Retarded flywheel - removal

[Prof]

Ok,
 
Here\'s the story,
 
Engine out of car, all the ancillaries are off, and had the devils own job trying to get the 54mm nut off the engine - it met it\'s end and won\'t be going back on any car
 
However, as the big but was so heavily torqued onto the shaft, the flywheel is also on so hard that it won\'t come off using the methods listed below:
 
1) Soft approach - hit the flywheel around the outer edge with a rubber mallet / soft faced hammer - FAILED
 
2) Slightly more serious approach - Pry against the rear engine casting - as described in the Haynes guide and suggested in the Service Manual - FAILED
 
3) Tough aproach - went and got a hub puller - bolted it to the flywheel -- packed the end of the eshaft with an old idle pulley mount with a big washer on it and started torquing the big screw - clang - flywheel lose - NO - it\'s cracked the hub puller casting clean through on one side - FAILED
 
What do I try now ?
 
The flywheel has to come off for the rest of the engine to come apart - I am getting tempted to take the grinder to it - but it would be a waste of a machineable flywheel and could well wreck the eshaft.
 
Ideas please...

[steve garbutt]

When using any hub puller for any perpose i always just put pressure on the puller then tap with a mallet, then tighten a little more then tap again and continue till there is movement.

[DR SCHNITZEL]

When using any hub puller for any perpose i always just put pressure on the puller then tap with a mallet, then tighten a little more then tap again and continue till there is movement.

Here here. that must be on soo tight

[Nitronige]

You could try a bit of heat (blowtorch or other) on the flywheel whilst trying to pull/prise. Just be careful of melting seals, etc.

Nige

[AtomicRex]

Heat the flywheel, whilst using a puller.  Make sure you heat all around the flywheel not just around the nut section.  If you put some "spit" on the flywheel then you can tell if its hot enough when it sizzles.....just hope not in the same way as James May has sizzles!!
 
It will come with a bang though

[HaywardRotary]

Give me a buzz if you like,
I will talk you through an easy way.

Regards
Carl

[bumpstart]

if counter weight or flywheel  is very reluctant then try winding a couple of bolts through the puller holes provided in the flywheel
( on counterweight just pick two of the 6 circumference bolts )
wind them in until they bite into the outer edge of the rear main seal/ stat gear flange
wind in enough to make good tension,, taking up all the shaft float

then whack with mallet at the already prescribed position

-never fails -

[Prof]

Update - it\'s not moving :Grrr
 
Already tried the bolt trick - but that didn\'t work.
 
Tried Carl\'s suggestion - sadly also without success.
 
I do wonder if this was put on with some threadlock or something.  I know the eccentric shaft is tapered - and I suspect the big nut was torqued on a little too much as well - so not good at all.
 
I never had this problem with the other flywheel - and from all the comments - a couple of well served knocks is all it should usually take.

[HaywardRotary]

you need to do it pretty hard Dave.
If you get stuck bring it to me and i\'ll do it for nothing.
Regards
Carl

[TRex]

You need to use HEAT
Get a torch on it, Tap and Pull....


 And just to brighten you up, if you think the Flywheel is a biatch, \'good luck\' with the front Crank Bolt.... jesus wept! :o

[Prof]

You need to use HEAT
Get a torch on it, Tap and Pull....
 
 
And just to brighten you up, if you think the Flywheel is a biatch, \'good luck\' with the front Crank Bolt.... jesus wept! :o

That one wasn\'t a problem - big bar on it with extension and my not inconsiderable weight behind it.

[antnicuk]

put some pull tension on it with a puller or the bolts through the holes as mentioned above and with a smallish metal hammer,  give it lots (really lots) of small taps all the way around the f/w,  the sonic vibration may shift it.

[jantore]

very simple solution, get a rubber mallet. hit it hard, around the flywheel. soon it will fall off.

that\'s what i always do.

JT

[Grizzly]

Don\'t use a rubber mallet, it doesn\'t produce the shock needed as long as its a stock flywheel and not Alloy etc smack it quite hard with a Steel hammer on the back face (try and keep the hammer face square and don\'t catch the ring gear). You don\'t need to turn it to different positions but it some times helps.

You have to really watch using Pullers as they tend to destroy the Pilot bearing in the end of the E-shaft if your not very carefuller.

[jantore]

Oh yeas it does if you have one of those hard rubber mallets that is filled with sand. Hmm should have mentioned that as that is what i use and it works great.

JT