ISM, ISMe, and QSM11 – 016-005   Flywheel

WARNING  This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly.

• Remove the vehicle driveline and transmission. Refer to the OEM service manual.
• Remove the clutch discs and pressure plate. Refer to the OEM service manual.

Hold the flywheel to prevent rotation.

Install M10 – 1.50 x 40 puller capscrews (at points 1 and 2).

Remove capscrew (3) and install guide pin, Part Number 3376696.

NOTE: If a clutch is used in the equipment, the threads in the clutch pressure plate mounting capscrew holes can be metric or standard. Be sure to use the correct capscrews.

Determine the capscrew thread design and size, and install two “t-handles” in the flywheel (at points 4 and 5).

Remove the remaining seven flywheel mounting capscrews.

WARNING  This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly.

Tighten capscrews (1 and 2) in alternating sequence to loosen the flywheel.

Remove the flywheel from the guide pin.

WARNING  When using a steam cleaner, wear safety glasses or a face shield as well as protective clothing. Hot steam can cause serious personal injury.

WARNING  When using solvents, acids or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury.

Use a wire brush to clean the crankshaft pilot bore.

Use steam or solvent to clean the flywheel. Dry with compressed air.

Inspect for nicks or burrs.

Use Scotch-Brite™ 7448, Part Number 3823258 or equivalent, to remove small nicks and burrs.

WARNING  Do not use a cracked flywheel. A cracked flywheel can break and cause serious personal injury or property damage.

Inspect the flywheel for cracks.

Inspect the flywheel ring gear teeth for cracks and chips.

If the ring gear teeth are cracked or broken, the ring gear must be replaced.

Use a new pilot bearing when installing a new or rebuilt clutch.

Remove the pilot bearing with a mandrel and hammer.

Clean the pilot bore with Scotch-Brite™ 7448, Part Number 3823258, or equivalent.

Install the pilot bearing with a mandrel and hammer.

The pilot bearing must be installed flush with the pilot bore surface.

WARNING  This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly.

Install guide pin, Part Number 3376696, in the crankshaft flange.

Install the flywheel on the guide pin.

Install the seven capscrews.

Remove the “T-handles” and the guide pin.

Install the remaining capscrew in the hole.

Tighten the capscrews in a star pattern.

Use dial indicator gauge (1), Part Number 3376050 or equivalent, and dial gauge attachment (2), Part Number ST-1325, to inspect the flywheel bore (3) and face (4) runout.

Install the attachment to the flywheel housing.

Install the gauge on the attachment.

Install the contact tip of the indicator against the inside diameter of the flywheel bore.

Use the accessory driveshaft to rotate the crankshaft one complete revolution (360 degrees).

The total indicator reading must not exceed 0.127 mm [0.0050 in].

WARNING  This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly.

Remove the flywheel if the total indicator reading is greater than the specification.

Inspect the flywheel mounting surface for dirt or damage.

Inspect the crankshaft for dirt or damage.

WARNING  This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly.

Install the flywheel and inspect the bore runout again.

WARNING  This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly.

Replace the flywheel if the runout does not meet specifications.

Install the contact tip of the indicator against the flywheel face as close to the outside diameter as possible to inspect the face (4) run out.

Push the flywheel forward to remove the crankshaft end thrust.

Use the accessory driveshaft to rotate the crankshaft one complete revolution (360 degrees) while keeping the crankshaft end thrust pushed forward.

The total indicator reading must not exceed the following specifications.

WARNING  This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly.

• Install the clutch discs, pressure plate, transmission, and driveline, if equipped, in reverse order of removal. Refer to the OEM service manual.
• Align the universal joints on each end of the driveshaft to prevent vibration.
• Operate the engine and check for proper operation.