Solution Number: 72897
Solution Summary: 8.1L CNG Flywheel Assembly on 1502 ZF Transmission Option

Publication Date: Sep 28 2011

** Paper copies of solutions may not be the most current solutions**
Complaint or Symptom ;
Assembling ZF Transmission option 1502 flywheel hardware with latest hardware and assembly techniques.
Problem or Situation :
Numerous improvements to the design and assembly have been implemented in the ZF Transmission option 1502 Pe
Flywheel group. Instructions given in Component Technical Manual (CTM87) are out of date. Parts listed in Parts
Catalog (PC2502) are not accurately reflected. Finally, the assembly procedures have changed.
Solution :
Please follow the steps as listed below:

e Isstie a DTAC case documenting the unit that is in need of repair.

e Order supporting hardware as needed according to listing below.

« Always follow the safety cautions and special handling requirements according to the CTM87. Please pay special
attention to proper cleaning of parts and use of compressed air.

e Always use new parts when repairing an engine. Do NOT re-use washers, capscrews, or any other part that nay
have been damaged during operation and/or failure.

e Clean and inspect six crankshaft holes. Holes are through holes into oil pan and beyond oil seal, so extra care
should be taken as to not allow debris or solution to enter engine oil supply.

e Apply appropriate LOCTITE primer (7649) or equivalent to prep holes for application of LOCTITE coated screws
later in assembly process.

e IMPORTANT: All parts must be clean and free of oil before installing. Using a clean towel and solvent, wipe all
mating parts clean before assembly.

° Install dowel.

e Wi pe the crankshaft hub area to remove all contaminants.

° Two clean guide pins in a horizontal position opposite of one another may be used for centering of parts.

e Install inner flywheel diamond plate washer over the guide pins and to the crankshaft hub.

e Using a clean towel and solvent, wipe the flywheel crankshaft hub area mating surface to remove all contaminants.

e Install flywheel over the guide pins and dowel.

18/2014
Using a clean towel and solvent, wipe the mating flywheel hub area surface to remove all contaminants.

e Install outer flywheel diamond plate washer over the guide pins and to the flywheel hub.

°@

Install four clean flexplates.
e Install retainer plate.

e Werify the alignment of the flexplates and retainer plate in regards to the open flywheel and crankshaft holes.
Ensure that the outer flex plate torque converter bolt holes are aligned with the outer flywheel access holes.

« Remove guide pins.

¢ Install and lightly tighten all six capscrews.

¢ Remove one capscrew and apply LOCTITE 242 or equivalent threadlocking solution.
e Install coated capscrew along with washer.

e Toraue coated capscrew to new torque value of 40NM plus 60°.

e Repeat above steps until all six capscrews are secured and torqued to specified value. Complete one capscrew
assembly at a time with its proper torque procedure before moving to next capscrew.

e Use paint marker on the head of flywheel capscrews after they have been tightened to torque.

e Assemble remaining transmission and drive train components according to their normal assembly procedures.
The following hardware will be needed for repair:

| - RES09354 Flywheel

e | - R41934 Dowel

6 - R93238 Capscrew (marked *180ABN” on head of screw)

e ***] ~R524669 Retainer Plate

e ***) ~ R524748 Diamond Plate Washers

e ***4 ~ R524737 Flexplate w/o phosphate coating

e LOCTITE 242 Thread Lock and Sealer (Medium Strength) or its equivalent.

*** = New hardware may need to be supplied directly from the factory or DTAC representative. Filing DTAC case
will help aid in documenting needs and facilitate supply of hardware direct from the factory.

Additional Information :

8/8/2014

[RANSMISSION, RG, BROKEN, HARDWARE. FLYWHEEL, NG, CTM87, POWERTECH, CRANKSHAFT,
HOUSING, FAIL, ENG, F0433