Chrysler Full-Size Vans 1989-1998 Repair Guide

Flywheel/Flexplate

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REMOVAL & INSTALLATION



See Figure 1

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

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.The bolts should be loosened a little at a time in a crisscross pattern to avoid warping the pressure plate.
    2.  
    3. Remove the flywheel bolts.The flywheel bolts should be loosened a little at a time in a crisscross pattern to avoid warping the flywheel.
    4.  
    5. Replace the pilot bearing in the end of the crankshaft after removing the flywheel.
    6.  
    7. The flywheel should be checked for cracks and glazing. It can be resurfaced by a machine shop.
    8.  

  8.  
  9. 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.
  10.  

Polish the inner surface of the new ring gear and heat it in an oven to about 600

F (316C)



Quickly place the ring gear on the flywheel and tap it into place, making sure that it is fully seated.


WARNING
Never heat the ring gear past 800F (426C), or the tempering will be destroyed.

  1. If your vehicle has an automatic transmission:
    1. Remove the torque converter from the transmission. This is done by removing the c-clamp from the edge of the bell-housing, and carefully sliding the torque converter off of the input shaft of the transmission.
    2.  

  2.  


CAUTION
The torque converter is usually rather heavy, be prepared for the weight when the converter comes off of the input shaft.



The converter is mated to the engine by a drive plate. To unbolt it, remove the retaining bolts from the crankshaft.

Click image to see an enlarged view

Fig. Fig. 1: Removing the starter ring gear with a cold chisel

 
To install:If your vehicle has a manual transmission:
  1. Position the flywheel on the end of the crankshaft. Tighten the bolts a little at a time, in a cross pattern, to 55 ft. lbs. (75 Nm).
  2.  
  3. Install the clutch assembly.
  4.  

 
If your vehicle has a automatic transmission:
  1. Install the torque converter on the input shaft.
  2.  
  3. Install the c-clamp that retains the converter to the bell housing.
  4.  

 
Install the transmission.
 
Lower the vehicle.
 
Connect the negative battery cable.
 
Check the transmission fluid level.
 

 
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