Flywheel Resurface

Remove transmission or transaxle, clutch assembly, and flywheel from the engine block. Send flywheel for machining at a qualified shop, then reinstall all components with new clutch parts.

Warnings

Tools required

Parts

• Clutch disc × 1 — Use OEM specification or quality aftermarket
• Clutch pressure plate × 1 — Use OEM specification or quality aftermarket
• Pilot bearing or bushing × 1 — Use OEM specification
• Throwout bearing (release bearing) × 1 — Use OEM specification
• Transmission input shaft seal × 1 — Use OEM specification
• Rear main seal (if leaking) × 1 — Use OEM specification
• Transmission mounting bolts (if damaged) × 4 — Use OEM specification
• Flywheel mounting bolts × 6 — Grade 8 or OEM specification

Fluids

• Dexron III ATF

Preparation

1. Park vehicle on level ground and set parking brake firmly.
2. Disconnect negative battery cable to prevent accidental starter engagement.
3. Raise vehicle and support securely on jack stands at frame rails.
4. Remove both rear wheels to improve access (optional but recommended).
5. Position transmission jack or suitable support under transmission.
6. Have replacement clutch components and new flywheel bolts on hand before beginning disassembly.

Procedure

1. 1

   Drain transmission fluid and disconnect driveshaft
   Place drain pan under transmission. Remove drain plug and drain fluid completely. Using paint or marker, mark alignment between driveshaft flange and rear differential yoke. Remove 4 U-bolt nuts and straps securing rear U-joint to differential. Slide driveshaft rearward to disengage from transmission output shaft, then lower and remove from vehicle. Install plug or tape over transmission extension housing to prevent fluid loss.
2. 2

   Disconnect clutch linkage and speedometer cable
   Disconnect clutch fork return spring from throwout bearing fork. Remove clutch cross-shaft and linkage from bellhousing (specific configuration depends on side-mount vs frame-mount linkage). Unscrew speedometer cable from driver-side of transmission. Disconnect any backup light switches or electrical connections.
3. 3

   Remove transmission mount and crossmember
   Support transmission weight with transmission jack. Remove 2 nuts securing transmission mount to crossmember. Remove 4 bolts securing crossmember to frame rails. Lower crossmember and remove from vehicle.
4. 4

   Remove bellhousing and transmission assembly
   Remove 4 bellhousing-to-engine block bolts. Carefully slide transmission and bellhousing assembly rearward, keeping input shaft aligned to avoid damaging clutch disc. Once input shaft clears clutch assembly, lower transmission on jack and remove from under vehicle. Remove bellhousing from transmission if additional access is needed.
5. 5

   Remove clutch pressure plate and disc
   Insert clutch alignment tool or spare input shaft through clutch disc to support it. Mark pressure plate-to-flywheel orientation with paint for reassembly reference. Remove 6 pressure plate mounting bolts in a cross-pattern, loosening gradually to prevent warping. Remove pressure plate and clutch disc together. Inspect clutch disc for contamination, wear, or damage.
6. 6

   Remove flywheel from crankshaft
   Use flywheel holding tool or wedge large prybar between flywheel teeth and bellhousing mounting surface to prevent rotation. Mark flywheel-to-crankshaft orientation for proper balance on reinstallation. Remove 6 flywheel mounting bolts. Carefully pull flywheel from crankshaft flange and dowel pins. Inspect flywheel surface for cracks, heat checking, scoring, and glazing.
7. 7

   Inspect and measure flywheel
   Clean flywheel thoroughly with parts washer solvent. Inspect clutch friction surface for deep scoring, cracks radiating from bolt holes, or heat discoloration (blue/purple indicates overheating). Check for warpage using straightedge across friction surface. Measure flywheel thickness at multiple points to ensure adequate material remains for machining (minimum thickness typically 1.50 inches for small block Chevy, but verify with machine shop). If flywheel passes inspection, proceed to machining.
8. 8

   Send flywheel for resurfacing
   Transport flywheel to qualified automotive machine shop for resurfacing. Specify that friction surface should be cut to restore flat, smooth surface with proper finish for clutch engagement (typically 60-80 RMS). Request verification of final thickness after machining to ensure it meets minimum specification. Machine shop will also check for runout and balance if requested.
9. 9

   Inspect and replace pilot bearing
   Remove pilot bearing or bushing from end of crankshaft using slide hammer with internal puller attachment or appropriate bearing removal tool. Inspect pilot bearing bore in crankshaft for wear or damage. Install new pilot bearing using appropriate driver, seating it flush to specified depth. Lubricate bearing lightly with high-temperature grease.
10. 10

    Inspect crankshaft flange and rear main seal
    Clean crankshaft flange and dowel pins thoroughly. Inspect flange surface for damage or wear. Check rear main seal for oil leakage; if seeping or damaged, now is ideal time to replace (requires additional disassembly). Ensure crankshaft mounting bolt holes are clean and threads are not damaged.
11. 11

    Install resurfaced flywheel
    Align flywheel with crankshaft dowel pins, matching orientation marks made during removal to maintain engine balance. Install 6 new flywheel mounting bolts with thread locking compound. Tighten bolts in cross-pattern sequence in three stages: first to 30 ft-lbs, then 50 ft-lbs, then final torque of 60 ft-lbs. Use flywheel holding tool to prevent rotation during tightening.
12. 12

    Install new clutch disc and pressure plate
    Lightly lubricate pilot bearing and input shaft splines with high-temperature grease (avoid getting grease on clutch friction surfaces). Position new clutch disc against flywheel with longer side of hub (protruding splines) facing transmission. Insert clutch alignment tool through disc and into pilot bearing to center disc. Position new pressure plate over clutch disc, aligning with previous orientation marks if reusing (though new pressure plate is recommended). Install 6 pressure plate mounting bolts finger-tight, then tighten in cross-pattern sequence gradually to 35 ft-lbs to prevent disc or pressure plate warping. Remove alignment tool.
13. 13

    Reinstall transmission assembly
    Install new throwout bearing on clutch fork. Apply light coat of grease to transmission input shaft splines and seal surface. Reattach bellhousing to transmission if separated earlier. Raise transmission on jack, aligning input shaft with clutch disc splines (alignment tool previously installed should guide shaft). Slide transmission forward carefully until bellhousing seats against engine block. Install 4 bellhousing-to-engine block bolts and tighten to 37 ft-lbs in cross-pattern.
14. 14

    Reinstall crossmember and transmission mount
    Raise transmission slightly and position crossmember between frame rails. Install 4 crossmember-to-frame bolts and tighten to 25 ft-lbs. Position transmission mount and install 2 mount-to-crossmember nuts, tightening to 35 ft-lbs. Remove transmission jack.
15. 15

    Reinstall driveshaft and connect linkage
    Lubricate transmission output shaft splines with gear oil. Align driveshaft with output shaft and slide forward into transmission. Align driveshaft flange with differential yoke per marks made during removal. Install 4 U-bolt straps and nuts, tightening to 16 ft-lbs. Reconnect clutch linkage, return spring, speedometer cable, and any electrical connections. Adjust clutch pedal free play per factory specification (typically 1 inch at pedal pad).
16. 16

    Refill transmission and final checks
    Refill transmission with Dexron III ATF to proper level per dipstick or fill plug specification (if manual transmission uses ATF per factory spec). Reinstall rear wheels if removed and torque lug nuts to specification. Lower vehicle from jack stands. Reconnect negative battery cable.

Reassembly

1. Torque all fasteners to specification in proper sequence to prevent warping or damage.
2. Replace all clutch components as a complete set; never reuse old clutch disc or throwout bearing with resurfaced flywheel.
3. Use new flywheel bolts and apply thread locking compound to prevent loosening under vibration.
4. Verify clutch pedal free play adjustment after reassembly to ensure proper throwout bearing clearance.

Verification

• Start engine and verify no abnormal noises from bellhousing area (rattling or grinding indicates improper installation).
• With engine running and transmission in neutral, depress clutch pedal fully and shift through all gears to verify smooth engagement without grinding.
• Test drive vehicle and verify smooth clutch engagement without chatter, slipping, or grabbing.
• Inspect for fluid leaks around transmission and rear main seal after test drive.
• Verify no vibration at highway speeds, which could indicate improper driveshaft alignment or flywheel balance issue.

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