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post #1 of (permalink) Old 08-11-2003, 01:19 AM Thread Starter
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stripped teeth on flywheel, what to do?

my brother just got a 2.8L Bronco Duece with the 5 spd and the flywheel teeth are stripped such that the truck must be roll started. what's the cheapest way to fix this? is the only way to fix it to get a new flywheel complete with the disc? I've only worked on 1 stick and I don't remember if it was just one unit or if there was a "flexplate" with the teeth that bolted on behind the flywheel. If we do have to replace the whole thing, where would be the cheapest place to get one? I looked on Oreilly's site and they don't list one, so is this a junkyard/dealership type thing?

Also, if the Bendix on the starter is worn down too, can that be replaced separate from the starter? It's a new starter but the PO was using it with the bad flywheel for a little while so it might be gimped as well.
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post #2 of (permalink) Old 08-11-2003, 04:43 AM
 
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Re: stripped teeth on flywheel, what to do?

not shure on a 2.8L, but most all you need to buy is a starter ring gear and slip it on the flywheel with an interference fit.
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post #3 of (permalink) Old 08-11-2003, 08:28 AM
 
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Re: stripped teeth on flywheel, what to do?

Pull a replacement from the boneyard. Price check a replacement first and make sure it's worth the effort.
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post #4 of (permalink) Old 08-11-2003, 03:36 PM Thread Starter
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Re: stripped teeth on flywheel, what to do?

well i answered my own question... it was under a different section on the Oreilly site but they had flywheels and also the separate ring gears, which are around $40. thanks for the help [img]images/graemlins/40BEER.gif[/img]

(btw, wait till you see what we're doing with this Bronco II [img]images/graemlins/cool.gif[/img] )
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post #5 of (permalink) Old 08-11-2003, 05:26 PM
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Re: stripped teeth on flywheel, what to do?

if you buy just the ring gear, cut a groove in the old one with a cut-off wheel 3/4 way through and smack the groove with a BIG punch and hammer and it will split and fall right off. You`ll need to heat the new one with a torch or find some other way convenient for you to expand the new ring gear in order to install it.
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post #6 of (permalink) Old 08-11-2003, 06:35 PM
 
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Re: stripped teeth on flywheel, what to do?

i put the bare flywheel in the freezer, and bake the ring gear at about 250-300* in the oven.
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post #7 of (permalink) Old 08-12-2003, 03:59 PM Thread Starter
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Re: stripped teeth on flywheel, what to do?

good info! right now we're trying to decide whether we want to pull the engine or drop the tranny. I don't have a tranny jack but I've done it before with a good floor jack... not easy since it was a sm465 cast iron stick that weighed a ton! But the other thing is the engine leaks like no tomorrow, I think from the front crank seal but probably the rear main and oilpan gasket could use a replacement. I tell ya the weird thing... this 2.8L is carbed but it has a bunch of wiring harnesses leading to a EEC-IV computer under the kick panel! [img]images/graemlins/blush.gif[/img] Apparently it's some kind of hybrid between FI and carb and even has all the damn emissions equipment [img]images/graemlins/bs.gif[/img] I'm sure we'll strip all that crap out along with the A/C system since we're told it doesn't work. I read some writeups on swapping to a real carb and also swapping to real FI off a 3.8 RWD car, but before we do that much work there will be a 302 under the hood [img]images/graemlins/grin.gif[/img]

PICS TO BE POSTED TODAY! [img]images/graemlins/40BEER.gif[/img]

<img src=http://www.arkansasmud.com/bronco2/driverside.jpg>
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post #8 of (permalink) Old 08-17-2003, 07:13 PM Thread Starter
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Re: stripped teeth on flywheel, what to do?

well that turned out to be a project and a half! tight quarters doesn't even begin to describe how gawdamn cramped it is under that little Bronco! [img]images/graemlins/mad.gif[/img] It took hours to do things that should take 15 minutes, like removing the tranny bolts... I was getting close to yanking the body off [img]images/graemlins/smirk.gif[/img] a 550 ring and a frozen flywheel did the trick nicely... 350 just wasn't enough heat. I plugged SIX vac lines that had been plugged with rotting hose and a bolt in the end, and I plugged a 7th port that previously had a vac line running straight from manifold vacuum to the EGR valve! [img]images/graemlins/blush.gif[/img] Yeah, that thing was wide open at all times before I took that line off. Plugging that exhaust port quieted that thing down nicely, just a little valvetrain tick to let me know she's running [img]images/graemlins/smirk.gif[/img]

I was trying to tighten up the radius arm bushings and the nut would barely budge, or maybe the arm was twisting, but I noticed the bushing would travel straight up and down an inch or so. It's not supposed to do that, right? This thing is beyond squirrelly and I think that's the main reason. The front left wheel bearing is also slightly loose but I bet my d44 socket won't fit that little d28 spindle nut [img]images/graemlins/frown.gif[/img]

It was a hellifed 2 day process but she starts right up now, idles nicely, no exhaust coming into cabin, and I now know exactly where every wiring harness on the truck goes [img]images/graemlins/chairfall.gif[/img] [img]images/graemlins/40BEER.gif[/img]
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post #9 of (permalink) Old 08-21-2003, 01:32 AM Thread Starter
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Re: stripped teeth on flywheel, what to do?

UPDATE: Oh man I can't wait to get the 31" muds on here, this thing is awesome already with the baby tires! Today I decided to track down a little knock/pop sound it was making and realized the inner core of one of the spark plugs had broken loose from the threaded housing and was moving in and out with the engine strokes [img]images/graemlins/blush.gif[/img] Well we didn't have a spare plug so we decided to go play in a little mud, and I (being new to a v6 stick) promptly got the thing stuck in some ruts made by a 35" tire (hmm wonder who made those [img]images/graemlins/grin.gif[/img]) Well my bro took over (he drives a stick everyday) and was making good progress giving the truck absolute hell when all the sudden we heard a BOOOOM that sounded like a tire exploding, followed by a hissing pattern. At first I thought he'd thrown a rod and that was the end of our fun, but then I remembered the spark plug. Sure enough, the compression had built up enough to blow that sucker clear of the block, shooting it straight into the firewall with ferocity [img]images/graemlins/chairfall.gif[/img] No problem, I pulled him out and he drove home on 5 cylinders, which I guess we've more or less been doing since we got the truck since that body was very loose. All the plugs are rusty and way overdue to be replaced... new plugs with less than 1/4" gap ought to help the performance quite a bit [img]images/graemlins/grin.gif[/img]

Just FYI, not that you'll ever need to know this, but the D44 4-prong socket also fits the Dana 28 ttb, and the inner and outer wheel bearings on the D28ttb are identical to the outer bearing on the d44ttb [img]images/graemlins/40BEER.gif[/img]

good times in the baby Bronco! [img]images/graemlins/laugh.gif[/img] [img]images/graemlins/RockOn.gif[/img]
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post #10 of (permalink) Old 08-21-2003, 02:20 AM
 
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Re: stripped teeth on flywheel, what to do?

Sounds like fun Muddy! Are you hackin fenders or putting a lift on to fit the 31's?
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