SERIES 60 SERVICE MANUAL
2. Install two guide studs, J 36107, to the gear case. See Figure 1-174.
1. Front Gear Case Cover
4. Locating Dowel (Round)
2. Front Engine Lift Bracket
5. Locating Dowel (Diamond)
3. Front Gear Case Housing
Figure 1-174
Gear Case Cover Guide Stud Location
All information subject to change without notice.
6SE483 0204 Copyright © 2002 DETROIT DIESEL CORPORATION
From Bulletin 8-60-02
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1.10
GEAR CASE COVER
3. Support the gear case cover with a suitable lifting device, using the front engine lift
bracket. See Figure 1-172.
4. Position the gear case cover on the guide studs and slide it forward. Index the two dowels
in the gear case. See Figure 1-174.
5. For Series 60 2002 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 60 2002 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:
1-220
From Bulletin 8-60-02
All information subject to change without notice.
6SE483 0204 Copyright © 2002 DETROIT DIESEL CORPORATION
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 1-175.
NOTE:
Bolts 21 and 22 are rear bolts on pre-1991 engines.
Figure 1-175
[b]
Gear Case Cover Bolt Torque Sequence (Front)
Torque bolts 1 through 16, 21, 22 (see note), to 58-73 N·m (43-54 lb·ft).
All information subject to change without notice.
6SE483 0204 Copyright © 2002 DETROIT DIESEL CORPORATION
From Bulletin 8-60-02
1-221
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 160-200 N·m (118-148 lb·ft). See Figure 1-175.
[e]
Bolts F1 through F5 are fan support bracket bolts. Install the fan support bracket and
torque bolts F1, F2 and F3 to 58-73 N·m (43-54 lb·ft). Torque bolts F4 and F5 to
160-200 N·m (118-148 lb·ft).
[f]
Install the six bolts on the intake (left) side of the engine around the air
compressor drive. Torque the bolts to 58-73 N·m (43-54 lb·ft), using the sequence.
See Figure 1-176.
Figure 1-176
[g]
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Air Compressor Drive Torque Sequence
Install the SRS to the gear case; refer to section 2.29.3.
From Bulletin 8-60-02
All information subject to change without notice.
6SE483 0204 Copyright © 2002 DETROIT DIESEL CORPORATION
SERIES 60 SERVICE MANUAL
[h]
Install the two rear mounted bolts (pre - 1991 engines only) bolts on the exhaust
(right) side of the engine. Torque the number 2 and 3 bolts to 58-73 N·m
(43-54 lb·ft) torque. See Figure 1-177.
Figure 1-177
Gear Case Cover Bolt Torque Sequence (Right Rear)
7. Install a new crankshaft front oil seal. Refer to section 1.8.7.
8. Install the accessory drive assembly to the gear case. Refer to section 1.28.5.
9. Install the vibration damper to the crankshaft. Refer to section 1.12.3.
10. Install the crankshaft pulley to the end of the crankshaft. Refer to section 1.13.3.
11. Install the water pump assembly. Refer to section 4.2.8 for gear case mounted.
Refer to section 4.3.7 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 30-38 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.
All information subject to change without notice.
6SE483 0204 Copyright © 2002 DETROIT DIESEL CORPORATION
From Bulletin 8-60-02
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1.10
GEAR CASE COVER
15. Install the camshaft drive gear access cover to the gear case cover. Torque the bolts to
30-38 N·m (22-28 lb·ft), using the tightening sequence. See Figure 1-178.
Figure 1-178
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 8.2.3. Install the alternator drive
belts. Refer to section 13.13.10.
18. Adjust the alternator and air conditioner compressor drive belts to the specifications.
Refer to section 13.13.10.
19. Install the engine oil pan. Refer to section 3.11.4. Fill the crankcase with recommended
lubricating oil. Refer to section 13.13.1.
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From Bulletin 8-60-02
All information subject to change without notice.
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SERIES 60 SERVICE MANUAL
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From Bulletin 8-60-02
1-223b
1.10
GEAR CASE COVER
1.10.4
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 1-181 and see Figure 1-182for installation on
Group B without accessory drive. See Figure 1-183 and see Figure 1-184for typical Group C
installations. See Figure 1-185 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 1-4.
2. 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
Required Torque
M6 x 1.0
13-16 N·m (10-12 lb·ft)
M8 x 1.25
30-38 N·m (22-28 lb·ft)
M10 x 1.5
58-73 N·m (43-54 lb·ft)
Table 1-4
Acoustical Cover Fastener Torque Values
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From Bulletin 8-60-02
All information subject to change without notice.
6SE483 0204 Copyright © 2002 DETROIT DIESEL CORPORATION