REMOVAL & INSTALLATION
See Figures 1, 2 and 3
- Raise the vehicle and support it safely on jackstands.
- Remove the transmission, as outlined in Drive Train .
- On manual transmission models, remove the bell housing, clutch pressure plate and clutch disc.
- On automatic transmission models, remove the torque converter.
- Install a dial indicator, so that the indicator rests against the face of the ring gear adjacent to the gear teeth (automatic), or against the flywheel face (manual). Hold the flywheel and crankshaft forward or backward as far as possible to prevent crankshaft end-play from being indicated as flywheel runout. Zero the dial indicator, then turn the flywheel one complete revolution by hand while observing the total dial indicator reading. If the runout exceeds 0.001 in. (0.025mm) on 2.3L engines; 0.025 in. (0.635mm) for manual, or 0.060 in. (1.5mm) for automatic on 2.8L engines; 0.070 in. (1.8mm) on 3.0L engines; and 0.005 in. (0.127mm) on 4.0L engines, the flywheel/flexplate will have to be replaced. On manual transmissions, the flywheel clutch surface can be machined true, if the runout is not excessive.
- Remove the flywheel/flexplate mounting bolts and remove the flywheel/flexplate and ring gear assembly.
- On automatic transmissions models, inspect the flexplate for cracks or other indications that would make it unfit for further use. Check the ring gear for worn, chipped or cracked teeth and replace, if any damage is found.
- On manual transmissions models, inspect the flywheel for cracks, heat damage or other problems that would make it unfit for further use. Machine the clutch friction surface if it is scored or worn. If it is necessary to remove more than 0.045 in. (1.14mm) of stock from the original thickness, replace the flywheel. Check the ring gear for worn, chipped or cracked teeth and replace, if any damage is found.
All major rotating components including the flexplate/flywheel are individually balanced. Do not attempt to install balance weights on a new flywheel.
- Position the flywheel/flexplate on the crankshaft flange and apply oil resistant sealer to the mounting bolts. Install and tighten the bolts in a crisscross pattern to the specifications given in the Torque Specifications Chart.
- On manual transmissions models, install the clutch disc and pressure plate as outlined in Drive Train . On automatic transmissions models, install the torque converter.
- Install the transmission, as outlined in Drive Train , then lower the vehicle.
RING GEAR REPLACEMENT
To replace a damaged ring gear on a manual transmission flywheel, perform the following:
- Heat the ring gear with a blow torch on the engine side of the gear and knock it off the flywheel. Do not hit the flywheel when removing the gear.
- Heat the new ring gear evenly until the gear expands enough to slip onto the flywheel. Make sure the gear is seated properly against the shoulder. Do not heat any portion of the gear more than 500°F (260°C) or the temper will be removed from the ring gear teeth.