Hi

The Flywheel ring gear is almost knackered on my 98 Skoda 1.9 diesel pick up.

Obviously have to remove box - and I am told I can get it out ( just ???) without taking out whole lump.

Haynes manual tends to offer varying facts,

Any help/advice would be most welcome before I start

What kind of advice are you after? If it's possible, or specific procedures?

I've never done a diesel one, but the petrol ones can be tight depending on the bottom pulley fitted. Having looked at the diesel ones, I'd think it'd be tight getting that out as well, but the other option is dropping the engine down (with everything attached) a few inches to get the 'box off - certainly this is what I have to do on my rally car as the bottom pulley is bigger than standard, meaning there's not enough clearance to angle the engine down and get the box out quickly. :-(

Thanks for that

I had never thought about dropping the whole lot down a few inches - it seems like a good idea.

I will wait to see if here are any other posts

JC

dont bother replacing the ring gear, it's a difficult and extremely fiddly job, just replace the whole flywheel, you can pick them up for about £25 from a breaker.. there's plenty of room to get the gearbox out without lowering the engine down, you will need a tool to lock the flywheel in place to undo the bolts because they are f-ing tight

i made this tool from a piece of 6mm steel bar that i found lying about in my junk pile using just a hacksaw and drill and a few nuts and a piece of studding, but you can buy them ready made if you have bags of money to burn... £10 approx

The problem with replacing the entire flywheel is balance - they're externally balanced, so you could get a flywheel which is a long way out of balance for the crank you have.

vw cranks aren't balanced as a whole assembly, the crank is balanced seperately from the flywheel and they should interchange without any problems.. and beside from this is only at old rattle box diesel anyway

 

you will need a tool to lock the flywheel in place to undo the bolts because they are f-ing tight

i made this tool from a piece of 6mm steel bar that i found lying about in my junk pile using just a hacksaw and drill and a few nuts and a piece of studding, but you can buy them ready made if you have bags of money to burn... �10 approx

here is a weird one related: according to Haynes, in order to change the timing chain, you have to lock the flywheel with a for-rich-people flywheel lock (see my photo), but my question is: wtf? do I have to remove the gearbox to change that chain ??? sheesh...

here is a weird one related: according to Haynes, in order to change the timing chain, you have to lock the flywheel with a for-rich-people flywheel lock (see my photo), but my question is: wtf? do I have to remove the gearbox to change that chain ??? sheesh...

If it helps, in my copy it says to engage fifth gear and have someone hold the brake pedal down - it does however mention locking the flywheel as the alternative if the engine is out of the car.

 

here is a weird one related: according to Haynes, in order to change the timing chain, you have to lock the flywheel with a for-rich-people flywheel lock (see my photo), but my question is: wtf? do I have to remove the gearbox to change that chain ??? sheesh...

That's to stop everything changing position and also to help you with getting the crank pulley bolt out. I've never needed to do one like that, but don't forget that if you do need to hold the engine still you can put it in gear as Robin says to get the bolt out, or you can remove the starter and lock the ring gear using the access you get to it without the starter in place.

the gearbox does come out easy enough on the diesel, you will find that removing the gearbox end cover makes it 10 times easyer

another method i've done for locking the flywheel, i bought a knackered starter motor from a breakers yard for £3, completely stipped it down into it's bare parts, put some washers behind the pinion gear to force it out into it's fully extended position (to engage with the flywheel ring gear), then welded up the redcution gear solid so it wont turn...

then just pop the starter motor out, bung mine in, then job done

i'll see if I can find it and post up a pic

Edited 13 December, 201015 yr by TeflonTom

 

i'll see if I can find it and post up a pic

we got the idea. nice.

I found another method on Youtube channel realfixesrealfast which is a true gold mine for automotive DIYers.

Have a look at

at 3:20 when the impact gun couldn't budge that pulley nut.

Changed the ring gear round, in situ, on the pickup.Warmed it up with blow lamp, levered it off, carefully, abit at a time, turned it, rewarmed it and slid it back on. 15 mins.