How difficult is it to replace the flywheel on a 1980 928?
08-20-2004, 01:58 AM
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How difficult is it to replace the flywheel on a 1980 928?
I own a 1980 European 928. It is making that horrible noise every once in a while, that we all dread to hear. The starter spins but doesn't move the flywheel. I believe I might have to replace either the starter or the flywheel. The teeth of the flywheel appear to be slightly damaged on the edges. The starter looks like it isn't engaging completely into the flywheel teeth. I plan on replacing the starter first and if this doesn't solve the problem I will be forced to replace the flywheel. I was wondering if anyone here has ever done this before and how difficult was it to do? Is there a web site that explains how to remove the flywheel? Any help in this matter would be greatly appreciated. 
08-20-2004, 09:18 AM
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You should be able to change the ring gear without removing the flywheel. If your shark is outfitted with a double disc clutch, the ring gear is bolted to the clutch intermediate ring.
08-20-2004, 10:41 AM
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You will probably fix the problem by replacing the starter, as long as the ring gear isn't too gored up. The bendix gear is not properly extending. You might look up an alternator/starter shop and see if they can repair it inexpensively.
08-20-2004, 12:41 PM
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If this were a 5 speed then the ring gear for the starter is on the intermediate plate not the flywheel . I believe this is an automatic so the ring gear is on the fly wheel . The front flex plate hub and driveshaft are in the way and Porsche says remove rear suspension ,remove transmission ,remove central drive tube ....then change ring gear . I have been told that it is possible to get the flex plate out by unbolting it from it's hub then sneak out the ring gear . There are two versions of the flywheel ring gear , 78-79 and 80-84 on one the ring gear is part of the flywheel the other it is a separate bolt on ring. This being a Euro car where the year is often recorded incorrectly when imported it could be either one
08-21-2004, 08:39 PM
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Even if the flywheel is one piece on an AT and Porsche says to remove the rear suspension and tranny, I was able to remove the flywheel on my 89 AT without doing so. It looks impossible, but with nothing more than lossening the tranny mounts and sliding it back (only a inch allowed due to the pan hitting the crossmember), I was able to get the flywheel to fall out so I could replace the rear main seal. Here is how I did it.
Rear Main Seal
Rear Main Seal
Last edited by Bill Ball; 08-25-2004 at 02:01 PM.
