Caution: Do not put too much lubricant on
the bearing or in the recess. Excess lubri-
cant will be thrown out of the pilot bearing
and can ruin the clutch disc. Note that some bearings
are prelubricated and do not require any additional
lubrication.
Flywheel Service
The flywheel is large and very heavy, and removing it
can be difficult and even dangerous. It should not be
removed unless it is in need of resurfacing. It is rare to find
a flywheel that is not showing some sign of wear or over-
heating. Judgment is called for in deciding if it must be
resurfaced. In many cases, the flywheel can be reused
without machining. If the flywheel is not badly worn, it can
be cleaned by light sanding.
Flywheel inspection
Visually inspect the flywheel for obvious signs of dam-
age. Check the flywheel machined surface for discoloration
(caused by overheating), scoring, or extremely shiny sur-
faces. In some cases, the flywheel may have deep heat
cracks. Look for warping. Inspect the threads in the holes
for the clutch cover attaching bolts. If they are stripped,
they can be restored by installing a thread repair insert.
Also, check the flywheel ring gear for damage. If even one
ring gear tooth is broken, the ring gear must be replaced.
Note that if the ring gear teeth are damaged, you should
also check the teeth of the starter drive pinion for damage.
If the flywheel is not obviously damaged, use a
straightedge and feeler gauge to check for warped contact
surfaces. Manufacturers’ specifications as to maximum
warpage vary. As a general rule, if more than a 0.01″
(0.25 mm) feeler gauge fits under the straightedge, the
flywheel must be resurfaced.
A dial indicator also can be used to check for a warped
flywheel. In addition, it can be used to check the flywheel
runout. Push the flywheel toward the engine to remove
crankshaft endplay. Then, mount the dial indicator on a
stationary part of the engine with the indicator point bearing
on a smooth, relatively undamaged part of the machined fly-
wheel surface, as shown in Figure 7-25. Rotate the flywheel
and watch the dial to determine how much fluctuation in val-
ues there seems to be, which would give an indication of
warping. If, rather than a series of fluctuations, the dial shows
a steady increase for half a turn and then a steady decrease,
flywheel runout may be excessive. In either case, the fly-
wheel must be removed and resurfaced or repositioned.
To check warpage, zero the dial indicator; then, slowly
turn the flywheel through about a quarter of a revolution.
Watch the indicator face and note if displacement ever
exceeds 0.01″ (0.25 mm). Without moving the indicator,
142 Manual Drive Trains and Axles
Driving tool
Clutch pilot
bearing
Crankshaft
flange
Figure 7-23. A new pilot bearing should be installed with the
proper bearing driver.Use a driver that contacts the outer race only
when driving a roller- or ball-type pilot bearing. Always be very
careful to avoid damage when installing a new bearing. (Ford)
Lightly
grease recess
Pilot bearing to
be installed to
spec distance
Crankshaft
Pilot
bearing
Figure 7-24. Grease the recess behind the pilot bearing, but be
careful to use only a small amount. Lack of grease will allow the
bearing to run dry and be damaged. On the other hand, too
much grease will drip out and damage the clutch disc. (Ford)
Flywheel
surface
Dial
indicator
Read while
rotating crankshaft
Figure 7-25. Proper mounting of the dial indicator is important.
The base must be solidly attached to the rear of the engine.
Push on the flywheel to remove crankshaft endplay. Position
indicator so that plunger just touches the flywheel. The dial is
then zeroed. (Ford)