Media Search - REHS4838 - Replacing the Gaskets on the Flywheel Housing and Coupling Housing on 797 and 797B

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Special Instruction

Replacing the Gaskets on the Flywheel Housing and Coupling Housing on 797 and 797B Off-Highway
Truck Engines{1157, 3279, 7555}
Media Number -REHS4838-03

Publication Date -28/08/2012

Date Updated -28/08/2012

i05036290

Replacing the Gaskets on the Flywheel Housing and Coupling

Housing on 797 and 797B Off-Highway Truck Engines{1157,
3279, 7555}
SMCS - 1157; 3279; 7555

Off-Highway Truck:
797 (S/N: 5YW1-UP)
797B (S/N: JSM1-UP)

Introduction
Do not perform any procedure that is outlined in this Special Instruction and do not order any parts until
the entire instruction has been read and understood.
This Special Instruction describes the rework procedure for adding a gasket to the joint between the
cylinder block and gear housing.
The procedure requires that some of the bolts in the housing be retightened after at least five hours of
operation. To retighten the bolts without removal of the cam drive gears, gears with larger holes for
accessing the bolts are needed. Due to the heat treatment of the cam gears, the original gears cannot
be modified. Refer to Table 2 for the part numbers and description of these new gears.
The original timing ring can be modified for use. Drill four oversized holes as shown in Illustration 1.

References
Disassembly and Assembly, RENR2276, "Flywheel Housing - Remove"
Disassembly and Assembly, RENR2276, "Flywheel Housing - Install"
Disassembly and Assembly, RENR2276, "Engines - Separate"
Disassembly and Assembly, RENR2276, "Engines - Connect"
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Media Search - REHS4838 - Replacing the Gaskets on the Flywheel Housing and Coupling Housing on 797 and 797B Off-Highway Truck Engines{...

Required Parts
Table 1
Part Number

Part Description

309-4550

Gasket

8T-9013

Silicone Sealant
Table 2

New Part Number

Former Part Number

362-2834

156-9744

Camshaft Gear

362-3278

127-2342

Camshaft Drive Gear

362-2835

7E-5324

Ring

Illustration 1

Part Description

g02221713

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Media Search - REHS4838 - Replacing the Gaskets on the Flywheel Housing and Coupling Housing on 797 and 797B Off-Highway Truck Engines{...

(1) Diameter 48 + 0.50 - 0.00 mm (1.890 + 0.020 - 0.00 inch)

(A) Location 40.7 mm (1.60 inch)
(B) Location 70.6 mm (2.78 inch)
(2) Diameter 44.5 + 0.50 - 0.00 mm (1.75 + 0.020 - 0.00 inch)
(C) Location Datum
(D) Location 70.4 mm (2.77 inch)

Procedure
Disassembly
1. Separate the engines and remove the coupling housing.
ReferenceDisassembly and Assembly, RENR2276, "Engines - Separate"
2. Remove the rear flywheel housing.
ReferenceDisassembly and Assembly, RENR2276, "Flywheel Housing - Remove"
3. If the housing will be reused, 0.7 mm (0.028 inch) must be removed from the surface of the
housing which faces the engine. The flatness of the housing surface must be 0.1 mm (0.004 inch)
with a surface finish of 3.2 um (125 micro inches). Mark any housing that is reworked with the
appropriate part number. Refer to Table 3 for the proper thickness of the housing and the new
part numbers that will replace the current part numbers of the housings.
Table 3
Housings Thickness After
Machining
219.3 mm (8.63 inch)
169.3 mm (6.67 inch)
234.3 mm (9.22 inch)

New Part Number for

Housings

Former Part
Number

Part
Description

345-0592

188-4700

Flywheel
Housing

345-0594

166-5073

Housing

345-0597

136-3242

Housing

4. Remove all sealant from the engine block.

5. Clean the threads in the engine block with the appropriate sized thread tap in order to remove any
residual sealant that was left in the bolt holes.
Note: Any gasket sealant that remains in the bolt holes could cause false torque readings.
6. Inspect the joint between the engine block and the flywheel housing for fretting.
7. Discard all the used bolts.
Repeat Steps 2 through 7 for the 188-4700 Flywheel Housing that is attached to the front engine and
the 166-5073 Housing that couples the engines.
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Media Search - REHS4838 - Replacing the Gaskets on the Flywheel Housing and Coupling Housing on 797 and 797B Off-Highway Truck Engines{...

Assembly
During assembly, the left-hand cam gear must be oriented so that the elongated holes in the gear web
align with the offset and oversized holes in the timing ring. This allows the housing bolts to be
retightened through the holes in the gear and timing ring. Note two of the holes in the gear are
elongated towards the outside of the gear. The other two are elongated towards the center of the gear,
corresponding to the offset holes in the timing ring. Refer to Illustration 2.

Illustration 2

g02225694

Left side view of cam gear and timing wheel assembly 362-2836

1. Remove any perforated sections of the gasket.

2. Apply some 8T-9013 Silicone Sealant to the surface of the engine block at the location of the
puzzle piece joints and on the side of the gasket which faces the housing. Use the gasket sealant
sparingly in order to retain the gasket against the engine block.
3. Position the gasket on the engine block face.
4. Install the flywheel housing.
ReferenceDisassembly and Assembly, RENR2276, "Flywheel Housing - Install"

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Media Search - REHS4838 - Replacing the Gaskets on the Flywheel Housing and Coupling Housing on 797 and 797B Off-Highway Truck Engines{...

Illustration 3

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Flywheel housing
Typical example
(1) 1/2 inch bolts
(2) 5/8 inch bolts

Note: Use the following reduced torque, only if the bolts are tightened with a DC electric tool.
5. Torque the flywheel housing bolts.
Tighten the 1/2 inch bolts for the flywheel housing (1) to the following torque: ... 120 20 Nm
(89 15 lb ft)
Tighten the 5/8 inch bolts for the flywheel housing (2) to the following torque. ... 240 40 Nm
(177 30 lb ft)
Note: Use the following torque if a torque wrench is used.
Tighten the 1/2 inch bolts for the flywheel housing (1) to the following torque: ... 135 20 Nm
(100 15 lb ft)
Tighten the 5/8 inch bolts for the flywheel housing (2) to the following torque. ... 270 40 Nm
(199 29 lb ft)

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Media Search - REHS4838 - Replacing the Gaskets on the Flywheel Housing and Coupling Housing on 797 and 797B Off-Highway Truck Engines{...

Illustration 4

g01975965

(3) T-joint

6. Trim the bottom of the gasket even with the block and the housing.
7. Apply gasket sealant along the T-joint intersection and on both sides of the end of the gasket.
8. Install the engine oil pan.
9. Install the coupling housing and connect the engines.
ReferenceDisassembly and Assembly, RENR2276, "Engines - Connect"
Repeat Steps 1 through 9 for the 188-4700 Flywheel Housing that is attached to the front engine.
Repeat Steps 1 through 3, and Steps 5 and 9 for the 166-5073 Housing that couples the engines:

Retighten Bolts After at least Five hours of Engine Operation

The housing gasket will naturally compress due to heat and vibration of the running engine. This results
in reduced bolt stretch and reduced clamp load in the housing to block joints. This lost bolt stretch can
be recovered and maintained by retightening the housing bolts.
Following a 5 hour or longer dyno test of the engine package (front and rear engines coupled), retighten
the bolts shown in Illustration 5. This does not require removal of the flywheel. The master ECM
mounting bracket on the rear engine must be unbolted and moved to provide clearance to tighten the
housing bolts. Torque the specified bolts to same torque used in Step 5.
Refer to Illustration 5, A typical view of rear and front flywheel housing bolts. Bolt 11 is the first 1/2 inch
bolt on the lower top left corner. Bolt 24 is last 1/2 inch bolt on the lower top right corner. Only
retighten bolt 11 through 24 of the flywheel housing. Bolt numbers increase going clockwise.
Bolts 12,13,14 and 21,22,23 on the rear housings can be retightened without removal of the cam gear.
The engine crankshaft must be rotated so that the elongated hole in the cam gear and timing ring aligns
with the housing bolt to be tightened. Refer to Illustration 5 and 6.

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Media Search - REHS4838 - Replacing the Gaskets on the Flywheel Housing and Coupling Housing on 797 and 797B Off-Highway Truck Engines{...

Illustration 5

g02221578

Typical view of rear housing bolts

(1) 1/2 inch bolts to retorque

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Media Search - REHS4838 - Replacing the Gaskets on the Flywheel Housing and Coupling Housing on 797 and 797B Off-Highway Truck Engines{...

Illustration 6

g02327234

Typical view of front housing bolts

Note: If the engine is new, remanufactured, or was dyno tested less than 5 hours retighten bolts at
first 250 hour valve adjustment.
Note: Retightening of the bolts is only required once after new gasket installation.
Copyright 1993 - 2015 Caterpillar Inc.
All Rights Reserved.

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