REAR ENGINE

POWER TAKE-OFF

(REPTO)
SERVICE MANUAL
APRIL 2000
FOR MACK E7 AND E-TECH ™ ENGINES 5-901
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-ii
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Please complete and mail this form or FAX
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Thank You For Your Assistance

Mack Trucks, Inc.
(ATTENTION: RTS STAFF, 6S3)

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 REAR ENGINE
POWER TAKE-OFF
(REPTO)
SERVICE MANUAL
FOR MACK E7 AND E-TECH™ ENGINES

APRIL 2000 © MACK TRUCKS, INC. 2000

(REVISED – SUPERSEDES ISSUE DATED OCTOBER 1994) 5-901
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ATTENTION
The information in this manual is not all inclusive and
cannot take into account all unique situations. Note that
some illustrations are typical and may not reflect the
exact arrangement of every component installed on a
specific chassis.
The information, specifications, and illustrations in this
publication are based on information that was current at
the time of publication.
No part of this publication may be reproduced, stored in a
retrieval system, or be transmitted in any form by any
means including electronic, mechanical, photocopying,
recording, or otherwise without prior written permission
of Mack Trucks, Inc.

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TABLE OF CONTENTS

TABLE OF CONTENTS

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TABLE OF CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vi
Advisory Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vi
Service Procedures and Tool Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
EXPLANATION OF NUMERICAL CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
MACK REAR ENGINE POWER TAKE-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pressure Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REPTO Unit Oil Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
MAJOR COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DISASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Before Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
BENCH PROCEDURES AND COMPONENT REBUILD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Idler Gear Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Idler Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Crankshaft Seal Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Dowel Pin Located in Drive Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Output Shaft/Bearing Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSPECTION OF PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Inspection and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Oil Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
REASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
General Reassembly Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Reassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
After REPTO Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
FITS AND LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Output Shaft Bearing End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Idler Shaft Bearing Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Crankshaft Seal Installation Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
ASSEMBLY LUBRICANT AND SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Assembly Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Assembly Sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
REPTO FEATURES AND CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
SPECIAL TOOLS & EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Special Tools for REPTO Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
INDEX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

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INTRODUCTION

INTRODUCTION

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INTRODUCTION
SAFETY INFORMATION
Advisory Labels
Cautionary signal words (Danger-Warning-Caution) may appear in various locations throughout this
manual. Information accented by one of these signal words must be observed to minimize the risk of per-
sonal injury to service personnel, or the possibility of improper service methods which may damage the
vehicle or cause it to be unsafe. Additional Notes and Service Hints are used to emphasize areas of pro-
cedural importance and provide suggestions for ease of repair. The following definitions indicate the use
of these advisory labels as they appear throughout the manual:

Activities associated with Danger indicate that death or serious personal

injury may result from failing to heed the advisory. Serious personal injury
may be equated to career-ending injury.

Activities associated with Warning indicate that personal injury may result
from failing to heed the advisory. In this case, personal injury is not equated to
career-ending injury, but results in possible change in quality of life.

Activities associated with Caution indicate that product damage may result from fail-
ing to heed the advisory. Caution is not used for personal injury.

A procedure, practice, or condition that is essential to emphasize.

A helpful suggestion that will make it quicker and/or easier to perform a procedure,
while possibly reducing service cost.

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INTRODUCTION
Service Procedures and Tool Usage
Anyone using a service procedure or tool not recommended in this manual must first satisfy himself
thoroughly that neither his safety nor vehicle safety will be jeopardized by the service method he selects.
Individuals deviating in any manner from the instructions provided assume all risks of consequential
personal injury or damage to equipment involved.

Also note that particular service procedures may require the use of a special tool(s) designed for a
specific purpose. These special tools must be used in the manner described, whenever specified in the
instructions.

1. Before starting a vehicle, always be seated in the driver’s seat, place the
transmission in neutral, be sure that parking brakes are set, and disengage
the clutch (if equipped).

2. Before working on a vehicle, place the transmission in neutral, set the

parking brakes, and block the wheels.

3. Before towing the vehicle, place the transmission in neutral and lift the rear
wheels off the ground, or disconnect the driveline to avoid damage to the
transmission during towing.

Engine driven components such as Power Take-Off (PTO) units, fans and fan
belts, driveshafts and other related rotating assemblies, can be very danger-
ous. Do not work on or service engine driven components unless the engine is
shut down. Always keep body parts and loose clothing out of range of these
powerful components to prevent serious personal injury. Be aware of PTO
engagement or nonengagement status. Always disengage the PTO when not
in use.

REMEMBER,
SAFETY . . . IS NO ACCIDENT!

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INTRODUCTION
Mack Trucks, Inc. cannot anticipate every r Use hoists or jacks to lift or move heavy
possible occurrence that may involve a potential objects.
hazard. Accidents can be avoided by recognizing
r NEVER run engine indoors unless exhaust
potentially hazardous situations and taking
fumes are adequately vented to the outside.
necessary precautions. Performing service
procedures correctly is critical to technician safety r Be aware of hot surfaces. Allow engine to
and safe, reliable vehicle operation. cool sufficiently before performing any
service or tests in the vicinity of the engine.
The following list of general shop safety practices
r Keep work area clean and orderly. Clean up
can help technicians avoid potentially hazardous
any spilled oil, grease, fuel, hydraulic fluid,
situations and reduce the risk of personal injury.
etc.
DO NOT perform any services, maintenance
procedures or lubrications until this manual has r Only use tools that are in good condition,
been read and understood. and always use accurately calibrated torque
wrenches to tighten all fasteners to specified
r Perform all service work on a flat, level
torques. In instances where procedures
surface. Block wheels to prevent vehicle
require the use of special tools which are
from rolling.
designed for a specific purpose, use only in
r DO NOT wear loose-fitting or torn clothing. the manner described in the instructions.
Remove any jewelry before servicing
vehicle.
r ALWAYS wear safety glasses and protective
shoes. Avoid injury by being aware of sharp
corners and jagged edges.

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INTRODUCTION
EXPLANATION OF NUMERICAL
CODE
The organization of MACK service manuals has
been upgraded to standardize manual content
according to a reference system based on
component identification. The new reference
system will help link the information contained in
this publication with related information included
in other MACK service/warranty publications,
such as associated service bulletins, warranty
manuals, and MACK Service Labor Time
Standards.
The system is based on a numerical code, the
first digit of which identifies the general
component grouping as listed here:
GROUP 000 — GENERAL DATA
GROUP 100 — CHASSIS
GROUP 200 — ENGINE
GROUP 300 — CLUTCH, TRANSMISSION,
TRANSFER CASE AND PTO
Example:
Numerical Code
GROUP 400 — STEERING, AXLES, WHEELS
AND TIRES, DRIVELINE
GROUP 500 — BRAKES, AUXILIARY SYSTEMS
GROUP 600 — CAB, TRUCK BODY
GROUP 700 — ELECTRICAL
The second two digits of the three-digit code are
used to identify the system, assembly or
subassembly, as appropriate, within each of the
groupings. The codes applicable to this
publication may be shown at the beginning of
each procedure or section heading, as
necessary, to guide you to specific component
information.
Additionally, a two-character alpha code (i.e., [PJ]
PTO ASSEMBLY, REAR ENGINE) may be
referenced with each procedure. This alpha code,
in combination with the three-digit group number,
identifies the specific assembly, subassembly or
part, and directly relates to the first five positions
of the operation code listed in MACK Service
Labor Time Standards.
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NOTES

x
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DESCRIPTION AND OPERATION

DESCRIPTION AND OPERATION

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DESCRIPTION AND OPERATION

MACK REAR ENGINE POWER TAKE-OFF
1

Figure 1 — Rear Engine Power Take-Off (REPTO) Cutaway View

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DESCRIPTION AND OPERATION
Description
The MACK Rear Engine Power Take-Off
(REPTO) is intended for use with the MACK E7
and E-Tech™ series engines. The REPTO
provides live continuous power output that
operates at 123% of engine speed. The
continuous power output feature provides
efficient mechanical drive for hydraulic pumps
that propel mixer barrels on MACK RD and DM
construction chassis.
The REPTO unit mounts at the rear of the engine
block and uses an integral housing that replaces
the conventional flywheel housing.
Figure 2 — MACK RD600
The REPTO drive gear is mounted between the
end of the engine crankshaft and flywheel.
Powerflow is from the drive gear through the idler
input/idler output gear assembly to the output
shaft gear. A drive flange or yoke is mounted on
the REPTO output shaft that provides power to
driven equipment.
Durable tapered roller bearings are used to
maintain correct gear and shaft position and are
located at both the idler gear and output shafts.
The REPTO unit allows a powertrain package
that is short, low-weight and easily serviced. It
also eliminates the need for a special
transmission input pinion, thereby providing
additional cost savings in parts and service.
2
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DESCRIPTION AND OPERATION

Pressure Lubrication 3

The REPTO unit is pressure lubricated with

pressure created by the engine oil pump.
Lubricant lines are piped from the engine oil filter
adapter to the REPTO unit to deliver the
pressurized engine oil. The unpressurized return
oil from the REPTO unit drains into and shares
the engine oil sump. This is accomplished by
mounting the REPTO drive gear to the rear of the
engine crankshaft and moving the crankshaft rear
oil seal to the rear of the drive gear.

Approximately one quart of engine oil must be

added to the normal engine oil sump capacity to
provide adequate lubrication for the REPTO
components.

REPTO Unit Oil Drain

The REPTO housing contains a cavity which
holds approximately one quart of oil for splash
lubrication. A magnetic drain plug in the housing
cavity allows a complete and total oil drain.
Whenever engine oil is changed, the drain plug
should be removed so that fresh oil can fill the
cavity.
Figure 3 — REPTO Drain Plug Location

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COMPONENT LOCATOR

COMPONENT LOCATOR

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COMPONENT LOCATOR
MAJOR COMPONENT LOCATIONS
4

Figure 4 — REPTO Cross Sectional View

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COMPONENT LOCATOR
1. REPTO Housing 18. Flywheel-to-Drive Gear Mounting Bolt and Washer
2. Output shaft 19A. Engine Crankshaft-to-Drive Gear Dowel Pin
3A. Output Shaft Front Bearing Cone 19B. Drive Gear-to-Flywheel Dowel Pin
3B. Output Shaft Front Bearing Cup 20. Crankshaft Seal
4A. Output Shaft Rear Bearing Cone 21. Crankshaft Seal Retainer
4B. Output Shaft Rear Bearing Cup 22. Crankshaft Seal Retainer Capscrew
5. Output Shaft Bearing Retainer O-Ring 23. Flywheel
6. Output Shaft Bearing Retainer Shim 24A. Engine Speed Sensor (Current Production)
7. Output Shaft Bearing Retainer Capscrews 24B. Engine RPM/TDC Sensor (Noncurrent)
8. Output Shaft Bearing Retainer 25. REPTO Housing Drain Plug And Washer
9. Output Shaft Seal 26. Drive Gear Oil Slinger Teeth (Noncurrent)
10. Output Shaft Flange 27. Drive Gear
11. Output Shaft Flange Washer 28. Engine Crankshaft
12. Output Shaft Flange Mounting Bolt 29. Idler Input Gear
13. Idler Gear Shaft O-Ring 30. Idler Output Gear
14. Idler Gear Shaft Shim 31. REPTO Housing Mounting Bolt
15. Idler Gear Shaft 32A. Idler Gear Shaft Front Bearing Cone
16A. Idler Gear Shaft Rear Bearing Cone 32B. Idler Gear Shaft Front Bearing Cup
16B. Idler Gear Shaft Rear Bearing Cup 33. Idler Gear Assembly Mounting Bolt
17. Idler Gear Shaft Mounting Bolt

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NOTES
5

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REPAIR INSTRUCTIONS

REPAIR INSTRUCTIONS

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REPAIR INSTRUCTIONS
DISASSEMBLY PROCEDURES 6

Before Disassembly
1. Secure the chassis from service and
disconnect the batteries (negative cable
first).
2. Be sure that the spring parking brakes are
set. Then chock the wheels and place the
transmission into Neutral.
3. Disconnect the propeller shaft from the
transmission (at U-joint).
4. Remove the transmission from the chassis
(use a transmission jack).
5. Remove the clutch assembly components,
including release bearing, pressure plate
assembly, and friction disc.
6. Remove the magnetic drain plug from
engine oil pan and drain the oil into an
approved catch container.
7. Remove the magnetic drain plug and drain
the lubrication oil from the REPTO housing
into an approved catch container. Clean the
engine oil pan and REPTO housing
magnetic drain plugs to remove any debris.
Figure 5 — REPTO Drain Plug Location

8. Disconnect the driveline from the REPTO

output shaft flange.
7

Figure 6 — Disconnect the Output Flange

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REPAIR INSTRUCTIONS
Disassembly Procedures 9

Unless a complete overhaul is needed, remove

only those parts required to gain access to faulty
parts. Do not disturb parts with a heavy press fit
(interference fit) unless they must be replaced.
When replacement is necessary, use proper
press setups and pullers as required to avoid
damaging parts that can be reused.

1. Disconnect the upper and lower oil supply

lines from the REPTO housing.

To ensure adequate lubrication to the upper

REPTO housing during cold weather starting
conditions, the upper lubricant supply line has
been changed from a No. 4 diameter hose to a Figure 8 — Disconnect Lower Oil Supply Line
larger No. 6 diameter hose. Mack recommends
installing this revised oil line arrangement on all 2. Remove the four capscrews from the output
existing units. The lower lubricant supply line shaft bearing retainer (see Figure 9).
remains a No. 4 diameter line. 10

Figure 9 — Remove Capscrews

Figure 7 — Disconnect Upper Oil Supply Line

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REPAIR INSTRUCTIONS
3. Remove the mounting bolt and clamp plate 5. Note the output shaft bearing retainer shims
from the output shaft flange. Then remove (see arrow, Figure 12). Tag and record shim
the output flange (see Figure 10). thickness for reassembly purposes.
11 13

Figure 10 — Remove Mounting Bolt, Clamp Plate and
Flange
4. Install two of the capscrews into the jack
holes provided in the output shaft bearing
Figure 12 — Bearing Retainer and Shims Removed
6. Remove the output shaft assembly from the
housing.
14

retainer. Then remove the retainer from the

housing.
12

Figure 13 — Removing Output Shaft Assembly

Figure 11 — Remove the Output Shaft Bearing Retainer

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REPAIR INSTRUCTIONS
7. If so equipped, remove the timing access 16

cover from the bottom of the REPTO

housing and remove the engine timing
pointer.
15

Figure 15 — Remove Engine Speed Sensor (Current

Production)

9. For noncurrent E7 engines, loosen the

engine RPM/TDC sensor jam nut. Then
Figure 14 — Remove Pointer (Noncurrent) unscrew and remove the sensor from the
housing.
8. On current production E-Tech™ engines, 17

remove the engine speed sensor retaining

capscrew and remove the sensor from the
REPTO housing by pulling straight back.
Remove sensor mounting flange shim and
wire tag it for reassembly purposes.

Figure 16 — Remove Engine RPM Sensor (Noncurrent)

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REPAIR INSTRUCTIONS
10. Remove the six flywheel mounting bolts and 12. Remove the eight capscrews from the
washers from the flywheel. crankshaft seal retainer.
18 20

Figure 17 — Remove Mounting Bolts and Washers
11. Install two bolts for “hand-holds” at the
locations shown. Then remove the flywheel.
If a new clutch pilot bearing will be installed
into the flywheel during reassembly, remove
the old bearing, using a slide hammer-type
puller (see arrow, Figure 18).
19
Figure 19 — Removing Crankshaft Seal Retainer
Capscrews
13. Loosen the crankshaft seal retainer, using a
heel bar at the notches cast into the REPTO
housing.
21

Figure 20 — Loosening the Seal Retainer

Figure 18 — Removing Flywheel

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REPAIR INSTRUCTIONS
14. Remove the crankshaft seal retainer from 16. Remove the drive gear as shown.
the REPTO housing. 24

22

Figure 23 — Removing the Drive Gear

Figure 21 — Removing the Seal Retainer

15. Install two of the flywheel mounting bolts into

the jack holes provided in the drive gear.
Then separate the drive gear from the Perform the following step only if the REPTO
crankshaft. housing will be removed as part of the overhaul
23
procedure. This step is not required to achieve
disassembly of the REPTO components.

Figure 22 — Separate the Drive Gear

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REPAIR INSTRUCTIONS
17. Drive two cup plugs from the REPTO 19. Thread a bolt into the center hole of the idler
housing, using a hammer and punch. gear shaft flange. Install a slide hammer-
25
type puller (with locking plier attachment)
onto the bolt and loosen the idler gear shaft
enough to allow grasping by hand.
27

Figure 24 — Removing Cup Plugs

18. Remove the three mounting bolts from the

idler gear shaft. Figure 26 — Separate the Idler Gear Shaft Flange
26

Figure 25 — Removing Mounting Bolts

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REPAIR INSTRUCTIONS
20. Support the idler gear assembly with one
hand through the housing. Then carefully
withdraw the loose shaft, along with shims.
(Tag and record shim thickness for
reassembly purposes.)
28
Routine REPTO disassembly stops at this point.
If a REPTO unit failure has occurred however, it is
necessary to remove, clean and inspect the
engine oil pan and REPTO housing.
To achieve REPTO housing removal, proceed as
follows:
r Remove the wiring and starter motor from
the REPTO housing.
r Remove the engine oil pan isolator bolts and
isolator nuts from the vertical studs at the
rear of the pan. Remove the oil pan.
r Remove the eight mounting bolts and
washers from the REPTO housing. Separate
the housing from the engine, using an
overhead hoist.

Figure 27 — Removing the Idler Gear Shaft

21. Remove the idler gear assembly from the

REPTO housing. Use care to prevent the
loose bearing cones from falling.
29

Figure 28 — Removing Idler Gear Assembly

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REPAIR INSTRUCTIONS
BENCH PROCEDURES AND Idler Gear Assembly
COMPONENT REBUILD 1. Remove the front and rear bearing cones.
32

Idler Gear Shaft

1. Remove the O-ring from the idler gear shaft.
30

Figure 31 — Removing Bearing Cones

2. If separating the input and output idler gears

for parts renewal, remove the six mounting
Figure 29 — Removing O-Ring bolts as shown.
33
2. Examine the lube hole in the bottom of the
idler gear shaft. Be sure that there is no
blockage or debris.
31

Figure 32 — Removing Mounting Bolts

Figure 30 — Lube Hole in Idler Shaft

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REPAIR INSTRUCTIONS
3. Secure the input and output idler gears 36

together by torquing the six mounting bolts

to specification.
34

Figure 33 — Torquing Mounting Bolts

4. To remove each bearing cup from the idler

gear assembly, use a hammer and punch to
drive the cup out from the opposite side as
shown (Figure 34 and Figure 35).
35

Figure 35 — Front Bearing Cup Removal

Figure 34 — Rear Bearing Cup Removal

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REPAIR INSTRUCTIONS
5. To install new bearing cups into the idler 38

gear assembly, use driver (J 9742) and

press setup as shown (Figure 36 and
Figure 37).
37

Figure 37 — Front Bearing Cup Installation

Figure 36 — Rear Bearing Cup Installation

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REPAIR INSTRUCTIONS
Crankshaft Seal Retainer 2. Position a new crankshaft seal into the seal
retainer as shown.
1. Remove the crankshaft seal from the seal 40

retainer, using a hammer and punch.

39

Figure 38 — Removing Crankshaft Seal

Figure 39 — Positioning Crankshaft Seal

REPTO units use seal P/N 446GC323, which is

identified by the absence of the red-colored
outside diameter sealant seen on other MACK
rear engine seals. Before installing this seal into
the stamped steel seal retainer, apply a thin film
of Loctite® 609 to seal the outside diameter.

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REPAIR INSTRUCTIONS
3. Drive the crankshaft seal into the seal Dowel Pin Located in Drive Gear
retainer, using installer (J 41147) and press
setup as shown. REMOVAL
Support the drive gear as shown. Then drive the
pin out from opposite side, using a blunt-nose
punch and hammer.
Installer J 41147 must be used to achieve correct 42

depth and squareness of the seal in the retainer.

41

Figure 41 — Drive the Dowel Pin from Drive Gear

Figure 40 — Installing Crankshaft Seal

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REPAIR INSTRUCTIONS
INSTALLATION Output Shaft/Bearing Retainer
The dowel pin must be installed in the FRONT BEARING CUP REMOVAL
0.5562-inch bore in the drive gear. Align the pin
with the drive gear as shown. Then drive the pin Remove the front bearing cup from the REPTO
until seated, using a brass hammer. housing, using a suitable puller as shown (see
Figure 43).
44

Be sure that the broad side of the dowel pin is

positioned in the drive gear as shown (see arrow,
Figure 42). This is needed to correctly index the
flywheel-to-drive gear for easy and accurate
flywheel installation.
43

Figure 43 — Removing Front Bearing Cup

Figure 42 — Seat the Dowel Pin in Drive Gear

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REPAIR INSTRUCTIONS
FRONT BEARING CUP INSTALLATION OUTPUT SHAFT FRONT AND REAR BEARING
CONE REMOVAL
Install the front bearing cup into the REPTO
housing, using a hammer and driver (J 7818) as 1. Pull the rear bearing cone from the output
shown (Figure 44). Refer to Figure 45 for shaft, using a suitable knife edge-type puller
completed cup installation. arrangement. (Refer to Figure 46.)
45

To avoid damaging the bearing cone, do not

apply pulling force through the cage. Use pulling
force on only the inner race of the bearing cone.
47

Figure 44 — Installing Front Bearing Cup

46

Figure 46 — Pulling Rear Bearing Cone

1. Puller Assembly J 39477 2. Bearing Separator

J 8176

Figure 45 — Front Bearing Cup Installation Complete

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REPAIR INSTRUCTIONS
2. Pull the front bearing cone from the output
shaft, using a suitable knife edge-type puller
arrangement. (Refer to Figure 47.)
To avoid damaging the bearing cone, do not
apply pulling force through the cage. Use pulling
force on only the inner race of the bearing cone.
48
OUTPUT SHAFT FRONT AND REAR BEARING
CONE INSTALLATION
1. Press a new front bearing cone onto the
output shaft, using driver J 5590 or
equivalent. Support the output shaft in the
press as shown (see Figure 48).
To avoid damaging the bearing cone, do not
apply press force through the cage. Use press
force on only the inner race of the bearing cone.
49

Figure 47 — Pulling Front Bearing Cone

1. Puller Assembly J 39477 2. Bearing Separator

J 8176
Figure 48 — Installing Front Bearing Cone

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REPAIR INSTRUCTIONS
2. Press a new rear bearing cone onto the BEARING RETAINER DISASSEMBLY
output shaft, using driver J 41152 or
1. Remove the O-ring from its groove in the
equivalent. Support the output shaft in the
bearing retainer (see Figure 50).
press as shown (see Figure 49). 51

To avoid damaging the bearing cone, do not

apply press force through the cage. Use press
force on only the inner race of the bearing cone.
50

Figure 50 — Removing O-Ring

Figure 49 — Installing Rear Bearing Cone

An interference condition may exist between the

REPTO unit output flange and bearing cones
available from different manufacturers. To
eliminate this problem, Mack has specified
Timken® tapered roller bearing cone (part
number 186GB240) for use at the output shaft
rear location. The Timken bearing must be used
in this application. DO NOT substitute. This part
replaces the previously used bearing cone (part
number 62AX216).

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REPAIR INSTRUCTIONS
2. Drive the output shaft seal out of the bearing 53

retainer from the opposite side of the

retainer, using a hammer and soft drift as
shown (see Figure 51).

The output shaft seal is destroyed during

removal. Be sure to have a new seal in stock,
before removal.
52

Figure 52 — Removing Rear Bearing Cup

BEARING RETAINER REASSEMBLY

1. Support the bearing retainer in a press as
shown (see Figure 53). Install the bearing
cup into the retainer, using the press and
driver J 9742 or equivalent.
54

Figure 51 — Removing Output Shaft Seal

3. Support the bearing retainer in a vise as

shown (see Figure 52). Use a hammer and
soft drift to drive the bearing cup from the
opposite side of the bearing retainer.

Use a soft drift to avoid damaging the retainer or

bearing cup.

Figure 53 — Installing Rear Bearing Cup

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REPAIR INSTRUCTIONS
2. Support the bearing retainer in a press as
shown (see Figure 54). Install a new seal,
using the press and bearing driver J 9742 or
a suitable diameter flat plate.
The diameter of the flat plate installation tool must
be larger than that of the seal so that the seal is
mounted flush with face of the bearing retainer.
55
Figure 54 — Installing Output Shaft Seal
Page 28
INSPECTION OF PARTS
Inspection and Cleaning
Before inspecting the parts, make sure to
thoroughly clean the housing and all internal
parts.
Use a suitable safety solvent to remove grease,
oil and foreign matter.
Dry the parts (except bearing cones), using
moisture-free compressed air.
Bearings
Wash the bearings in clean solvent. Set the
bearings aside to dry on clean, lint-free cloths.
Do not spin bearings using compressed air.
This action can cause the bearing to fly apart
and cause personal injury.
Use clean solvent and lint-free cloths to wipe oil
and foreign matter from mating bearing cups.
Check cleaned bearings for flaking, cracks,
fractures, cavities, indentations, measurable
wear, brinelling, fretting, corrosion, nicking, or
cage wear or deformation and other damage. If
any of these conditions are present, replace the
bearing.
Apply a light coat of fresh EO-M or current
specification engine oil to the bearings. Turn the
races slowly by hand, to be sure that they move
freely and smoothly. If there is resistance to
movement, or the bearing cones or cups feel
rough, install new bearings.
Clean bearings that are satisfactory for
installation should be wrapped in clean, lint-free
cloths, and stored for assembly.
5_90199repair.fm Page 29 Monday, November 29, 1999 11:36 AM
REPAIR INSTRUCTIONS
If a bearing cone or cup needs replacement,
install a complete new bearing assembly,
including cup and mating cone. If bearing cups or
cones are mismatched during assembly,
premature bearing failure can result.
Do not remove a new bearing from its packing
before time of installation.
Never clean protective grease from new bearings.
Do not handle bearings with dirty hands. Rags
must be clean and lint-free.
An interference condition may exist between the
REPTO unit output flange and bearing cones
available from different manufacturers. To
eliminate this problem, Mack has specified
Timken® tapered roller bearing cone (part
number 186GB240) for use at the idler shaft and
the output shaft rear locations. The Timken
bearing must be used in this application. DO NOT
substitute. This part replaces the previously used
bearing cone (part number 62AX216).
56
Figure 55 — Required Bearing Cones
1. Idler Shaft Bearing Cones 2. Output Shaft Rear
186GB240 Bearing Cone
186GB240
Gears
Replace all gears having teeth that show signs of
abrasive wear, scratching (except for normal
manufacturing tool marks), ridging, scoring,
surface fatigue, pitting, spalling, corrosive wear,
digging in or cracking.
Gears should be always be inspected using
magnaflux (or similar method) for cracks that
would not otherwise be detected.
Oil Seals
Use a new seal to replace any oil seal removed
during a repair procedure. When an overhaul is
required, replace all oil seals.
Use care when handling and installing the seal to
be sure that the sealing lip surface is not
damaged, turned back, or cut.
A nick or burr on the mating shaft surface can cut
the seal. Remove any sharp edges that can
damage the seal (chamfer the edges if possible).
Press the seal into the seal retainer or bearing
retainer, using smooth uniform pressure to
prevent the seal from cocking. Be sure to use a
properly sized seal driver for installation. Make
sure seals are correctly installed to the proper
depth as follows:
r Crankshaft Seal — Seal installer J 41147
must be used to achieve correct depth and
squareness of the seal in its retainer. Refer
to the bench procedures section for proper
tool use.
REPTO units use seal P/N 446GC323, which is
identified by the absence of the red-colored
outside diameter sealant seen on other MACK
rear engine seals. Before installing this seal into
the stamped steel seal retainer, apply a thin film
of Loctite® 609 to seal the outside diameter.
Page 29
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REPAIR INSTRUCTIONS
r Output Shaft Seal — Install the seal FLUSH
with the face of the bearing retainer. Refer to
the bench procedures section for proper seal
installation method.
Always use extreme care when installing a shaft
through a new oil seal. Otherwise, splines,
keyways, or holes in the shaft can damage the
seal.
General Inspection
A new housing must be installed if a crack(s) is
discovered.
Beginning with engines produced approximately
mid-November 1998, the flywheel housing
mounting pad fasteners changed to 16 mm. If a
new REPTO housing is being installed, the
associated brackets and fasteners must be
reworked or replaced to fit a 16 mm fastener.
Check all other parts for wear or damage. Install
new parts as required.
Clean up any threads that show mutilation.
Repair stripped threads by using Heli-coil or
equivalent repair parts.
Page 30
REASSEMBLY PROCEDURES
General Reassembly Guidelines
Refer to the following sections for additional
information:
r “TORQUE SPECIFICATIONS” on page 48.
r “FITS AND LIMITS” on page 50.
r “ASSEMBLY LUBRICANT AND SEALANT”
on page 51.
r “REPTO FEATURES AND CAPACITIES” on
page 53.
Use a properly calibrated torque wrench to
ensure correct assembly torque of fasteners.
Before installation, lubricate fastener threads,
using fresh EO-M or current specification engine
oil.
Install new O-rings and oil seals during
reassembly.
Coat all working metal parts, especially the
bearings, with fresh EO-M or current specification
engine oil during reassembly. This ensures
immediate lubrication during the first start-up
after overhaul, and helps prevent parts from
seizing.
Always use correct bearing drivers to install
bearings. Do not apply force to an unloaded
bearing race. The resulting damage (even if not
visible at this time) can cause premature bearing
failure. Apply installation force evenly to prevent
the bearing from cocking.
While assembling moving parts, check frequently
to make sure that they move freely.
5_90199repair.fm Page 31 Monday, November 29, 1999 11:36 AM

REPAIR INSTRUCTIONS
If the REPTO housing was removed from the Reassembly Procedures
engine during disassembly, reinstall the housing
as follows: 1. Install front and rear bearing cones into the
idler gear assembly.
1. Apply Silastic sealant on the rear surface of 58
the engine block.
2. Using an overhead hoist, position the
REPTO housing on the engine block. Install
flush with the block surface.
3. Install the eight REPTO housing mounting
bolts and washers to secure the housing.
Tighten the bolts to the specified torque.
Note that there are six long bolt and two
short bolt locations (see arrows in
Figure 56).
57

Figure 57 — Installing Bearing Cones

An interference condition may exist between the

REPTO unit output flange and bearing cones
available from different manufacturers. To
eliminate this problem, Mack has specified
Timken® tapered roller bearing cone (part
number 186GB240) for use at the idler shaft
location. The Timken bearing must be used in this
application. DO NOT substitute. This part
replaces the previously used bearing cone (part
number 62AX216).

Figure 56 — Housing Mounting Bolt Locations

4. Reinstall the starter motor and engine oil

pan. Torque the oil pan mounting fasteners
as follows:

r Oil pan 8 mm isolator bolts 23 lb-ft

(31 N•m)
r Nuts for oil pan isolator studs 15 lb-ft
(20 N•m)

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REPAIR INSTRUCTIONS
2. Keep the bearings in place, using split tube 3. Install the idler gear assembly into the
holder J 41149. The length of the holder REPTO housing (large gear toward engine).
spans the outer distance of the front and 60

rear bearing cone inner races. It may be

necessary to add a hole at rear of the tube to
help remove the tube holder later using a
hooking tool such as an Allen wrench (see
arrow in Figure 58).
59

Figure 59 — Install Idler Gear Assembly

4. Slide the idler gear assembly into position as

shown in Figure 60.
61

Figure 58 — Use Tool (J 41149) to Keep Bearings in

Place

Figure 60 — Position the Idler Gear Assembly

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REPAIR INSTRUCTIONS
5. While supporting the idler gear assembly,
withdraw the split tube holder J 41149, using
a suitable hooking tool as shown in
Figure 61.
62
Figure 61 — Removing Split Tube Holder J 41149
6. Insert the idler gear shaft (without O-ring)
and then seat the shaft in the REPTO
housing, using a soft head mallet.
63
Figure 62 — Installing Idler Shaft
7. Use a tapered feeler gauge to measure the
gap between the housing boss and the idler
shaft flange.
64
Figure 63 — Measure Gap Using Tapered Feeler Gauge
8. The required bearing preload for the idler
shaft bearings is 0.002 to 0.006 in. (0.051 to
0.152 mm). Add enough shims to fill the
measured gap, then subtract (take away)
shims from the shim pack to obtain the
required bearing preload.
EXAMPLE:
a. Begin procedure using NO shims under
the idler shaft flange.
b. For this example, measured gap under
the flange is 0.015 in. A 0.015-in. shim
pack is needed to fill the gap.
c. Remove (subtract) 0.002–0.006 in.
shims from the pack to obtain the
required bearing preload. Final shim
pack thickness to be installed must be
0.009 to 0.013 in.
... continued next page
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REPAIR INSTRUCTIONS
66

The following shim sizes (thickness) are available

for service:
0.003 in. (0.076 mm)
0.005 in. (0.127 mm)
0.007 in. (0.178 mm)
0.015 in. (0.381 mm)
0.030 in. (0.762 mm)

d. Use a micrometer to measure shim

pack thickness as shown.
65 Figure 65 — Installing O-Ring

10. Install a guide pin into the housing upper

threaded hole for the idler gear shaft flange
(see arrow in Figure 66). Then position
predetermined shim pack on the pin so that
the bolt holes line up.
Reinstall the idler gear assembly with
bearing cones as done previously.
11. Position the flange of the idler gear shaft on
the guide pin so that the lube hole in the
shaft faces DOWN and the “UP” marking on
the flange is placed UP.
Seat the shaft using a soft head mallet, and
then remove the guide pin.
67

Figure 64 — Measuring Shim Pack Thickness

9. Remove the idler gear shaft and idler gear

assembly. (Refer to the steps for idler gear
and shaft assembly removal in “MAJOR
COMPONENT LOCATIONS” on page 6.)
Lubricate a new O-ring using fresh EO-M or
current specification engine oil. Then install
it into the O-ring groove in the idler gear
shaft.

Figure 66 — Installing Shim Pack and Idler Gear

Assembly

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REPAIR INSTRUCTIONS
68 69

Figure 67 — Positioning Idler Shaft

To save time, it is acceptable to install SPLIT

shims under the idler shaft flange. Shims must be
split as shown. Make sure not to overlap mating Figure 68 — SERVICE HINT Use Split Shims
edges of shim halves during installation.
This method eliminates having to install the idler
gear assembly and shaft twice. When using this
method, be sure to install a new O-ring into the
O-ring groove of the idler gear shaft before
installation.

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REPAIR INSTRUCTIONS
12. Install the three mounting bolts in flange of 14. Install cup plug into the REPTO housing,
the idler gear shaft and tighten to specified using the driver tool and a hammer.
torque. 72

70

Figure 71 — Installing Cup Plug

Figure 69 — Install Idler Shaft Mounting Bolts
15. Two locations require cup plugs (see arrows
13. Install two new cup plugs (if removed). Place in Figure 72).
a cup plug on driver tool J 41456 with handle 73

J 8092 as shown. Apply a bead of sealant

(Loctite® No. 277) to the outer edge of the
cup plug.
71

Figure 72 — Cup Plug Locations

Figure 70 — Applying Sealant to Cup Plug

Page 36
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REPAIR INSTRUCTIONS
16. Install guide pins into threaded holes in the
crankshaft at two locations 180 degrees
apart (see Figure 73).
74
Figure 73 — Install Two Guide Pins
17. Position the drive gear onto the crankshaft
so that the dowel pins in the crankshaft and
drive gear are aligned (see arrows in
Figure 74). The dowel pin in the crankshaft
must enter the mating hole in the drive gear.
75
Figure 74 — Drive Gear Aligned for Installation
18. With dowel pins aligned, slide the drive gear
over the guide pins.
76
Figure 75 — Installing the Drive Gear
19. Use four bolts with spacers (flywheel
thickness) as shown, to seat the drive gear
onto the crankshaft. Alternately tighten the
four bolts to draw the drive gear on evenly.
There is an interference fit between the drive
gear hub and crankshaft flange.
Remove the four bolts and spacers after
drive gear is seated on crankshaft.
77
Figure 76 — Seat Drive Gear on Crankshaft
Page 37
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REPAIR INSTRUCTIONS
20. Apply a bead of Silastic sealant to the seal
retainer boss of the REPTO housing.
78
Figure 77 — Apply Sealant to Seal Retainer Boss
21. Install the crankshaft seal retainer assembly
onto the drive gear. Note that this is a “dry”
seal installation that uses a pilot sleeve
supplied with the new seal. (Do NOT use
any lubricant.)
79
Figure 78 — Install Crankshaft Seal Retainer
Page 38
22. After seal retainer assembly installation,
remove the pilot sleeve as shown (see arrow
in Figure 79).
80
Figure 79 — Remove Seal Pilot Sleeve
23. Install the seal retainer capscrews and seal
alignment tool J 41147.
r Loosely install the eight crankshaft seal
retainer capscrews.
r Install alignment tool J 41147 so that
the lip of the tool seats between the
seal retainer and the drive gear (see
inset in Figure 80). Using the alignment
tool J 41147 achieves accurate retainer
and seal concentricity.
5_90199repair.fm Page 39 Monday, November 29, 1999 11:36 AM

REPAIR INSTRUCTIONS
81 82

Figure 81 — Torquing Capscrews

25. Install two bolts in the flywheel to be used as

Figure 80 — Installing Alignment Tool and Seal Retainer
Capscrews
“handles” (see arrows in Figure 82). Position
the flywheel so that its mating hole aligns
with the dowel pin in the drive gear. Then
slide the flywheel over the guide pins and
onto the drive gear.
83

24. Tighten the capscrews to the specified

torque, using a criss-cross pattern for even
tightening.

After alignment tool J 41147 is installed, rotate

the tool slightly both ways to make sure it is
seated correctly.
Also rotate the tool after tightening each
capscrew. This helps ensure continued
concentricity of the seal and retainer.

Figure 82 — Installing Flywheel

Page 39
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REPAIR INSTRUCTIONS
26. Install and hand tighten four of the flywheel 28. If equipped, install the engine timing pointer
mounting bolts and washers. Remove the into the threaded hole at the bottom of the
two guide pins and install the remaining two REPTO housing (see arrow in Figure 85).
mounting bolts and washers. Remove the Install the timing access cover and six
two bolts used as installation handles. mounting bolts. Refer to the E7 Engine
84
Overhaul Manual 5-101 for pointer-to-engine
timing instructions.

Install a new clutch pilot bearing into the flywheel,

if removed during disassembly. After the bearing
is properly installed, pack the cavity in back of the
bearing, using the recommended clutch pilot
grease. To avoid damaging the bearing seal,
make sure not to fill the space occupied by the
transmission main driving pinion.
86

Figure 83 — Removing Guide Pins

27. Tighten the six flywheel mounting bolts to

specified torque, using a criss-cross pattern
for even tightening.
85

Figure 85 — Install Pointer and Timing Access Cover

(Noncurrent)

Figure 84 — Tightening Mounting Bolts

Page 40
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REPAIR INSTRUCTIONS
29. Install the output shaft assembly into the 31. Use two tapered feeler gauges to measure
REPTO housing with the larger bearing the space between the bearing retainer and
toward the rear (see arrow in Figure 86). the REPTO housing. Take at least two
Insert the assembly until seated in the front measurements. Then average and record
bearing cup. the results.
87

To achieve greater accuracy while taking

measurements, apply hand pressure against the
bearing retainer. This is done to push the retainer
toward the REPTO housing and keep the
bearings seated.
89

Figure 86 — Installing Output Shaft Assembly

30. Install the output shaft bearing retainer and

four capscrews, leaving the capscrews
loose. Do NOT install shims or O-ring at this
time.
88

Figure 88 — Measuring Gap with Tapered Feeler Gauges

Figure 87 — Install Bearing Retainer and Capscrews

Page 41
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REPAIR INSTRUCTIONS
32. The required output shaft bearing end play is 90

0.001 to 0.005 in. (0.025 to 0.127 mm).

Calculate the required shim pack thickness
and install the O-ring as follows:
a. Remove the capscrews and bearing
retainer.
b. Select enough shims to bring the
measured space under the bearing
retainer to zero. Then add additional
shim thickness to obtain the required
0.001 to 0.005 in. (0.025 to 0.127 mm)
output shaft bearing end play.
c. EXAMPLE:
— Begin procedure using NO shims
or O-ring on the bearing retainer.
— Measure the space under the
bearing retainer. For this example,
the space is 0.100 in.
— A 0.100-in. shim pack is needed to Figure 89 — Shim Pack and O-Ring Installed
fill the measured space.
— Add 0.001 to 0.005 in. additional 33. Install the bearing retainer, using a drift to
shim thickness to the pack to line up the capscrew holes in the retainer
obtain the required end play. with the capscrew holes in the housing.
Install the four capscrews that secure the
— Final shim pack thickness to bearing retainer. Carefully draw the retainer
obtain the required 0.001 to into the REPTO housing by alternately
0.005 in. end play is 0.101 to tightening the capscrews evenly.
0.105 in. for this example. 91

d. Install the predetermined shim pack

onto the bearing retainer (see arrow in
Figure 89).
e. Lubricate a new O-ring, using fresh
EO-M or current specification engine
oil. Then install O-ring into the O-ring
groove in the bearing retainer.

Shims must be seated in groove behind the

flange of the bearing retainer.

Figure 90 — Seating the Bearing Retainer

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REPAIR INSTRUCTIONS
34. Finish tightening the capscrews to specified
torque.
92
Figure 91 — Tightening Capscrews
35. Install the output shaft flange, mounting bolt
and clamp plate (see Figure 92).
93
Figure 92 — Installing Flange, Mounting Bolt and Clamp
Plate
36. Tighten the output shaft flange bolt to
specified torque.
94
Figure 93 — Tightening the Flange Bolt
37. Fill the engine oil sump and reconnect the oil
supply lines as follows:
a. Clean and reinstall the magnetic oil
drain plugs for the REPTO housing and
engine oil pan. (The REPTO drain plug
location is shown in Figure 3.)
b. Fill engine sump to the required level
with fresh EO-M or current specification
engine oil. Add additional oil required
for the REPTO unit (approximately one
quart).
c. Reconnect the upper and lower oil
supply lines to the REPTO housing and
tighten the fittings (see Figure 94 and
Figure 95).
To ensure adequate lubrication to the upper
REPTO housing during cold weather starting
conditions, the upper lubricant supply line has
been changed from a No. 4 diameter hose to a
larger No. 6 diameter hose. Mack recommends
installing this revised oil line arrangement on all
existing units. The lower lubricant supply line
remains a No. 4 diameter line.
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REPAIR INSTRUCTIONS
95
d. Also check that the lube line “T”
connector at the engine oil filter adapter
is properly connected and tightened
(see Figure 96).
97

Figure 94 — Reconnect Upper Oil Supply Line

96

Figure 96 — Lube Line “T” Connector Installation

1. Oil Supply “T” at Oil Filter 2. Upper Oil Supply Line

Adapter 3. Lower Oil Supply Line

38. On current production E-Tech™ engines,

remove the tag placed on the engine speed
sensor shim at disassembly. Position and
align the shim with the sensor openings.
Install engine speed sensor into the REPTO
housing bore by pushing the sensor straight
in. Install the retaining capscrew into the
sensor mounting flange and tighten to 7 lb-ft
(9 N•m).

Figure 95 — Reconnect Lower Oil Supply Line

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REPAIR INSTRUCTIONS
99
If the REPTO housing required replacement, the
sensor depth must be rechecked. Refer to MACK
E-Tech™ Engine Service Manual 5-106 for
procedures on checking and adjusting the engine
speed sensor depth.
98
After REPTO Reassembly
Figure 97 — Installing Engine Speed Sensor (Current
Production)
39. For noncurrent E7 engines, screw the
engine RPM/TDC sensor into the REPTO
housing until the sensor contacts the
flywheel. Then back off one complete turn.
Secure the sensor in this position by
tightening the jam nut to specified torque.
Refer to the E7 Engine Overhaul Manual
5-101.
Figure 98 — Installing Engine RPM/TDC Sensor
(Noncurrent)
1. Reinstall the clutch assembly components
including friction disc, pressure plate
assembly, and release bearing.
2. Reinstall the transmission (use a
transmission jack).
3. Reinstall the propeller shaft to the
transmission (at U-joint).
4. Reconnect the auxiliary driven equipment to
the REPTO output shaft flange.
5. Reconnect the batteries (negative cable
last).
6. Check that the chassis is clear of any tools
and parts from overhaul work.
7. Be sure that the chassis air system is
recharged and instruments show normal
readings before attempting to move the
truck.
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NOTES

Page 46
5_90199specify.fm Page 47 Monday, November 29, 1999 11:39 AM

SPECIFICATIONS

SPECIFICATIONS

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SPECIFICATIONS
TORQUE SPECIFICATIONS
100

Figure 99 — Fastener Torques (Side View)

1. 40 lb-ft (54 N•m) 6B.55 lb-ft (75N•m) Plug

2. 111 lb-ft (150 N•m) 7. 55 lb-ft (75 N•m)
3. 40 lb-ft (54 N•m) 8. 15 lb-ft (20 N•m) Oil Pan Stud Nut
4. 185 lb-ft (251 N•m) 9. 170 lb-ft (230 N•m) for Bolt Lengths of 55 mm and
5. 40 lb-ft (54 N•m) 170 mm
6A. 15 lb-ft (20 N•m) Jam Nut (RPM/TDC Sensor) 10. 135 lb-ft (183 N•m)

Lubricate fastener threads using fresh EO-M or

current specification engine oil prior to
installation.

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SPECIFICATIONS
101

Figure 100 — Fastener Torques (Rear View)

1. 40 lb-ft (54 N•m) 12. 170 lb-ft (230 N•m) Length 170 mm
2. 111 lb-ft (150 N•m) 13. Beginning with engines produced approximately mid-
3. 40 lb-ft (54 N•m) November 1998, the flywheel housing mounting pad
5. 40 lb-ft (54 N•m) fasteners changed to 16 mm. If a new REPTO housing is
9. 170 lb-ft (230 N•m) Length 50 mm being installed, the associated brackets and fasteners
11. 15 lb-ft (20 N•m) must be reworked or replaced to fit a 16-mm fastener.

Lubricate fastener threads using fresh EO-M,

EO-M PLUS or current specification engine oil
prior to installation.

Page 49
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SPECIFICATIONS
FITS AND LIMITS Crankshaft Seal Installation Depth
Refer to “C” in Figure 101.
Output Shaft Bearing End Play
r Seal installation depth: 0.270 in. (6.86 mm)
Refer to “A” in Figure 101.
r Depth controlled by installer tool J 41147
r End play specification: 0.001–0.005 in. 102

(0.025–0.127 mm)
r Controlled by shim (1)

Idler Shaft Bearing Preload

Refer to “B” in Figure 101.
r Preload specification: 0.002–0.006 in.
(0.051–0.152 mm)
r Controlled by shim (2)
r Shim sizes are available in varying
thicknesses for service:
— 0.003 in. (0.076 mm)
— 0.005 in. (0.127 mm)
— 0.007 in. (0.178 mm)
— 0.015 in. (0.381 mm)
— 0.030 in. (0.762 mm)

Figure 101 — Assembly Fits and Limits

Page 50
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SPECIFICATIONS
ASSEMBLY LUBRICANT AND
SEALANT
Be careful not to block any screw hole(s) when
Assembly Lubricant applying sealant.
r Refer to O-ring locations (1 and 2) in 103

Figure 103.
r Coat each O-ring using fresh MACK EO-M,
EO-M PLUS or current specification engine
oil, prior to installation into mating groove.
r Install new O-rings during unit reassembly.

Assembly Sealant
r Use specified sealant at the following
locations during unit reassembly (Refer to
Figure 102 and Figure 103):
A. Apply Silastic on the rear of the E7 or
E-Tech™ engine block surface before
installing the REPTO housing.
B. Apply Loctite No. 277 sealant to the two
cup plugs, and cup plug bores in the
REPTO housing before installing the
cup plugs.
C. Apply a bead of Silastic to the housing
seal retainer boss before installing the
crankshaft seal retainer assembly.
D. Apply Loctite No. 609 to the outside
diameter of the engine rear seal before
installing it into the stamped steel
retainer.
Figure 102 — Assembly Lubricant and Sealant
Locations (Rear View)

... continued next page

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SPECIFICATIONS
104

Figure 103 — Assembly Lubricant and Sealant

Locations (Side View)

Page 52
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SPECIFICATIONS
REPTO FEATURES AND CAPACITIES
MANUFACTURER Mack Trucks, Inc.
HOUSING MATERIAL Aluminum
MOUNTING POSITION 1 O’clock
(only position available)
OUTPUT ROTATION Engine-wise
ENGINE-TO-OUTPUT DRIVE RATIO 0.81:1
OUTPUT SHAFT SPLINES (1310 AND 1350 SERIES FLANGES):
r Type Involute
r Number 23
r Outside Diameter 1.500 in.
r Root Diameter 1.325 in.
BEARINGS:
r Idler Gear Shaft Tapered Roller, Single Row
(Two)
r Output Shaft Tapered Roller, Single Row
(Two)
GEAR FACE WIDTHS:
r Drive Gear 1.125 in.
r Idler Input Gear 1.125 in.
r Idler Output Gear 1.562 in.
r Output Shaft Gear 1.562 in.
GEAR TYPE Spur
HORSEPOWER OUTPUT @ 1,800 ENGINE RPM 250
TORQUE OUTPUT @ 1,800 ENGINE RPM 730 lb-ft
LUBRICATION CAPACITY (APPROX.) 1 qt. EO-M, EO-M PLUS or
current specification engine
oil
UNIT WEIGHT (APPROX.) 300 lbs.

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NOTES

Page 54
5_90199spectool.fm Page 55 Monday, November 29, 1999 11:40 AM

SPECIAL TOOLS & EQUIPMENT

SPECIAL TOOLS & EQUIPMENT

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5_90199spectool.fm Page 56 Monday, November 29, 1999 11:40 AM

SPECIAL TOOLS & EQUIPMENT

SPECIAL TOOLS
Special Tools for REPTO Overhaul

Tool No. Description

J 8092 Driver Handle
J 8176 Bearing Separator
J 9742 Bearing Cup Driver
J 23775-01 100–600 lb-ft Torque Wrench
J 24407 30–250 lb-ft Torque Wrench
J 26900-1 0–1 inch Outside Micrometer
J 29048 Tapered Feeler Gauge
J 29369-1 Bearing Puller
J 29369-2 Bearing Puller
J 39477 Bar-Type Puller
J 41147 Crankshaft Seal Installer
J 41149 Split Tube Holder
J 41456 Driver Tool

Page 56
Index.fm Page 57 Monday, November 29, 1999 11:41 AM

INDEX

INDEX

Page 57
Index.fm Page 58 Monday, November 29, 1999 11:41 AM

INDEX
A I
ADVISORY LABELS. . . . . . . . . . . . . . . . . . . . . vi
AFTER REPTO REASSEMBLY . . . . . . . . . . .45
ASSEMBLY LUBRICANT . . . . . . . . . . . . . . . .51
ASSEMBLY LUBRICANT AND SEALANT . . .51
ASSEMBLY SEALANT . . . . . . . . . . . . . . . . . .51
B
BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . .28
BEFORE DISASSEMBLY . . . . . . . . . . . . . . . .10
BENCH PROCEDURES AND COMPONENT
REBUILD . . . . . . . . . . . . . . . . . . . . . . . . . .18
C OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
CRANKSHAFT SEAL INSTALLATION
DEPTH . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
CRANKSHAFT SEAL RETAINER . . . . . . . . . .21
D
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . .3
DISASSEMBLY PROCEDURES . . . . . . . . . . .10
DISASSEMBLY PROCEDURES . . . . . . . . . . .11
DOWEL PIN LOCATED IN DRIVE GEAR . . . .22
E REPTO FEATURES AND CAPACITIES . . . . . 53
EXPLANATION OF NUMERICAL CODE . . . . . ix
F
FITS AND LIMITS . . . . . . . . . . . . . . . . . . . . . .50
G
GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
GENERAL INSPECTION . . . . . . . . . . . . . . . . .30
GENERAL REASSEMBLY GUIDELINES . . . .30
IDLER GEAR ASSEMBLY . . . . . . . . . . . . . . . 18
IDLER GEAR SHAFT . . . . . . . . . . . . . . . . . . . 18
IDLER SHAFT BEARING PRELOAD . . . . . . . 50
INSPECTION AND CLEANING . . . . . . . . . . . 28
INSPECTION OF PARTS . . . . . . . . . . . . . . . . 28
M
MACK REAR ENGINE POWER TAKE-OFF . . . 2
MAJOR COMPONENT LOCATIONS . . . . . . . . 6
O
OUTPUT SHAFT BEARING END PLAY . . . . . 50
OUTPUT SHAFT/BEARING RETAINER . . . . 23
P
PRESSURE LUBRICATION . . . . . . . . . . . . . . . 4
R
REASSEMBLY PROCEDURES . . . . . . . . . . . 30
REASSEMBLY PROCEDURES . . . . . . . . . . . 31
REPTO UNIT OIL DRAIN . . . . . . . . . . . . . . . . . 4
S
SAFETY INFORMATION . . . . . . . . . . . . . . . . . .vi
SERVICE PROCEDURES AND TOOL
USAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . 56
SPECIAL TOOLS FOR REPTO
OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . 56
T
TORQUE SPECIFICATIONS . . . . . . . . . . . . . 48

Page 58
 REAR ENGINE POWER TAKE-OFF

(REPTO)
SERVICE MANUAL
FOR MACK E7 AND E-TECH ™ ENGINES

PRINTED IN U.S.A.
5-901 © MACK TRUCKS, INC. 2000