A significant amount of friction occurs when the clutch disc presses against the flywheel. It adheres to the surface and helps the car move forward on the road. This grip begins to loosen when the lining wears out. Therefore, when replacing the pressure plate, people often ask: “How to resurface a flywheel?” So, let’s discuss the process!
How to Resurface a Flywheel: Comprehensive Inspection and Resurfacing
A car’s flywheel has various functions, including storing energy to keep the crankshaft moving and balancing rotating assemblies.
It provides power by smoothly transmitting energy to the transmission. The clutch assembly helps the engine deliver power to the transmission.
Every flywheel will need resurfacing at some point. Generally, people prefer to do it when replacing the clutch or pressure plate. The flywheel’s mass absorbs the heat generated by the clutch’s normal operation.
The clutch generates more heat when it starts to slip or is abused. It can also develop cracks and blisters on the flywheel surface.
Thus, according to expert maintenance advice, a thorough inspection of the flywheel is necessary to detect damage and assess its condition. Below are two main methods for resurfacing a flywheel.
Flywheel Cutting
A brake lathe is needed to begin the cutting technique. The procedure must be performed carefully because mounting a flywheel on the lathe is not an easy task. The drawback of this method is that it leaves uneven areas.
Since the brake lathe does not treat hard spots, people prefer to remove a large amount of metal. When you want to know “how to resurface a flywheel“, you need to be familiar with both cutting and grinding techniques.
In vehicles with hydraulic linkages, the bearings may be limited. It is imperative to understand that the clutch tends not to release fully when too much metal is removed.
Flywheel Grinding
This is the most commonly used technique for flywheel resurfacing. A block grinder is needed to perform the task effectively. Compared to the dedicated flywheel grinder, head and block grinding equipment requires a high setup time.
Make sure to check if a machine shop has a dedicated flywheel grinder for a stepped flywheel. If not, look for another shop that has specific equipment for this job.
Maintaining the correct clutch height becomes essential in the case of a stepped flywheel.
Care must be taken to remove an equal amount of metal from both surfaces. You can measure this using a flywheel depth gauge.
To achieve the necessary flatness with minimal metal removal, a dedicated flywheel grinder works effectively by eliminating hard spots and leaving a uniform surface. This process typically takes barely five minutes.
In the process of learning how to resurface a flywheel, the equipment becomes of the utmost importance.
The crankshaft flange allows for mounting the flywheel and centering a recessed flywheel. Wet grinding with silicon carbide stones helps.
What About Dual-Mass Flywheels?
In the case of BMW, General Motors, and Porsche models equipped with a dual-mass flywheel, no resurfacing is necessary. Replacement becomes necessary when the dual-mass flywheel is worn.
On Ford vehicles, the resurfacing process requires removing the bolts and separating the primary and secondary flywheels. The Ford automobile manufacturer suggests using new bolts when reassembling the flywheels.
For applications such as the Ford 7.3L and GM 6.5L diesel trucks, ordinary solid flywheels are used to replace the expensive dual-mass flywheels.
The same clutch is not suitable for solid flywheels. To enhance the transmission’s torque capacity, they manufacture it with a larger diameter clutch in mind.
What Should Be Considered When Replacing the Clutch and Flywheel?
When replacing the clutch, all critical parts of the system should be replaced. From the pressure plate to the clutch disc and the release bearing, everything must be replaced.
On some vehicles, it is also necessary to replace the pilot bearing or bushing. It works by aligning the clutch disc on the flywheel.
This will lead to rapid wear of the clutch and release bearing after they are worn. A serious consequence is the clutch disengagement problem.
No indexing of the flywheel position on the crankshaft is mandatory when replacing a flywheel on an internally balanced engine.
However, index positioning becomes crucial in the case of an externally balanced engine. The technique here is to mark the position before removing and reinstalling the flywheel on the crankshaft.
This pro tip will help you maintain the engine’s balance accurately. Mark the flywheel when you are unsure if an engine is internally or externally balanced. This will help you install it in exactly the same position as before.
Car Flywheel FAQ
1. How much material should I remove when resurfacing a flywheel?
The amount of material to remove depends on the condition of the flywheel and the manufacturer’s specifications. It is essential to consult the service manual or manufacturer’s recommendations for your specific vehicle.
2. Can I reuse a flywheel after resurfacing, or do I need to replace it?
Flywheels can generally be reused after resurfacing if they meet the manufacturer’s specifications and are within the allowed tolerances. If the flywheel is excessively worn or damaged, it may need to be replaced.
3. What are the benefits of resurfacing a flywheel?
Resurfacing a flywheel restores its smooth and flat surface, ensuring proper clutch engagement, reducing clutch slippage, and improving overall vehicle performance. It can also extend the lifespan of the clutch components.
4. How much does flywheel resurfacing cost?
The cost of flywheel resurfacing can vary depending on your location and the workshop you choose. It is best to obtain quotes from local automotive service providers for accurate pricing.
5. Can I resurface a flywheel multiple times?
Flywheels can be resurfaced multiple times, but the amount of material that can be removed is limited. Excessive resurfacing can lead to a loss of flywheel performance, necessitating its replacement.
Final Notes
A car’s flywheel is a crucial element of automobiles. Considering the information above, you will be greatly assisted in your quest to know how to resurface a flywheel.
It is highly recommended to seek a professional if you are a beginner or have never performed flywheel resurfacing before.