ISC, ISCe, QSC8.3, ISL, ISLe3, ISLe4 and QSL9 Engines – 016-004   Flexplate

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

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.

• Disconnect the battery. Refer to Procedure 013-009 in Section 13.
• Remove the transmission and related components. Refer to the OEM service manual.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

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.

• Disconnect the batteries. Refer to Procedure 013-009 in Section 13.
• Remove the drive gear. Refer to OEM service manual.

For automotive and industrial applications, inspect the flexplate ring gear teeth for damage.

If the flexplate ring gear is damaged, make sure to evaluate the following possible causes prior to replacing the flexplate.

Mechanical

A mechanical issue can typically be identified by seeing damage to the ring gear of the flexplate in 3 distinct locations for 6 cylinder engines (commonly called 120 degree milling), and 2 locations for 4 cylinder engines (commonly called 180 degree milling). The following can be causes for mechanical issues:

1. The possibility of improper starter motor spacing. Refer to Procedure 013-020 in Section 13.
2. The interference between the ring gear land area and the starting motor pinion. The wrong starting motor might be installed, refer to the original equipment manufacturer’s specifications.
3. The possibility of a damaged starter motor pinion. Inspect the pinion for nicks and burrs. If replacement of the starting motor is necessary. Refer to Procedure 013-020 in Section 13.
4. The torque converter/transmission is damaged or incorrectly mounted. Refer to the OEM service manual.
5. Incorrect starting motor pinion to flexplate ring gear pitch and teeth match. Refer to the OEM service manual.

Electrical

An electrical issue can typically be identified by seeing damage to the ring gear of the flexplate 360 degrees around the circumference of the ring gear (commonly called 360 degree milling). The following can be causes for electrical issues:

1. The operator is attempting to start engine while engine is already running. Check if a starter lockout feature is available through the OEM (activated with INSITE™ electronic service tool) or the starting motor manufacturer.
2. The key switch is causing intermittent starting motor engagement when the engine is running. Inspect the key switch. Refer to Procedure 013-020 in Section 13.
3. The orientation of the starter relay, where in the direction of the pull contact is in the direction of the vehicle’s travel. This results in intermittent starter motor engagement when the engine is running. Relocate the starter relay. Refer to the OEM service manual.
4. Intermittent starter motor wiring issues. Refer to the OEM service manual.

Remove the flexplate capscrews and flexplate.

NOTE: Some flexplates require mounting plates and/or adapters. It may be necessary to remove any mounting plates and/or adapters prior to or with the flexplate. Make sure to note the location of any mounting plates and/or adapters for later installation.

Remove the nine flex-coupling guard capscrews, harness connector, and the flex-coupling guard (if equipped).

Remove the flexplate mounting capscrews.

Remove the flexplate from the flywheel.

Inspect the teeth of the ring gear for chips or uneven wear.

Check the flexplate for cracks.

Replace the flexplate if any damage is found.

Check the flexplate for cracks at the mounting holes, drive splines, and the inner drive plate.

Replace the flexplate if any damage is found.

NOTE: Some flexplates require mounting plates and/or clamp rings. It may be necessary to install any mounting plates and/or clamp rings prior to or with the flexplate as noted during removal.

Install the flexplate, the flexplate capscrews, and tighten.

Install the flexplate and flexplate mounting capscrews.

Tighten the capscrews.

If the engine is equipped with a flex-coupling guard plate, install the flex-coupling guard plate onto the flywheel housing. Position the wiring harness connector at the 11 o’clock position, as shown in the illustration. Install a capscrew to hold it in place.

Install the remaining eight capscrews.

Tighten the capscrews.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

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.

• Connect the batteries. Refer to Procedure 013-009 in Section 13.
• Install the transmission and related components. Refer to the OEM service manual.
• Operate the engine and check for noise or vibration.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

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.

• Connect the batteries. Refer to Procedure 013-009 in Section 13.
• Install the drive gear. Refer to OEM service manual.
• Check the crankcase end play.Refer to Procedure 001-016 in Section 1.
• Operate the engine and check for noise or vibration.