FLYWHEEL

Flywheel- remove

1. Restrain crankshaft and remove 6 bolts securing flywheel.
2. Remove flywheel.

Inspect

1. Inspect flywheel face for cracks, scores and overheating. The flywheel can be refaced providing thickness does not go below minimum.
Flywheel minimum thickness A = 39.93 mm

2. Inspect ring gear for worn, chipped and broken teeth.

3. Renew ring gear if necessary.

Flywheel ring gear - renew

1. Drill a 10 mm diameter hole axially at base of tooth and inner diameter of starter ring, sufficiently deep enough to weaken ring gear.

CAUTION: Do not allow drill to enter flywheel.

2. Secure flywheel in soft jawed vice.
3. Split ring gear using a cold chisel.

WARNING: Wear safety goggles and take precautions against flying fragments when splitting ring gear.

4. Remove flywheel from vice, remove old ring gear, and place flywheel, clutch side down, on a flat surface.
5. Heat new ring gear uniformly to between 170°and 175° C.

Do not exceed this temperature.

6. Locate ring gear on flywheel with chamfered inner diameter towards flywheel flange.

NOTE: If ring gear is chamfered on both sides, it can be fitted either way round.

7. Press ring gear onto flywheel until it butts against flywheel flange.
8. Allow flywheel to air cool.

Flywheel - refit

1. Fit flywheel and locate on 2 dowels.
2. Fit flywheel bolts.
3. With assistance, restrain crankshaft and tighten flywheel bolts to correct torque.

DRIVE PLATE AND RING GEAR ASSEMBLY

Drive plate and ring gear assembly - remove

1. Mark each component to enable reassembly in original position.
2. Remove 4 bolts securing drive plate.
3. Remove clamp ring, flexible drive plate, hub aligner and ring gear assembly.
4. Remove 6 socket head screws securing crankshaft adapter plate, remove adapter plate and selective shim.

Inspect

1. Inspect flexible drive plate for cracks and distortion.
2. Renew drive plate if necessary.
3. Inspect ring gear for worn, chipped and broken teeth.
4. Renew ring gear assembly if necessary.

Drive plate and ring gear assembly - refit

CAUTION: To prevent distortion to flexible drive plate when bolted to torque converter, drive plate setting height must be checked as follows:

1. Fit existing shim and crankshaft adapter plate.
2. Fit socket head screws and lightly tighten.
3. Fit ring gear assembly, hub aligner, drive plate and clamping ring, fit bolts and lightly tighten.
4. Check the setting height.
Drive plate setting height A = 8.08 to 8.20 mm.
5. Remove bolts, remove clamp ring, flexible drive plate, hub aligner and ring gear assembly.
6. Remove socket head screws, remove crankshaft adapter and shim.

7. Measure existing shim and, if necessary, select appropriate shim to maintain setting height.
Shims available:
1.20 - 1.25mm
1.30 - 1.35mm
1.40 - 1.45mm
1.50 - 1.55mm
1.60 - 1.65mm
1.70 - 1.75mm
1.80 - 1.85mm
1.90 - 1.95mm
2.00 - 2.05mm
2.10 - 2.15mm
8. Fit shim selected, position adapter, ensuring marks previously made line up, fit socket head bolts and tighten to correct torque.
9. Fit ring gear assembly, hub aligner, flexible drive plate and clamp ring. ensuring marks previously made line up.
10. Apply Loctite 242 to threads of bolts, fit bolts and tighten to correct torque.