Tools Required

1. Remove the transmission. Refer to Transmission Replacement in Manual Transmission - ZF S6-650.
2. Remove the starter. Refer to Starter Motor Replacement in Engine Electrical.
3. Remove the clutch. Refer to Clutch Assembly Replacement in Clutch.



4. Install the J 44643 to the starter opening in order to hold the flywheel.




Important: The dual mass flywheel may require re-indexing in order to access the flywheel to crankshaft bolts through the secondary ring of the flywheel.

5. In order to access the flywheel to crankshaft bolts re-index the dual mass flywheel using the following procedure.

5.1.	Install 2 bolts into the clutch pressure plate mounting holes 180 degrees apart. Do not use the clutch pressure plate bolts. Use a bolt of the correct thread and a length that protrudes enough to use a pry bar.

5.2.	Using a long pry bar turn the secondary ring of the dual mass flywheel clockwise until the flywheel mounting bolts can be accessed. It may require to turn the secondary ring past the bolt holes in order to compensate the spring tension.




6. Loosen the flywheel mounting bolts and discard.
7. Remove the J 44643 .
8. Remove the flywheel.



9. Remove the pilot bearing using a hammer and a punch from the flywheel. The pilot bearing is removed from the crankshaft side of the flywheel.

1. Inspect the flywheel for the following:

•	Missing or damaged clutch plate pins (1)

•	Excessive wear to the ring gear teeth (2)

•	Broken damper springs (3)

•	Loose rivets (4)

•	Clutch surface for cracking, hot spots, grooved, or excessive wear (5)

2. Replace the flywheel assembly if any of the conditions are found.
3. Replace the ring gear on the flywheel if teeth are worn or damaged.



4. Using the following procedures replace the ring gear on the flywheel:

4.1.	Heat the ring gear evenly with a torch. Do not overheat.

4.2.	Using a hammer and punch remove the ring gear.

1. Replace the ring gear, if removed.

Important: When heating the ring gear with a torch do not overheat. Do not get the ring gear so hot that it turns blue or red.

1.1.	Heat the ring gear evenly with a torch.

1.2.	Using a hammer and a brass punch install the ring gear until seated.




2. Install the pilot bearing in the flywheel.



3. Install the flywheel assembly.

Important: Use NEW bolts to install the flywheel.

4. Loosely install the NEW flywheel bolts.



5. Install the J 44643 in order to hold the flywheel from rotating.




Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

6. Use the following steps and the proper sequence to tighten the bolts:

Tighten

1. Tighten the flywheel bolts to 78 N·m (58 lb ft).
2. Tighten the flywheel bolts to 60 degrees using the J 36660-A .
3. Tighten the flywheel bolts again to 60 degrees using the J 36660-A .
7. Remove the J 44643 .
8. Install the clutch. Refer to Clutch Assembly Replacement in Clutch.
9. Install the starter. Refer to Starter Motor Replacement in Engine Electrical.
10. Install the transmission. Refer to Transmission Replacement in Manual Transmission - ZF S6-650.