Media Search - SEPD1213 - 2010/12/06

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Service Magazine
2010/12/06

Media Number -SEPD1213-00

Publication Date -06/12/2010

Date Updated -06/12/2010

i04157609

A New Gasket, New Front Housings, Rear Housings, Camshaft

Gears, and Timing Rings Are Used on Engines for 797 OffHighway Trucks {1151, 1157, 1162, 1206, 7555}
SMCS - 1151; 1157; 1162; 1206; 7555

Off-Highway Truck/Tractor:
797 (S/N: 5YW1-UP)
797B (S/N: JSM1-UP)
Service Magazine SEPD1209, 29 November 2010, "A New Gasket, New Front Housings, Rear Housings,
Camshaft Gears, and Timing Rings Are Used on Engines for 797 Off-Highway Trucks". The article has
been revised to increase the interval for retightening the housing bolts.
Description of Change: The new gasket, which is used on both ends of the engine, provides a better
seal between the cylinder block and the housings. To accommodate the thickness of the gasket, material
was removed from the inner surfaces of the new housings.
The new camshaft gears and the new timing ring have larger holes in order to provide access to
housing bolts. The housing bolts can be accessed when the covers are off the flywheel housing. For
access to the bolts, the gears must be oriented correctly.
Adaptable To:
Reference Special Instruction, REHS4838, "Replacing the Gaskets on the Flywheel Housing and
Coupling Housing on 797 and 797B Off-Highway Truck/Tractors"
The new 309-4550 Gasket is used in the joints between the cylinder block and the front and rear
housings. The gasket can be used on both ends of both engines (four locations).
If the original housings will be used with the new gasket, material must be removed from the sealing
surfaces of the housings.
The front housing on the front engine is already compatible with the new gasket. For that reason, no
change is needed to the front housing on the front engine.
To accommodate the thickness of the gasket, 0.7000 mm (0.02756 inch) of material was removed from
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Media Search - SEPD1213 - 2010/12/06

the sealing faces of the other three housings. The former housings were canceled and replaced by the
new housings. Refer to Table 1.
Use the 309-4550 Gasket with the new housings. Do not use the 309-4550 Gasket with the former
housings because of interference.
The former housings can be reworked into the new housings by following the procedure in Special
Instruction, REHS4838, "Replacing the Gaskets on the Flywheel Housing and Coupling Housing on 797
and 797B Off-Highway Truck/Tractors". If a housing is reworked, make sure that the housing is
identified with the new part number.
After 250 hours of engine operation with the new gasket, retighten some of the housing
bolts. The bolts are retightened in order to eliminate leaks due to relaxation of the gasket.
Refer to Special Instruction, REHS4838 for identification of the bolts.
Note: The bare housings are serviced on the front engine. The housings for the rear engine are
serviced as assemblies.The new housings and the former housings are identified in Table 1.
The new gears and timing ring along with the former gears and timing ring are identified in Table 2.
The change for all of the new parts is effective with serial numbers 5YW00278 and with JSM00489.
Table 1
Location
Front engine
Front housing
Front engine
Flywheel housing

Rear engine
Front housing
(Coupling)

Rear engine
Flywheel housing

New Part

Former Part

345-0591 Front Housing Gp

146-7335 Front Housing Gp

102-8634 Accessory Drive Housing (serviced)

345-0593 Flywheel Housing Gp

136-3225 Flywheel Housing Gp

345-0592 Flywheel Housing (serviced)

188-4700 Flywheel Housing

345-0596 Front Housing Gp

166-5074 Front Housing Gp

345-0595 Housing As (serviced)

166-5072 Housing As

345-0594 Front Drive Housing

166-5073 Housing

345-0599 Flywheel Housing Gp

136-3240 Flywheel Housing Gp

345-0598 Flywheel Housing Assembly

(serviced)

136-3241 Flywheel Housing

Assembly

345-0597 Flywheel Housing

136-3242 Housing

Table 2
New Part

Former Part

362-2834 Camshaft Drive Gear

175-5201 Camshaft Gear

362-2835 Ring

7E-5324 Ring

362-3278 Camshaft Drive Gear

156-9744 Camshaft Drive Gear

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