How do you replace a flywheel on a full size Bronco 1985?

Answer 1

Answer

the best thing to do is remove the transmission. the flywheel is bolted on the back of the engine.

If possible, pressure wash the underside of the truck. Get under there real clean; we work on these things to make them better, not to put dirt into everything.

Ok; You HAVE to remove the transmission. Of course, using all safety precautions including Good Jack Stands and a level surface, raise the vehicle.

Remove the driveshaft from the rear end. put the clamps and nuts back in the yoke for safe keeping.

Remove the shifter and boot. Look at the truck floor from underneath. Is there a large panel held by screws? If so, remove the seats and carpet. (Don't try to tilt the motor down as this will likely break something.

Support the transmission with a transmission jack. Don't even try the bench press method. Work smarter, not harder.

Remove the crossmember.

Remove the slave cylinder and carefulloy set aside without kinking the hose.

Remove the Starter after assuring the battery is disconnected.

Remove the front flywheel cover

Remove speedometer cable if equipped, (otherwise sensor is in the rear axle

Unplug Neutral B/U light wires

Remove Bellhousing to Engine bolts.

Move entire transmission rearward, straight until clear of input shaft then lower and move aside.

Remove pressure plate bolts surrounding perimeter of flywheel.

Remove clutch with pressure plate

Using flywheel holder, remove flywheel bolts. Important!!! Leave at leat two "Finger tight" until the flywheel is supported and ready to be removed. Use leather work gloves when handling the flywheel. Do not drop it on your head or anything else that you don't want to see blood come out of.

Take the flywheel for either surfacing or replacement. Don't imagine sanding it or else the new clutch will slip badly. Get a new clutch , pressure plate and throwout bearing. If the slave cylinder is inside there, replace it also.

Inspect/lubricate or replace pilot bushing in the crankshaft end.

Clean all bolts and mating surfaces of the crankshaft and flywheel, align boltholes and guidepins and insert a couple of bolts to hold while the CLEAN and locktite laden bolts are replace. Torque to specs found in the manual. Insert a pilot tool thru the clutch while mating up the pressure plate. Again clean, locktite and torque the pressure plate bolts.

Replace the transmission by inserting carefully in a straight line , placing the input shaft thru the clutch splines. Sometimes rocking longitudinally helps, other times pulling back and rotating the input shaft to align with the clutch splines. watch that the bellhousing to engine surface areas are parallel. continue to work with it until it mats. Don't dream of getting close and forcing together with the bolts. When the flanges mate, then insert bolts. Replace crossmember. (Sometimes help from above with a strap such as used to tie down motorcycles.)

Reconnect wiring, Slave cylinder and speedometer as applicable. Ensure that all wireties and clamps etc as placed by the factory are put back. (They are only there because they have to be, not just because Ford had a lot of money to spend on frilly little clamps.)

Replace driveshaft after inspecting/ lubricating or replacing u-joints.

Top off the transmission oil to level as indicated in the manual.

Bleed the slave cylinder. Even if you didn't replace it or lose the fluid, change the fluid.

Replace the shifter

Double check all bolts up to this point. Put a wrench on them, nobody has torque-eyeballs.

Replace covers as removed and the starter. (Go ahead and look closely at the starter while it's off; replace rather than get stranded.)

Take a can of paint and touch up the frame, crossmembers as needed.

Reconnect battery. Clean the terminals while You're there.

Start it up for a bit and be sure everything is bolted up correctly. Don't go putting it in gear and running it up on the jack stands. Not only dangerous but drives the ABS nuts.

Allow everything to cool down, check everthing again including oil levels.

Change the motor oil and filter.

Pull a couple wheels off and look at the brakes. ( Its up on stands, the tools are out and you are already kinda dirty.)

Put the floor panel back in once ensured all bolts are tight. Put the carpet back in and then the seats.