Note. The following special equipment is required for the work described below: plunger-type dial gauge and a suitable heat source (blowtorch or gas burner).
Note. Either the engine or transmission must be removed to gain access to the flywheel/drive plate. The choice is left to the discretion of the contractor, depending on the availability of appropriate lifting equipment.
Removing
1. Remove the engine or transmission.
2. On models with a manual transmission, mark the mounting position of the clutch basket on the flywheel. Gradually loosen and unscrew the mounting bolts, remove the basket from the guide pins and remove the clutch assembly.
3. Block the flywheel/drive plate from turning and unscrew its fastening bolts (see accompanying illustration).
1 - guide bearing
2 - bolts
4. Having marked the installation position of the flywheel / drive disk on the crankshaft trunnion, remove it from the vehicle.
Installation
1. Installation is carried out in the reverse order.
2. Follow the correct alignment of the landing marks applied during dismantling. Tighten the flywheel/drive plate mounting bolts to specification.
3. On models with a manual transmission, center the clutch disc on the crankshaft guide bushing using the old gearbox input shaft or a special centering tool for this purpose. In several stages, working diagonally, tighten the clutch basket mounting bolts to the required torque.
Status check
1. Estimate the amount of runout in contact with the clutch disc / rotation converter (working) flywheel/drive plate surface. If the runout value of both the flywheel/drive plate removed from the crankshaft and put on it exceeds 0.1 mm, the assembly should be replaced.
2. Check the working surface of the flywheel for cracks, deep scratches and burrs.
3. Check the crown teeth for chips, cracks and signs of actuation.
Attention! Replacing the flywheel ring gear is possible, the drive disk is not!
Flywheel ring gear replacement
1. Remove the flywheel from the vehicle and drill a ø 3 mm hole between the two ring teeth.
Note. The hole must not be through to avoid damage to the flywheel flange.
2. Place a chisel over the drilled hole and split the crown with sharp hammer blows.
3. Remove the crown from the flywheel, then remove any burrs and burrs from the seating surface.
4. Polish several areas on a new ring gear with sandpaper and start heating the latter until the polished areas turn a dark blue tint.
5. Quickly slide the crown onto the flywheel with the chamfered teeth up and away from the flywheel flange. Make sure that the crown is firmly seated and tightly pressed against the flange.
Attention! Allow the crown to cool naturally, in no case do not pour water over it!