200tdi flywheel resurfacing - Defender Source
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  #1  
Old November 28th, 2011, 11:24 AM
Naplm00
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Matthew
1983 110 200tdi 3 door soft top
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200tdi flywheel resurfacing

I sent my flywheel off to be resurfaced. shop says they cant do it because of the protruding tapered pins sticking out of the flywheel.


Are these removable or replaceable? or should only the center section get milled?
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  #2  
Old November 28th, 2011, 11:45 AM
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Mike Simpson
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Mine were cut off for resurfacing. I suspect they are an assembly aid and not necessary.
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  #3  
Old November 28th, 2011, 11:55 AM
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Jamie Austin
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They can be removed. Same as series 3 studs IIRC. they're a (tight) push fit. they're used to locate the clotch cover plate.
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  #4  
Old November 28th, 2011, 12:13 PM
Naplm00
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Matthew
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I've read some other posts saying that they are absolutely necessary to keep stress off the bolts. Did you guys grind them down?
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  #5  
Old November 28th, 2011, 12:26 PM
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I had the same problem, they had to weld something to them to get them out, with a puller I think.
They actually drilled a small whole through the back of the flywheel to knock them out in the future.
I went to a Big Truck place with its own machine shop
I got three new ones from George at RDS.
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  #6  
Old November 28th, 2011, 01:16 PM
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John B.
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Find a new shop NOW!!! All flywheels have locating dowels and they all are meant to be removed first and then put back in... Have these idiots ever seen a flywheel before?
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  #7  
Old November 28th, 2011, 01:18 PM
Naplm00
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Matthew
1983 110 200tdi 3 door soft top
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Yup, just got off the horn with George and have them coming up. Ill be picking up the flywheel from the shop tonight, told them to hold off.

Il going to tack weld a nut to the end and yank them off with a slide hammer and take it to a new shop.
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  #8  
Old November 28th, 2011, 01:53 PM
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Skinny Pete
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a good shop will have a slide hammer with different collets for grabbing the pins.
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  #9  
Old November 28th, 2011, 01:56 PM
Naplm00
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Matthew
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does not seem like a collet would work on this tapered shaft, does something like this exist?
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  #10  
Old November 28th, 2011, 02:03 PM
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The shop I used, tried, but eventually had to go with the welded nut and slide hammer.
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  #11  
Old November 29th, 2011, 09:17 AM
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Mike Simpson
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Quote:
Originally Posted by Red90 View Post
Find a new shop NOW!!! All flywheels have locating dowels and they all are meant to be removed first and then put back in... Have these idiots ever seen a flywheel before?
They aren't the only idiots out there. The transmission shop (reputable establishment in Denver that has been in business for years) that resurfaced mine told me they weren't needed, and ground them off. I suspect that is true, but I'm going to replace them anyway since it is still disassembled and I don't want to take any chances.

The bummer is that I now know that had I gone about this the right way, the job would have been easy and the dowels could've been re-used. The trick is to clamp a bar to your drill press, and drill a hole the size of the dowel. Drop the dowel in that hole to locate it, then drill a hole from the back side of the flywheel to use a punch to push the dowels out.

Would've been a 20 minute job had I researched it first, but I know better now.
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  #12  
Old November 29th, 2011, 10:54 AM
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Matthew
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well since they are milled flat now why dont you drill and tap them and just pull them out from the front? This way you dont need to possibly unbalance your flywheel
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  #13  
Old November 29th, 2011, 11:50 AM
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Mike Simpson
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Quote:
Originally Posted by Naplm00 View Post
well since they are milled flat now why dont you drill and tap them and just pull them out from the front? This way you dont need to possibly unbalance your flywheel
Good point, I may try that, except that I've also learned that they are hardened and a real bitch to drill.
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  #14  
Old December 2nd, 2011, 09:52 AM
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Matthew
1983 110 200tdi 3 door soft top
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Finally! got it from the shop today. looks great
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