I have an 88 S4 motor nearly torn down but the flywheel is being difficult to remove. I have tried the usual methods, i.e., tried tapping the flywheel from the motor side, tried a harmonic balancer puller and buried the centering point in the pilot bearing hole [fun getting the out], and tried striking the e-shaft with a rubber mallet with the nut turned back on half way. Is it really that difficult, or is it possible that the key was installed the wrong way previously and I need to take an alternative route?

I am also having difficulty removing the pully hub bolt on the opposite end of the e-shaft. My impact wrench at 130 psi won't budge it. Any tricks on that as well?

Thanks for any suggestions.

 

get a big heavy hammer, steel, not a rubber mallet. thread the nut on halfway, and hit the flywheel as hard as you can. aim for a section you don't care about dinging (ie not the friction surface). go nuts on it. your ears will be ringing afterwards. the flywheel center hole is tapered, so they get stuck on there pretty damn well.

 

This has been covered many times but the front bolt is loctite, so you gunna have to heat it up a good ammount... map gas or propane for abbout 10 mins and try it, if nothing then heat it for another 10 mins....

 

Some pry force on one side, big dead blow on the other.

BAM!

 

damn how old is that pic??? I think you posted that like over a year ago on the same topic LOL...

 

Yup - 9 month's ago - It seems like just yesterday.

 

Looks like I just need to get primitive with this thing. Thanks for the sugs guys.

 

UPDATE:

Well, after going to the gym to get adequately pumped for the "big dead blow"-- listening to a continuous loop of the "Rocky" theme on my MP3 player all the while--, I took a 4 lbs. maul, set a prybar behind the flywheel and gave the big nut a major wack.

Nothing!

Reared back and gave it another major wack and the threads on the inner face of the nut sheared completely off. Fortunately, the threads on the e-shaft appear to be salvageable.

I eventually resorted to my original approach applying a pry force while striking the wheel with the maul from the motor side, rotating the flywheel several times. Came free after a dozen strikes or so.

Moral of the story? I don't know. I know the big dead blow must work because others besides here recommended it. But, I am glad the nut was of lighter material than the e-shaft or we may have been looking at a new e-shaft.

As for heating the front pulley hub bolt, that worked like a charm. Heated it for 8-10 minutes with the torch and "ratta tat tat tat zing" off like a charm.

 

i use a puller i made from C-channel

two holes, two bolts, and something between the c-channel and e-shaft... very useful tool. pops it off every time (i've used it on 5/6 engines)

 

What, are you hitting the flywheel nut with a hammer? You need to hit the flywheel itself. Pry from behind with a bar (or better yet, have a helper do it) then hit the flywheel with a hammer (at least two pounds).

Flywheel removal is also covered in the FAQ.

 

That was tried long before we came to post on here.

 

I'm still trying to figure out how he sheared the threads off of the nut if he was hitting the flywheel with the dead blow.

Were you hitting the nut?