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MBE 4000 FLYWHEEL

Three special tools are required for this procedure. They are: ‪

Flywheel Removal

Remove the flywheel as follows: ‪

  1. Remove the transmission.
  2. Remove the clutch from the flywheel.
  3. Remove the crank angle position sensor from the flywheel housing. See Figure 41962 . Refer to section .

    1. Crank Angle Position Sensor ‪

    2. Camshaft (TDC) Sensor ‪

    Crank Angle Position Sensor Removal

  4. Remove the inspection cover from the flywheel housing and install the engine cranking tool (J 46167 or 407 589 00 63 00) . Insert the pin and make sure the tool is blocked. Refer to section .
  5. Using the 19-mm socket (J 45390 or 422 589 02 09 00) , remove two flywheel socket-head bolts from the flywheel, one from each side of the bolt circle. See Figure 41963 .

    1. Flywheel Mounting Bolt (10 qty.) ‪

    2. Flywheel ‪

    Flywheel (exploded view)

  6. Screw the two flywheel guide studs (904 589 02 63 00) into the empty bolt holes in the center of the flywheel. See Figure 41964 .

    1. Bolt used as a handle ‪

    2. Flywheel Mounting Bolt ‪

    Flywheel Removal

    FALLING FLYWHEEL

    To avoid injury from a falling flywheel when removing the last bolt, hold the flywheel against the crankshaft by hand to prevent it from slipping off the crankshaft. The flywheel is not doweled to the crankshaft.

    FALLING COMPONENT

    To avoid injury from a falling component, ensure a proper lifting device is used. ‪

  7. Remove the remaining eight flywheel bolts.
  8. Remove the engine cranking tool (J 46167 or 407 589 00 63 00) . Refer to section .
  9. Remove the flywheel, leaving the guide studs (904 589 02 63 00) in place. See Figure 41964 .
    1. On opposite sides of the bolt circle, screw a bolt into each of two threaded clutch bolt holes.
    2. Using the two bolts as handles, dislodge the flywheel from the crankshaft flange and remove it from the flywheel housing.
    3. After removing the flywheel, remove the bolts from the clutch bolt holes.
  10. Inspect the flywheel bolts. Replace the bolts if any of the shanks are stretched beyond the maximum length of 77.0 mm (3.03 in.). See Figure 41965 .

    1. Shank ‪

    Measuring the Flywheel Bolts

  11. Thoroughly clean the flywheel and check the clutch surface for cracks, burned spots, or scoring.

    If the damage exceeds the maximum depth of stock, replace the flywheel. Refer to section . ‪

  12. Inspect the flywheel flange for signs of wear or traces of hollowing caused by the radial seal.
  13. Inspect the flywheel ring gear for damaged teeth or signs of wear. Replace the ring gear if necessary. Refer to section .

Flywheel Installation

Install the flywheel as follows: ‪

  1. Grease the ring gear with a suitable heavy-duty grease.

    FALLING COMPONENT

    To avoid injury from a falling component, ensure a proper lifting device is used. ‪

  2. Install the flywheel over the guide studs (904 589 02 63 00) . Align the dowel on the crankshaft with the guide hole in the flywheel. Align the dowel on the crankshaft with the guide hole in the flywheel (arrow). See Figure 41966 .
  3. Install the engine cranking tool (J 46167 or 407 589 00 63 00) in the flywheel housing and secure with two bolts. Insert the pin and make sure the tool is blocked. Refer to section .

    Flywheel Alignment Mark

    Note: Verify the alignment of the crankshaft dowel with the guide hole in the flywheel.

  4. With a light coating of engine oil, lubricate the threads of the ten multipoint socket-head flywheel bolts.
  5. Tighten the eight bolts in two stages. In each stage, use an alternate sequence to tighten the bolts, as listed in Table .

    Max. Shaft Length, mm (in.)

    Tightening Stage

    Torque Value, Nm (lbft)

    77.0 mm (3.03 in) ‪

    Stage 1 ‪

    200 Nm (147.5 lbft) ‪

    77.0 mm (3.03 in) ‪

    Stage 2 ‪

    90 degrees ‪

    Tightening Stages, Flywheel Mounting Bolts
    1. Install eight bolts to hold the flywheel in position.
    2. Remove the two guide studs (904 589 02 63 00) and install the two remaining bolts in their place.
    3. Tighten the bolts, in an alternate tightening sequence, 200 Nm (147.5 lbft).
    4. Using the same tightening sequence, turn the flywheel bolts 90 degrees.
  6. Remove the engine cranking tool (J 46167 or 407 589 00 63 00) . Install the inspection cover on the flywheel housing with two bolts. Tighten the bolts 25 Nm (18 lbft).
  7. Install the crank angle position sensor into the flywheel housing. Refer to section .
  8. Install the clutch on the flywheel.
  9. Install the transmission.

Flywheel Inspection

Perform the following procedures for inspecting the flywheel. ‪

Flywheel Inspection

Inspect the flywheel as follows: ‪

  1. Remove the flywheel. Refer to section .
  2. Thoroughly clean the flywheel and check it for cracks, scoring, burned areas, or rough spots.
  3. Using an accurate straightedge and a feeler gauge, check the friction (clutch) surface for evenness. See Figure 41970 . If the surface has areas that are too high or too low, replace the flywheel.

    1. Straightedge ‪

    2. Friction Surface ‪

    Checking the Friction Surface for Evenness

  4. Check the bearing surface and the threaded holes for wear and damage.
Flywheel Machining

Machine the flywheel as follows: ‪

Note: Before beginning any machining work on the flywheel, check it to see if machining is possible. If the scores or cracks are deeper than 1 mm (0.04 inch), replace the flywheel. If the width of the flywheel between the friction surface and the mounting flange is less than 60 mm (2.4 inches), replace the flywheel.

PERSONAL INJURY

To avoid injury while performing the test or procedure, wear adequate eye, face protection, and heat-resistant gloves.

  1. Machine the flywheel friction surface, if required, to the specifications listed in Table . See Figure 41971 . The surface finish (peak-to-valley height) after machining should be 0.016 mm (0.0006 inch). A rougher surface finish will cause rapid clutch lining wear, while a smoother finish could cause difficulties in clutch disengagement. See Figure 41972 for the locations on the flywheel to coordinate with the specifications in the table.

    Machining the Flywheel Friction Surface

    Description

    Specification in mm (inches)

    Flywheel Outside Diameter ‪

    486.60-487.40 (19.157-19.189) ‪

    Flywheel Shoulder Diameter (for ring gear mounting) ‪

    432.450-432.645 (17.0256-17.0332) ‪

    Flywheel Diameter at Crankshaft Flange ‪

    114.980-115.015 (4.5268-4.5281) ‪

    Flywheel Diameter for Mounting Clutch ‪

    475.000-475.063 (18.7008-18.7032) ‪

    Flywheel Minimum Width Between Friction Surface and Mounting Flange After Machining ‪

    60 (2.4) ‪

    Flywheel Maximum Overall Width ‪

    70 (2.8) ‪

    Peak-to-Valley Height (R z ) of Clutch Friction Surface ‪

    0.016 (0.0006) ‪

    Flywheel Permissible Deviation From True (radial and lateral) ‪

    0.2 (0.008) ‪

    Flywheel Specifications

    1. Flywheel ‪

    2. Ring Gear ‪

    Flywheel Cross Section

    After machining, the friction surface must not have any cavities or chatter marks. ‪

  2. Check the radial and lateral deviation from true of the flywheel. The deviation from true must not exceed 0.2 mm (0.008 inch).
  3. Install the flywheel. Refer to section .