6 x 1.0 M8 x 1.25 M10 x 1.5 Required Torque N m (10-12 lb ft) N m (22-28 lb ft) N m (43-54 lb ft) Table 1-4 Acoustical Cover Fastener Torque Values From Bulletin SE Copyright 2002 DETROIT DIESEL CORPORATION