Removal and rework of a flywheel/ring gear assembly

By John Phillips

Today our project was the  from a 74 TR6. The ring gear was being pushed from the flywheel by repeated engagement of the starter over a long period of time.  The task is to properly re-seat the gear so that the starter will engage and start the car.

The car had been dropped off at the shop the week before so I went out about 8 in the morning to get started before anyone else showed up.  Got the car jacked up and on stands, and then removed the seats to reveal the first issue that needed resolution.  The floor carpet was one piece, not your standard carpet kit, and glued to the floor.  Ok, that decision required the owner so I started on the dash support removal.

The owner, Bob Jones, arrived and we discussed the carpet issue and completed removal of the dash support.  At some time in the car’s life someone had used a bunch of metric nuts and bolts, probably just to irritate me so I got out those funny wrenches to deal with the issue.

Bob settled on cutting the carpet and proceeded to uncover the transmission tunnel, which was toast, so it was just ripped out with very little trouble.  Tim Hensley arrived and jumped right in to help with the hardware removal from the back of the transmission and the front of the transmission.  The starter had been removed previously.  The clutch slave cylinder was left hanging, wires were unhooked and the speedometer cable removed from the overdrive unit.  The transmission was out in pretty short order.

Larry Young arrived to lend a hand and the transmission was placed on a workbench for evaluation.  It was filthy, just covered with grease and dirt.  We immediately checked the shaft pin and found it broken as we expected.  We drilled the clevis and punched the broken pin out before we realized the clevis has been welded to the shaft.  The shaft was cut from the transmission.

Bob took the transmission outside along with copious amounts of Castrol Super Clean and a brush.  After some work the water hose was used to expose the aluminum housing underneath the goop.  Ended up looking great.

The pilot bushing was not in good shape indicating some movement in the transmission bearings.  The clutch was worn but working well so all components as well as the flywheel will be resurfaced and reused in lieu of buying new stuff that may or may not last or work well.    The exception is the throw-out bearing which will be replaced along with the shaft, clevis, pin, bushings, etc.

As Dick Taylor had pointed out the ring gear was indeed on backward so we removed the gear and oriented it in the other direction to allow easier engagement with the starter.    By this time Ted Dorton had arrived and he and Tim borrowed my truck to take Ted’s hardtop back to Tim’s for a coat of primer prior to painting.

Sam Clark had arrived to take the pictures you see with this article so it was time to work on the flywheel.  Sharon Parker, Rolf Blom, Dewayne Pass and Richard Doolittle were also participating in a great tech session on a great sunny 70° day.  The only downer was shuttle catastrophe but we kept going.

We heated the gear to 400° so that it would slip right onto the flywheel.  Not!  So we used the method I had used to re-seat two previous ring gears.  Sequential pressure on the gear with a press was the eventual solution to the problem.  It re-seated and was ready to be refaced.

flywheel01 flywheel03




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