CTS 2003-2005

Flywheel or Flexplate & Ring Gear

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Removal & Installation



Please note that the entire transaxle assembly must be removed to perform this procedure. Make very sure of the diagnosis before beginning work. New service replacement flywheel bolts are recommended.

  1. Remove the transaxle from the vehicle. Please see Section 7.
  2.  
  3. A flywheel locking tool may be helpful to keep the crankshaft from rotating when the flywheel bolts are loosened. Remove the flywheel bolts. New service replacement bolts are recommended.
  4.  
  5. Remove the flywheel from the vehicle.
  6.  



Click image to see an enlarged view

Fig. This typical flywheel locking tool keeps the flywheel from turning when the bolts are loosened or tightened

To install:

  1. Clean all parts well. If there is evidence of oil leaking past the rear crankshaft oil seal, replace the oil seal using the procedures found in this section. Examine the teeth around the other edge of the wheel where the starter engages. If they are worn or damaged, replace the flywheel.
  2.  
  3. Flywheel bolts may have thread-locking adhesive on the threads. If the bolts must be reused, clean the threads on the bolts and in the crankshaft.
  4.  
  5. Apply fresh thread-locking compound to all of the flywheel-to-crankshaft bolts.
  6.  
  7. The remaining installation steps are the reverse of the removal procedure. Tighten the flywheel bolts evenly. Final torque should be:
    1. 3.1L and 3.4L engines: 60 ft. lbs. (82 Nm)
    2.  
    3. 3.5L and 3.8L engines: Tighten to 11 ft. lbs. (15 Nm) plus an additional 50 degrees. NEW BOLTS ARE MANDATORY.
    4.  

  8.  
  9. Install the transaxle as outlined in Section 7.
  10.  

2.8L & 3.6L Engines
  1. Remove the transmission.
  2.  
  3. Remove the engine flywheel bolts and the flywheel.
  4.  
  5. Clean and inspect the flywheel. If the flywheel teeth are damaged, inspect the starter for proper operation. Replace the starter if there is excessive wear or damage to the starter drive.
  6.  

To install:

  1. Place the engine flywheel in position on the crankshaft.
  2.  
  3. Install 2 NEW bolts in location at the top and bottom of the engine flywheel bolt pattern allowing the engine flywheel to hang in position.
  4.  
  5. Lock the crankshaft from turning.
  6.  
  7. Install the remaining NEW engine flywheel bolts.
  8.  
  9. Tighten the NEW engine flywheel bolts to 22 ft. lbs. (30 Nm), plus an additional 45 degrees.
  10.  

3.2L Engine
  1. Remove the transmission.
  2.  
  3. Counter hold the crankshaft with Crankshaft Hub Socket J-42098 and remove the flywheel bolts.
  4.  
  5. Discard the flywheel bolts.
  6.  
  7. Remove the engine flywheel and retainer from the crankshaft.
  8.  
  9. Clean the rear crankshaft flange.
  10.  
  11. Clean and inspect the engine flywheel.
  12.  

To install:

  1. Install the engine flywheel and retainer to the crankshaft.
  2.  
  3. Coat the new flywheel bolts with thread retaining compound.
  4.  
  5. Counter hold the crankshaft with the J-42098 and install the new flywheel bolts.
  6.  
  7. Tighten the flywheel bolts to 48 ft. lbs. (65 Nm).
  8.  
  9. Rotate the bolts 30 degrees, then an additional 15 degrees.
  10.  
  11. Install the transmission.
  12.  

5.7L Engine

NOTE
For manual transmission applications, note the position and direction of the engine flywheel before removal. The flywheel does not use a locating pin for alignment. Mark or scribe the end of the crankshaft and the flywheel before component removal. The engine flywheel must be reinstalled to the original position and direction. The engine flywheel will not initially seat against the crankshaft flange, but will be pulled onto the crankshaft by the engine flywheel bolts. This procedure requires a 3-stage tightening process.

  1. Remove the transmission.
  2.  
  3. If equipped with manual transmission, remove the clutch assembly.
  4.  
  5. Mark or scribe the end of the crankshaft and the flywheel.
  6.  
  7. Remove the engine flywheel.
  8.  
  9. Note the position and location of the manual transmission flywheel balance weights, if applicable.
  10.  
  11. Clean and inspect the engine flywheel.
  12.  

To install:

Click image to see an enlarged view

Fig. Engine flywheel bolt tightening sequence-5.7L

  1. Align the mark or scribe on the crankshaft with the mark or scribe on the existing flywheel.
  2.  
  3. Install the engine flywheel.
  4.  
  5. Apply threadlock to the threads of the flywheel bolts.
  6.  
  7. Install the engine flywheel bolts and tighten in sequence as follows:
    1. First pass in sequence to 15 ft. lbs. (20 Nm).
    2.  
    3. Second pass in sequence to 37 ft. lbs. (50 Nm).
    4.  
    5. Final pass in sequence to 74 ft. lbs. (100 Nm).
    6.  

  8.  
  9. Install the clutch assembly, if equipped.
  10.  
  11. Install the transmission.
  12.  

 
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