Flywheel Resurface

Remove the transmission and clutch assembly to access the flywheel, then remove the flywheel for machining to restore a flat friction surface for proper clutch engagement.

Warnings

Tools required

Parts

• Clutch alignment tool × 1 — Use correct size for 390 V8
• Flywheel bolts × 6 — Replace if stretched or damaged
• Pilot bushing × 1 — Inspect and replace if worn
• Clutch disc × 1 — Replace with flywheel service
• Pressure plate × 1 — Inspect and replace if worn
• Transmission input shaft seal × 1 — Replace during service

Preparation

1. Disconnect negative battery cable
2. Raise vehicle and support securely on jack stands at front and rear
3. Remove driveshaft and mark yoke orientation for reassembly
4. Disconnect clutch linkage at bellhousing and transmission
5. Disconnect speedometer cable from transmission
6. Disconnect backup light switch wiring if equipped
7. Support engine from above using a suitable engine support bar or chain hoist

Procedure

1. 1

   Support and remove transmission
   Position transmission jack under the transmission. Remove transmission mount bolts and crossmember. Remove bellhousing-to-engine bolts, noting different bolt lengths and locations. Carefully slide transmission rearward until input shaft clears clutch disc, then lower transmission from vehicle.
2. 2

   Remove clutch assembly
   Mark the pressure plate to flywheel orientation with a paint marker or center punch. Loosen pressure plate bolts gradually in a crisscross pattern to prevent warping. Remove all bolts and lift off pressure plate and clutch disc together. Inspect clutch disc for contamination or wear.
3. 3

   Mark flywheel position
   Using a center punch or paint marker, mark the flywheel position relative to the crankshaft flange. Note the location of any dowel pins. This ensures the flywheel will be reinstalled in the same position to maintain engine balance.
4. 4

   Lock crankshaft and remove flywheel bolts
   Insert flywheel holder tool or wedge a large screwdriver between flywheel teeth and bellhousing to prevent crankshaft rotation. Remove all six flywheel mounting bolts. On the 390 V8, these bolts may have thread-locking compound applied from the factory.
5. 5

   Remove flywheel from crankshaft
   Carefully pull flywheel away from crankshaft flange. The flywheel weighs approximately 25-30 pounds. Note the position of any dowel pins in the crankshaft flange. Inspect the pilot bushing in the crankshaft for wear while flywheel is removed.
6. 6

   Inspect flywheel condition
   Examine flywheel friction surface for heat checking, cracks, hot spots, and scoring. Check flywheel teeth for damage. Measure flywheel thickness if specifications are available. Minor glazing and scoring can be removed by resurfacing, but deep cracks or excessive wear require flywheel replacement.
7. 7

   Prepare flywheel for machining
   Clean flywheel thoroughly with brake cleaner and wire brush. Take flywheel to qualified automotive machine shop for resurfacing. Specify that material removal should be minimized and surface finish should be appropriate for organic clutch disc material. Machine shop will check for warpage and ensure flywheel meets minimum thickness specifications.

Reassembly

1. Clean crankshaft flange and flywheel mounting surface thoroughly with brake cleaner
2. Install flywheel aligned with marks made during disassembly, ensuring dowel pins are properly seated
3. Apply thread-locking compound to flywheel bolts and tighten in a star pattern to proper specification (typically 90-105 ft-lbs for AMC 390, verify with factory service manual)
4. Replace pilot bushing if worn, ensuring proper alignment with crankshaft centerline
5. Install new or inspected clutch disc and pressure plate, using clutch alignment tool to center disc
6. Tighten pressure plate bolts gradually in star pattern to specification
7. Remove clutch alignment tool and verify disc moves freely on input shaft splines
8. Apply light coat of high-temperature grease to transmission input shaft splines and release bearing
9. Reinstall transmission, ensuring input shaft properly engages clutch disc splines
10. Install and torque bellhousing bolts, transmission mount, and crossmember
11. Reconnect all linkage, wiring, and driveshaft with proper orientation marks aligned

Verification

• Start engine and verify no unusual noises from bellhousing area
• Test clutch pedal feel and ensure proper free play adjustment
• Road test vehicle through all gears checking for smooth engagement without chatter or slippage
• Verify no vibration during acceleration that would indicate improper flywheel installation or balance issue
• Check for fluid leaks around transmission input shaft seal

More procedures for this vehicle