Replacing an diesel engine flywheel can be a daunting task, like Cummins | Perkins | Deutz diesel engine, but for those who are fairly familiar with the inner workings of their car, it should not be necessary to seek the help of a mechanic. Engine flywheels are normally highly durable, but if the teeth of the flywheel become worn, which they will eventually, the flywheel will need replacing.
The replacement process itself is not overly complicated. Accessing the flywheel is by far the hardest part. You should also refer to the owner’s handbook for your vehicle to see if it has any further information specific to your car.
Step 1 – Remove the Drive Shaft
Disconnect the differential from the drive shaft. The drive shaft will be connected by a couple of bolts. There will be a nut on each end. Remove these with the wrench and pull it away. Place a drip pan underneath the area where the drive shaft meets the transmission. Any fluid that drains from the transmission should leak into the drip pan.
Step 2 – Disconnect the Other Components
You will need to disconnect the transmission cooler lines from the transmission, the speedometer cable, and the shift linkage line. You should be able to disconnect these three components using the wrench. Disconnect the cooler lines using a flare-nut wrench.
Step 3 – Disconnect the Transmission
Place the transmission jack beneath the transmission. Lift it until it rests firmly on the oil pan. Disconnect the transmission by removing the retaining nuts which attach it to the engine block. Remove bolts holding torque converter to flywheel. To reveal the flywheel, pull the transmission towards the back of the car once it has been disconnected.
Step 4 – Remove the Old Flywheel
The flywheel is held in place by retaining bolts, which you can find in its center. Remove these with a wrench, and then carefully remove the flywheel from the crankshaft by pulling it away. Put the replacement flywheel in its place and replace the retaining bolts, tightening them firmly.
Step 5 – Reattach the Transmission
Slide the transmission back to the engine and attach it in place. Make sure that the torque converter is correctly aligned with the holes of the flywheel. Tighten the retaining nuts to secure it in place. Return the retaining nuts to the transmission’s housing and tighten them. Reconnect the two transmission cooler lines using the flare-nut wrench again. Reconnect the speedometer cable, as well as the shift linkage line.
Step 6 – Reinstall the Drive Shaft
To replace the drive shaft, slide it back into the rear of the transmission and position its back against the differential. Return the bolts that you removed in Step 1, and tighten them appropriately. You will also need to add fluid back into the transmission.
Step 7 – Test the Vehicle
When everything has been put back together, test the vehicle to make sure that the new flywheel is working as intended.