Flywheel/driveplate - removal, inspection and refitting
Note: The manufacturers recommend that the flywheel/driveplate securing bolts are renewed after slackening. Suitable thread-locking agent will be required to coat the bolt threads.
1 If the engine is in the vehicle, remove the clutch or the automatic transmission, as applicable.
2 Prevent the flywheel/driveplate from turning by jamming the ring gear teeth or by bolting a strap between the flywheel/driveplate and the cylinder block.
3 Make alignment marks on the flywheel/driveplate and the end of the crankshaft, so that the flywheel/driveplate can be refitted in its original position.
4 Unscrew the securing bolts and withdraw the flywheel/driveplate. Do not drop it, it is very heavy. Note that on models with A4LD type automatic transmission, the driveplate may be secured with one or two reinforcing plates depending on model.
5 The engine adapter plate may now be withdrawn from the dowels if required (see illustration).
26.5 Withdrawing the engine adaptor plate
6 With the flywheel/driveplate removed, the ring gear can be examined for wear and damage.
7 If the ring gear is badly worn or has missing teeth it should be renewed. The old ring can be removed from the flywheel/driveplate by cutting a notch between two teeth with a hacksaw and then splitting it with a cold chisel. Wear eye protection when doing this.
8 Fitting of a new ring gear requires heating the ring to 400ºF (204ºC). This can be done by polishing four equally spaced sections of the gear, laying it on a heat resistant surface (such as fire bricks) and heating it evenly with a blow lamp or torch until the polished areas turn a light yellow tinge. Do not overheat, or the hard wearing properties will be lost. The gear has a chamfered inner edge which should fit against the shoulder on the flywheel. When hot enough, place the gear in position quickly, tapping it home if necessary, and let it cool naturally without quenching in any way.
9 Commence refitting of the flywheel/driveplate by refitting the engine adapter plate to the dowels on the rear of the cylinder block, where applicable.
10 Ensure that the mating faces are clean, then locate the flywheel/driveplate on the rear of the crankshaft, aligning the previously made marks (see illustration).
26.10 Flywheel located on crankshaft
11 Coat the threads of the securing bolts with a liquid thread-locking agent, then insert the bolts. Note that the manufacturers recommend the use of new bolts. Where applicable refit the reinforcing plate(s) on models with A4LD type automatics 12 Prevent the flywheel/driveplate from turning as described in paragraph 2, then tighten the securing bolts to the specified torque in a diagonal sequence (see illustration).
26.12 Use a strap to prevent the flywheel turning as its securing bolts are tightened
13 If the engine is in the vehicle, refit the clutch or the automatic transmission, as applicable.
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