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.



5. Loosen the flywheel mounting bolts.
6. Remove the J 44643 .

Caution: When removing, handling or installing this component wear protective gloves. The sharp edges on the component may be very sharp and may cause injury.

7. Remove the flywheel.

1. Inspect the flywheel for the following:

•	Excessive wear to the ring gear teeth

•	Clutch surface for cracking, hot spots, grooved, or excessive wear.

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.





Caution: When removing, handling or installing this component wear protective gloves. The sharp edges on the component may be very sharp and may cause injury.

2. Install the flywheel assembly.

Important: Use NEW bolts to install the flywheel.

3. Loosely install the NEW flywheel bolts.



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

Notice: Refer to Fastener Notice in the Preface section.




5. 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 .
4. Confirm the tightening torque is at least to 360 N·m (266 lb ft).
6. Remove the J 44643 .
7. Install the clutch. Refer to Clutch Assembly Replacement in Clutch.
8. Install the starter. Refer to Starter Motor Replacement in Engine Electrical.
9. Install the transmission. Refer to Transmission Replacement in Manual Transmission - ZF S6-650.