Chrysler Full-Size Trucks 1997-2000 Repair Guide

Flywheel/Flexplate

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REMOVAL & INSTALLATION




NOTE
Flexplate is the term for a flywheel mated with an automatic transmission.

The flywheel serves as the forward clutch engagement surface. It also serves as the ring gear with which the starter pinion engages to crank the engine. The most common reasons to replace the flywheel are:



Broken teeth on the flywheel ring gear
 
Excessive driveline chatter when engaging the clutch
 
Excessive wear, scoring or cracking of the clutch surface
 

3.9L, 5.2L, 5.9L Gasoline Engines

NOTE
The ring gear is replaceable only on engines mated with a manual transmission, or automatic transmissions with a non lock-up torque converter. On engines with an automatic transmission and lock-up torque converter, the ring gear is not replaceable, so you must replace the torque converter assembly.

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and support the vehicle.
  4.  
  5. Remove the transmission.
  6.  
  7. If your vehicle has a manual transmission:
    1. Remove the clutch assembly.
    2.  

  8.  


NOTE
The bolts should be loosened a little at a time in a crisscross pattern to avoid warping the pressure plate.

  1. Remove the flywheel bolts.
  2.  


NOTE
The flywheel bolts should be loosened a little at a time in a crisscross pattern to avoid warping the flywheel.

  1. Replace the pilot bearing in the end of the crankshaft after removing the flywheel.
  2.  
  3. The flywheel should be checked for cracks and glazing. It can be resurfaced by a machine shop.
  4.  

  1. If the ring gear is to be replaced, drill a hole in the gear between two teeth, being careful not to contact the flywheel surface. Using a cold chisel at this point, crack the ring gear and remove it. Polish the inner surface of the new ring gear and heat it in an oven to about 600ºF (316ºC). Quickly place the ring gear on the flywheel and tap it into place, making sure that it is fully seated.
  2.