Replace ring gear on flywheel

AR03.30-W-8312B

Replace ring gear on flywheel

12.12.08

5.7.06

Work procedure revised.



Removing

1

Remove flywheel (2)

AR03.30-W-8002B

 Danger!

Risk of injury to skin and eyes caused by handling hot or glowing objects.

Wear safety gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

2

Use a welding torch to rapidly heat up ring gear (1) and press it off the flywheel (2) using a suitable drift

 Underlay flywheel (2).



Measure

3

Measure ring gear inside diameter and flywheel diameter for mounting the ring gear (B) on flywheel (2) and calculate overlap between ring gear (1) and flywheel (2)

Ring gear inside diameter and overlap between ring gear and flywheel

*BE03.30-N-1002-04C

Flywheel diameter for mounting ring gear

*BE03.30-N-1005-03C

 If the standard flywheel diameter for mounting the ring gear (1) or the ring gear inside diameter and overlap between ring gear (1) and flywheel (2) are not reached:



Replace flywheel (2) or remachine diameter of flywheel (2) for mounting ring gear (1) to the next deviation and select a new ring gear (1) with an appropriate deviation.



Install

 Danger!

Risk of injury to skin and eyes caused by handling hot or glowing objects.

Wear safety gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

4

Heat new ring gear (1)

 The correct pulling on temperature is reached once ring gear (1) has a bright yellow annealing color.

*BE03.30-N-1002-04C

5

Lay ring gear (1) onto flywheel (2) up to the contact surface

 Allow ring gear (1) to cool for at least 2 minutes and then set back ring gear (1) using a brass drift.

6

Attach centerings on ring gear (1) through the bores for mounting bolts for clutch pressure plate (A)

 Use Ø 11.0 mm drill bit.

7

Drill out core hole bores for thread in the ring gear (1)

 Use a 4.5 mm Ø drill bit.

8

Drill core hole bores for thread in the ring gear (1)

 Use a 8.5 mm Ø drill bit.

9

Turn flywheel (2) and chamfer core hole bores in the ring gear (1)

10

Cut a thread in all core hole bores in the ring gear (1)

 Use a thread cutter M10

11

Install flywheel (2)

AR03.30-W-8002B

Number

Designation

Engine 541.9, 542.9 without code G02

BE03.30-N-1005-03C

Flywheel Ø

for mounting

Default

mm

432.490 to 432.645

Starter ring gear

Deviation 0.5

mm

431.990 to 432.145

Number

Designation

Engine
541.9, 542.9 with code G02

BE03.30-N-1002-04C

Starter ring gear

Inside Ø

Default

mm

-

Deviation 0.5

mm

-

Flywheel overlap

mm

-

Flywheel permissible radial runout

mm

-

Width

mm

-

Installation temperature

°C

-