Volvo 240/740/760/780/940/960 1990-1998

Flywheel/Flexplate

Print

REMOVAL & INSTALLATION



See Figures 1 and 2

The ring gear is contacted by the starter gear during engine start up. If any damage is found on the ring gear (broken or chipped teeth, cracks, etc.) the cause of the failure should be identified and repaired. The starter should be checked as a possible cause.

On vehicles with automatic transmission, the ring gear is an integral part of the flexplate and cannot be replaced. On vehicles with manual gearboxes, the ring gear on the flywheel can be removed and replaced. This replacement involves heating the ring to 450°F, and handling the heated ring. It is usually found to be easier to buy a complete flywheel and ring gear assembly than to attempt the replacement. If you possess the proper equipment for heating and handling the ring gear, the procedure is as follows:

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and support the vehicle.
  4.  
  5. Remove the transmission, as described in Drive Train .
  6.  
  7. If equipped with a manual transmission/transaxle, remove the clutch plate and disc.
  8.  
  9. Remove the bolts attaching the flywheel or ring gear to the crankshaft flange.
  10.  
  11. Remove the flywheel or ring gear.
  12.  
  13. Inspect the flywheel for cracks, grooves, or bluing and inspect the ring gear for burrs or worn teeth.
  14.  
  15. Replace the flywheel or ring gear if any damage is apparent.
  16.  
  17. Remove burrs with a mill file.
  18.  
  19. To replace a ring gear, use the following steps.
    1. Use a 10mm bit and drill a hole between two cogs (teeth) on the ring gear, being careful not to drill into the flywheel.
    2.  
    3. Mount the flywheel in a vise protected by soft jaws and split the ring gear at the hole with a chisel.
    4.  
    5. Heat the new ring gear to approximately 450°F (232°C). When handling the heated ring, wear heavy gloves and use tongs.
    6.  
    7. Position the ring gear with the beveled side facing the flywheel.
    8.  
    9. Use a brass drift and tap the ring gear until flush. Allow to air cool before installation; do not attempt to cool the metal with water, oil or other fluids.
    10.  

  20.  
  21. Install the flywheel.
  22.  
  23. Install the bolts and torque to specification in a crisscross pattern.
  24.  
  25. Install the transmission, as described in Drive Train .
  26.  
  27. Lower the vehicle.
  28.  
  29. Connect the negative battery cable.
  30.  



Click image to see an enlarged view

Fig. Fig. 1: The flywheel must be immobilized so that the retaining bolts can be removed; tool 5112 is being used here to hold the flywheel



Click image to see an enlarged view

Fig. Fig. 2: Check the ring gears teeth for damage; if damage is noted, replace the ring gear

 
label.common.footer.alt.autozoneLogo