Removal and Replacement

Flywheel And Starter Ring Gear

Flywheel - remove







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

NOTE: Dowel located

Flywheel and starter ring gear - inspection







1. Inspect flywheel face for cracks, scores and overheating. The flywheel can be refaced on the clutch face providing thickness does not go below minimum.
Flywheel minimum thickness A = 40.45 mm (1.6 in)

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

CAUTION: Do not attempt to remove reluctor ring.

3. Renew starter ring gear if necessary.

Starter ring gear - renew







1. Drill a 6 mm (0.250 in) diameter hole at root of 2 teeth.

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 (340 ° and 350 °F).

CAUTION: Do not exceed this temperature.

WARNING: Take care when handling hot ring gear.

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 on to 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. Using assistance, restrain crankshaft and tighten flywheel bolts to 80 Nm (59 ft. lbs.).