Replace ring gear on flywheel

AR03.30-G-8312B

Replace ring gear on flywheel

16.8.11

 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

1

Remove flywheel (1.1 or 1.2)

AR03.30-G-8002B

2

Heat up starter ring gear rapidly (2) using a welding torch

3

Force off starter ring gear (2) from flywheel (1.1 or 1.2)

4

Measure the flywheel diameter for mounting the starter ring gear (B)

*BE03.30-N-1002-03I

5

Measure starter ring gear inner Ø

 The overlap between starter ring gear (2) and flywheel (1.1 or 1.2) must be maintained.

*BE03.30-N-1001-04I

*BE03.30-N-1002-04I

6

Heat up new starter ring gear (2)

 Temperature is reached, when the starter ring gear (2) has a bright yellow annealing color.

*BE03.30-N-1005-04I

7

Press the starter ring gear (2) onto flywheel (1.1 or 1.2) up to the contact surface.

 When pressed on, the permissible radial runout of starter ring gear (2) must not be exceeded.

*BE03.30-N-1003-04I

*BE03.30-N-1004-04I

8

Attach centering pins through the holes in flywheel (1.2) for the threaded holes (A)

Only for flywheel (1.2) in engine 902, 906 with 443 dia. flywheel and 395 dia. clutch

 Use 11.0 dia. mm drill bit.

The centering pins are needed for the core drillings.

9

Pre-drill the core holes in starter ring gear (2) for the thread

Only for flywheel (1.2) in engine 902, 906 with 443 dia. flywheel and 395 dia. clutch

 Use a 4.5 mm dia. drill bit.

10

Drill the core holes in starter ring gear (2) to the final dimension for the thread

Only for flywheel (1.2) in engine 902, 906 with 443 dia. flywheel and 395 dia. clutch

 Use a 8.5 mm Ø drill bit.

11

Turn the flywheel (1.2) over and chamfer the core drillings in starter ring gear (2)

Only for flywheel (1.2) in engine 902, 906 with 443 dia. flywheel and 395 dia. clutch

12

Cut threaded holes (A) in all core drillings in the starter ring gear (2) to support the clutch pressure plate

Only for flywheel (1.2) in engine 902, 906 with 443 dia. flywheel and 395 dia. clutch

 Use a M10 thread tap.

13

Install flywheel (1.1 or 1.2)

AR03.30-G-8002B

Number

Designation

Engine 900.915/916, 904.927/928 with a 443 dia. flywheel and 362 dia. connector

Engine 900.920/921, 904.952/953, 924.916/923/931 with a 403 dia. flywheel and 362 dia. connector

BE03.30-N-1002-03I

Flywheel dia. for mounting starter ring gear (B)

mm

392.435 to 392.575

360.435 to 360.575

Number

Designation

Engine 902.923/924/935,
906.935/955,
926.969
with 443 dia. flywheel and 395 dia. connector

BE03.30-N-1002-03I

Flywheel dia. for mounting starter ring gear (B)

mm

392.435 to 392.575

Number

Designation

Engine 900.915/916, 904.927/928
with a 443 dia. flywheel and 362 dia. connector

Engine 900.920/921, 904.952/953,
924.916/923/931
with a 403 dia. flywheel and 362 dia. connector

BE03.30-N-1001-04I

Starter ring gear inner dia.

mm

392.000...392.140

359.690 to 359.830

BE03.30-N-1002-04I

Starter ring gear / flywheel - overlap

mm

0.295...0.575

0.605 to 0.885

BE03.30-N-1003-04I

Starter ring gear / flywheel - permissible radial runout

mm

0.5

0.5

BE03.30-N-1004-04I

Starter ring gear - width

mm

15.6...16.0

15.6...16.0

BE03.30-N-1005-04I

Starter ring gear - installation temperature

°C

250 to 280

250 to 280

Number

Designation

Engine 902.923/924/935, 906.935/955,
926.969
with 443 dia. flywheel and 395 dia. connector

BE03.30-N-1001-04I

Starter ring gear inner dia.

mm

392.000...392.140

BE03.30-N-1002-04I

Starter ring gear / flywheel - overlap

mm

0.295...0.575

BE03.30-N-1003-04I

Starter ring gear / flywheel - permissible radial runout

mm

0.5

BE03.30-N-1004-04I

Starter ring gear - width

mm

15.6...16.0

BE03.30-N-1005-04I

Starter ring gear - installation temperature

°C

250 to 280