Series 638

Section 1.16 Flywheel

Section 1.16
Flywheel

The flywheel is attached to the rear of the crankshaft with six bolts. The bolt holes in the crankshaft and flywheel are evenly spaced. The flywheel is indexed to the crankshaft with a roll pin. See Figure "Flywheel Assembly" .‪

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1.Flywheel‪

3.Ring Gear‪

2.Flywheel Housing‪

Figure 1. Flywheel Assembly

Section 1.16.1
Repair or Replacement of Flywheel

To determine if replacement of the flywheel is necessary, perform the following procedure. See Figure "Repair or Replacement of Flywheel Flowchart" .‪

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Figure 2. Repair or Replacement of Flywheel Flowchart

Section 1.16.2
Removal of the Flywheel

Removal of flywheel as follows:‪

  1. Remove engine speed sensor. Refer to "2.6.2 Removal of Engine Speed Sensor" .
  2. Remove transmission assembly. Refer to OEM guidelines.
  3. Remove clutch pressure plate and disk assembly. Refer to OEM guidelines.
  4. Remove six flywheel-to-crankshaft retaining bolts. See Figure "Flywheel-to-Crankshaft Retaining Bolts Location" .
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    1.Bolt‪

    3.Ring Gear‪

    2.Flywheel‪

    Figure 3. Flywheel-to-Crankshaft Retaining Bolts Location

  5. Remove flywheel from crankshaft.
Section 1.16.2.1
Inspection of the Flywheel

Inspect the flywheel as follows:‪

  1. Visually check the flywheel clutch surface for scoring and wear.
    1. If the clutch surface is scored or worn, replace the component. Refer to "1.16.3 Installation of Flywheel" .
    2. If the clutch surface is not worn or scored, proceed with step 2 of inspection.
  2. Visually check the flywheel clutch surface for cracking.
    1. If the clutch surface is cracked, replace the component. Refer to "1.16.3 Installation of Flywheel" .
    2. If the clutch surface is not cracked, proceed with step 3 of inspection.
  3. Visually check the flywheel ring gear for worn or damaged gear teeth.
    1. If the flywheel ring gear has worn or damaged gear teeth, replace the component. Refer to "1.16.3 Installation of Flywheel" .
    2. If the flywheel ring gear teeth are not worn or damaged, proceed with step 4 of inspection.
  4. Visually check the flywheel-to-crankshaft contact surface for fretting, brinelling, or burning.
    1. If the flywheel-to-crankshaft contact surface is fretted, brinelled, or burnt, repair the component with emery cloth or a stone. Refer to "1.16.3 Installation of Flywheel" .
    2. If the flywheel-to-crankshaft contact surface is not fretted, brinelled, or burnt, proceed with step 5 of inspection.
  5. Visually check the flywheel surface for grooving.
    1. If the flywheel surface is grooved, replace the component. Refer to "1.16.3 Installation of Flywheel" .
    2. If the flywheel surface is not grooved, reuse the component. Refer to "1.16.3 Installation of Flywheel" .

Section 1.16.3
Installation of Flywheel

Install the flywheel as follows:‪

  1. Install flywheel to the crankshaft using six retaining bolts. Torque bolts in diametrically opposite pairs to 137 N · m (101 lb · ft.). See Figure "Flywheel Torque Sequence" .

    Note: Lightly lubricate bolts with lubrication oil.

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    Figure 4. Flywheel Torque Sequence

  2. Install clutch pressure plate and disk assembly. Refer to OEM guidelines.
  3. Install transmission assembly. Refer to OEM guidelines.
  4. Install engine speed sensor. Refer to "2.6.3 Installation of Engine Speed Sensor" .
  5. Run the engine to verify repair.


Series 638 Service Manual - 6SE648
Generated on 10-13-2008

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