Flywheel and ring gear replacement (Opel Frontera B)

Removal

Remove the gearbox (see the relevant chapter).

Remove the clutch housing with the pressure plate and the driven clutch disc (see the relevant chapter).

Using a special tool, block the flywheel from turning and unscrew the 8 flywheel mounting bolts.



Use a tap to clean the threaded holes in the crankshaft for the flywheel mounting bolts.



Drill a 6mm diameter, 8mm deep hole in the flywheel ring gear.

Using a hammer and chisel, break the ring gear in the area of the drilled hole and remove it from the flywheel.

Installation

Heat the new flywheel ring gear to 200°C and install it onto the flywheel with the beveled side down.



Install the flywheel onto the crankshaft.

Using an arrow-type indicator, check the runout of the flywheel ring gear, which should not exceed 0.5 mm.



Using a special tool, block the flywheel from turning and, in the sequence shown in the figure, tighten the new flywheel mounting bolts to a torque of 54 N·m.



Install the clutch housing with the pressure plate and the driven clutch disc (see the relevant chapter).

Install the gearbox (see the relevant chapter).