Flywheel and Ring Gear

REMOVAL & INSTALLATION

1. Remove the transmission, following procedures in Section 7.
2. On a manual shift transmission, remove the clutch pressure plate and cover assembly and clutch disc, following the procedures in Section 7.

   Fig. 1: Lock the flywheel in place and remove the retaining bolts . . .

   Fig. 2: . . . then remove the flywheel from the crankshaft

3. Remove the flywheel attaching bolts and remove the flywheel.

   To install:

4. Position the flywheel on the crankshaft flange. Coat the threads of the flywheel attaching bolts with Loctite® or equivalent and install the bolts. Tighten the bolts in sequence across from each other to the following specifications:
   • 2.3L, 2.5L and 3.0L (B Series Pick-up) engines: 54–64 ft. lbs. (73–87 Nm)
   • 2.6L engine: 68–72 ft. lbs. (92–98 Nm)
   • 3.0L (MPV) engine: 76–81 ft. lbs. (103–109 Nm)
   • 4.0L engine: 50–55 ft. lbs. (68–74 Nm)

     Fig. 1: Cracks in the muffler are a guaranteed leak

     Fig. 2: Check the muffler for rotted spot welds and seams

     Your vehicle must be raised and supported safely to inspect the exhaust system properly. By placing 4 safety stands under the vehicle for support should provide enough room for you to slide under the vehicle and inspect the system completely. Start the inspection at the exhaust manifold or turbocharger pipe where the header pipe is attached and work your way to the back of the vehicle. On dual exhaust systems, remember to inspect both sides of the vehicle. Check the complete exhaust system for open seams, holes loose connections, or other deterioration which could permit exhaust fumes to seep into the passenger compartment. Inspect all mounting brackets and hangers for deterioration, some models may have rubber O-rings that can be overstretched and non-supportive. These components will need to be replaced if found. It has always been a practice to use a pointed tool to poke up into the exhaust system where the deterioration spots are to see whether or not they crumble. Some models may have heat shield covering certain parts of the exhaust system , it will be necessary to remove these shields to have the exhaust visible for inspection also.

     Fig. 3: Make sure the exhaust components are not contacting the body or suspension

     Fig. 4: Check for overstreached or torn exhaust hangers

     Fig. 5: Example of a badly deteriorated exhaust pipe

     Fig. 6: Inspect flanges for gaskets that have deteriorated and need replacement

     Fig. 7: Some systems, like this one, use large O-rings (donuts) in between the flanges