N54 Lightweight 8-Bolt Flywheel Installation Instructions
N54 Lightweight 8-Bolt FlywheelInstallation InstructionsProper service and repair procedures are vital to the safe, reliable operation of all motor vehicles as well as the personal safety of those performing the repairs. Standard safety procedures and precautions (includinguse of safety goggles and proper tools and equipment) should be followed at all times to eliminate the possibility of personal injury or improper service which could damage the vehicle or compromise its safety.
N54 LIGHTWEIGHT 8-BOLT FLYWHEEL INSTALLATIONT#553672INTRODUCTIONToday we’ll be installing our Turner Performance lightweight 8-bolt flywheel into a BMW E90 335i. This car came from the factory with adual mass flywheel mated to a non-damped clutch disc, and a self adjusting pressure plate that maintains pedal feel and free play as theclutch wears.Once we remove the original components, we’ll bolt up our lightweight single mass flywheel, followed up by a new sprung-hub clutchdisc and a self adjusting pressure plate. We’ll also install a new throwout bearing and pilot bearing, and show you how to inspect all otherkey components for wear. This Turner engineered exact-fit replacement flywheel bolts up without any modification. It’s less expensivethan a new OE dual mass flywheel, and its reduced mass will give us crisper throttle response, improved rev matching, and more positiveshifting.Some experience is recommended for this job, but we’re going to lay it out step by step, so even if you don’t have much “wrench” timeunder your belt, we’ll make it easy for you. There are a few special tools that are required, be sure to read through these instructionsbefore you begin. If you have an automotive lift and previous experience, you’ll probably be able to knock this out in an afternoon. Ifyou’re working on jack stands or have less experience you may want to plan an entire weekend for the project. You’ll be working withsome heavy components so keep a friend nearby for a helping hand.TABLE OF CONTENTSTechnical Notes.pg.3Optional Replacement Parts.pg.4Installation and Safety Notes.pg.5Bell Housing Bolt and Component Locations.pg.6Bell Housing Bolt Template.pg.8Removing the Transmission.pg.9Removing the Original Flywheel and Clutch.pg.26Cleaning the Engine Block.pg.27Preparing the Transmission for Installation.pg.28Installing the new Flywheel and Clutch.pg.33Reinstalling the Transmission.pg.37Torque Specifications.pg.39 2020 TURNER MOTORSPORT16 HUNT RD SOUTH AMESBURY, MA 019131.978.388.7769WWW.TURNERMOTORSPORT.COM2
N54 LIGHTWEIGHT 8-BOLT FLYWHEEL INSTALLATIONT#553672TECHNICAL NOTESHardened 4140 chromoly forexcellent engagement feeland durabilityThis flywheel has been designed in-house using state ofthe art 3D modeling and simulation software to optimizestrength and durability under extreme clamp and torqueloading as well as centrifugal forcesPrecisionbalancedSFI 1.1 tested and certifiedto ensure safe operationunder the most extremeconditionsCorrosion resistant black zinccoating on all non machined/non critical surfacesInduction hardenedring gear for superiorwear resistancePerformance Benefits: Crisper throttle responseSmoother shifting and improved rev-matchingImproved accelerationWeight savings 2020 TURNER MOTORSPORT16 HUNT RD SOUTH AMESBURY, MA 01913Our lightweight flywheels aremanufactured in an ISO certifiedfacility to exacting le of Contents3
N54 LIGHTWEIGHT 8-BOLT FLYWHEEL INSTALLATIONT#553672OPTIONAL REPLACEMENT PARTSOEM 335is Unsprung Clutch Kit(includes clutch disc, pressure plate, throwoutbearing, clutch fork & pressure plate bolts)HD Sprung Street Performance Clutch Kit(includes clutch disc, alignment tool,pressure plate, & pressure plate bolts)Xtreme Sprung Street Performance Clutch Kit(includes clutch disc, alignment tool,pressure plate, & pressure plate bolts)M12x90 Bell Housing Bolts (QTY 5)- Optional with all clutch kits -OEM Clutch Alignment Tool (QTY 1)- REQUIRED w/OEM clutch kit -Pilot Bearing (QTY 1)- Optional with all clutch kits -ECS Clutch Fork Pivot Pin (QTY 1)- Optional with all clutch kits -Flywheel Bolts (QTY 8)- Optional with all clutch kits 2020 TURNER MOTORSPORT16 HUNT RD SOUTH AMESBURY, MA 019131.978.388.7769WWW.TURNERMOTORSPORT.COMTable of Contents4
N54 LIGHTWEIGHT 8-BOLT FLYWHEEL INSTALLATIONT#553672INSTALLATION NOTES RH refers to the passenger side of the vehicle.LH refers to the driver side of the vehicle.Always use the proper torque specifications.If applicable to this installation, torque specifications will be listed throughout the document and at the end as well.Please read all of these instructions and familiarize yourself with the complete process BEFORE you begin.GENERAL PREPARATION AND SAFETY INFORMATIONTurner Motorsport cares about your health and safety, please read the following safety information. This information pertains to automotiveservice in general, and while it may not pertain to every job you do, please remember and share these important safety tips. Park your car in a safe, well lit, level area.Shut the engine off and remove the key from the ignition switch.Make sure any remote start devices are properly disabled.ALWAYS wear safety glasses.Make sure the parking brake is applied until the vehicle is safely lifted and supported.Whether lifting a vehicle using an automotive lift or a hydraulic jack, be sure and utilize the factory specified lift points.Lifting a vehicle in an incorrect location can cause damage to the suspension/running gear.ALWAYS support the vehicle with jack stands.ALWAYS read and follow all safety information and warnings for the equipment you are using.NEVER get underneath a vehicle that is supported only by a jack, andALWAYS make sure that the vehicle is securely supported on jack stands. 2020 TURNER MOTORSPORT16 HUNT RD SOUTH AMESBURY, MA 019131.978.388.7769WWW.TURNERMOTORSPORT.COMTable of Contents5
N54 LIGHTWEIGHT 8-BOLT FLYWHEEL INSTALLATIONT#553672BELL HOUSING BOLT LOCATIONSAccessing and removing the bell housing bolts is one of themost difficult parts of this job. Use these location charts and thetemplate on page 9 to assist with removal and to also make surethat you reinstall the bolts in the correct locations.1.2.3.4.5.6.7.8.9.10.11.Bell Housing Bolt M12x50mm Bolt. E14 TorxBell Housing/Starter M10x85mm Bolt. E12 TorxBell Housing Bolt M8x50mm Bolt. E10 TorxBell Housing Bolt M8x50mm Bolt. E10 TorxBell Housing Bolt M12x90mm Bolt. E14 or E18 TorxBell Housing Bolt M12x90mm Bolt. E14 or E18 TorxBell Housing Bolt M12x50mm Bolt. E14 TorxBell Housing Bolt M12x90mm Bolt. E14 or E18 TorxBell Housing Bolt M12x90mm Bolt. E14 or E18 TorxBell Housing Bolt M8x50mm Bolt. E10 TorxBell Housing Bolt M12x90mm Bolt. E14 or E18 Torx1278956103411Bolts 8 and 9 also hold a wiring harness bracket in place.1The original bell housing bolts in locations #5, #6,#8, #9, and #11 are aluminum and require an E18Socket. Replacement bolts are steel and require anE14 socket. Your vehicle may be equipped either waydepending on past service.2910 2020 TURNER MOTORSPORT16 HUNT RD SOUTH AMESBURY, MA e of Contents6
N54 LIGHTWEIGHT 8-BOLT FLYWHEEL INSTALLATIONT#553672BELL HOUSING BOLT LOCATIONS1.2.5.6.7.8.9.10.Bell Housing Bolt M12x50mm Bolt. E14 TorxBell Housing/Starter M10x85 Bolt. E12 TorxBell Housing Bolt M12x90mm Bolt. E14 or E18 TorxBell Housing Bolt M12x90mm Bolt. E14 or E18 TorxBell Housing Bolt M12x50mm Bolt. E14 TorxBell Housing Bolt M12x90mm Bolt. E14 or E18 TorxBell Housing Bolt M12x90mm Bolt. E14 or E18 TorxBell Housing Bolt M8x50mm Bolt. E10 Torx1278129101212. Slave Cylinder Mounting Nuts13. Reverse Light Switch14. Reverse Light Harness Clips714514613 2020 TURNER MOTORSPORT16 HUNT RD SOUTH AMESBURY, MA 019131.978.388.7769WWW.TURNERMOTORSPORT.COMTable of Contents7
N54 LIGHTWEIGHT 8-BOLT FLYWHEEL INSTALLATIONBell HousingBolt TemplateT#553672M10x85mmE12 SocketM12x50mmE14 Socket1Starter27(No bolt)M12x90mmE14 orE18 Socket89Print this page, tape it to a cardboardbox, and punch through at each bolthole location. Then as you remove thebell housing bolts, store each one in thecorresponding hole in the template106M8x50mmE10 Socket113 2020 TURNER MOTORSPORT516 HUNT RD SOUTH AMESBURY, MA 01913M12x90mmE14 or E18 Socket41.978.388.7769WWW.TURNERMOTORSPORT.COMTable of Contents8
N54 LIGHTWEIGHT 8-BOLT FLYWHEEL INSTALLATIONT#553672TRANSMISSION REMOVALStep 1:10mm Socket & Ratchet or 10mm WrenchDisconnect the negative battery terminal (the battery is located inthe trunk). Isolate the terminal so it does not accidentally contact thenegative battery post.CAUTION: To reduce the risk of fire, explosion, orpersonal injury, ALWAYS disconnect the batteryby removing the negative battery terminal.Step 2:We’re going to begin with the hardest bolt to reach, the top bellhousing bolt (#1 on the bell housing bolt chart). You can get at thisbolt in one of two ways: Less difficult: Remove the air box and wiper cowl to gainaccess from above.More difficult: Use a swivel joint and several long extensionsto access it from below.We opted for the less difficult option. The photo on the right showswhat you’ll see with the air box and wiper cowl removed.Proceed to step 3 for more tips and tricks for removing this trickybolt. 2020 TURNER MOTORSPORT16 HUNT RD SOUTH AMESBURY, MA 019131.978.388.7769WWW.TURNERMOTORSPORT.COMTable of Contents9
N54 LIGHTWEIGHT 8-BOLT FLYWHEEL INSTALLATIONT#553672TRANSMISSION REMOVALStep 3:E14 Torx Socket & Flex Head RatchetThe “key ” to removing these two bolts is in the tools you use. Takean E14 Torx socket and place it on a flex head ratchet, then anglethe head of the ratchet as shown in the picture. This combination isgoing to make this much easier.Step 4:The “key” to loosening the uppermostbell housing bolt and the upperstarter bolt: An E-drive torx socket onthe end of a flex head ratchetE14 Torx Socket & Flex Head RatchetFirst remove the upper bell housing bolt (#1 on the bell housingbolt chart). Guide the socket onto the head of the bolt and loosen it.You’ll find that there is just enough room to get this done.Since it’s too tight to really swing the ratchet, once the bolt is loose,try to reach in and turn it out by hand. If you cannot unthread it,here are two tricks you can use:1. An 11mm 12-point wrench will also fit the head of this bolt, ifyou have a stubby wrench it works best.2. An 11mm 6-point socket will also fit on the head of this bolt,use a 1/4” drive ratchet and small socket to help back out thebolt. 2020 TURNER MOTORSPORT16 HUNT RD SOUTH AMESBURY, MA 019131.978.388.7769Here you can see the upper bellhousing bolt between the firewall andengine.WWW.TURNERMOTORSPORT.COMTable of Contents10
N54 LIGHTWEIGHT 8-BOLT FLYWHEEL INSTALLATIONT#553672TRANSMISSION REMOVALStep 5:Flat Blade ScrewdriverLoosen the clamp securing the charge pipe elbow to the intercoolerpipe and pull the flexible elbow off the pipe. If you have anaftermarket charge pipe installed, make sure to disconnect it at thispoint.This will prevent damage to either component when theengine is tilted backwards to lower the transmission.Step 6:Automotive Lift (preferred)Safely raise and support the vehicle. Be sure to place thetransmission in neutral once the vehicle is off the ground.We strongly recommend the use of an automotivelift and a transmission jack for this procedure. If youare using jack stands, the job will be more difficultand extra time will be required. 2020 TURNER MOTORSPORT16 HUNT RD SOUTH AMESBURY, MA 019131.978.388.7769WWW.TURNERMOTORSPORT.COMTable of Contents11
N54 LIGHTWEIGHT 8-BOLT FLYWHEEL INSTALLATIONT#553672TRANSMISSION REMOVALStep 7:8mm, 10mm, 13mm Sockets & RatchetRemove the three plastic insulation panels below the engine andtransmission.Rear panelThe center panel has two brackets (arrows) that can be disconnectedat either the panel or the body. Disconnect them at the body andremove them with the center panel. This will keep them out of theway for transmission removal.Center panelFront panelStep 8:13mm, 18mm Sockets & RatchetRemove the rear body V-brace by removing the eight center platebolts and the two rear bolts. 2020 TURNER MOTORSPORT16 HUNT RD SOUTH AMESBURY, MA 019131.978.388.7769WWW.TURNERMOTORSPORT.COMTable of Contents12
N54 LIGHTWEIGHT 8-BOLT FLYWHEEL INSTALLATIONT#553672TRANSMISSION REMOVALStep 9:13mm, E10 Sockets & RatchetFirst remove the front exhaust support clamp holding the two centerpipes, then remove the entire support bracket by removing the twobolts that secure it to the rear transmission bracket.Step 10:Choose the following option that is applicable to your car:1. If the exhaust system is completely original, you will beremoving the entire system as one piece. Continue with step 11.2. In many instances, the exhaust has been cut and sleevedbetween the downstream converters and the x-pipe. If theexhaust on your car is sleeved, loosen the sleeves and slidethem onto the rear exhaust section as shown in the picture atright, then continue with step 11. 2020 TURNER MOTORSPORT16 HUNT RD SOUTH AMESBURY, MA 019131.978.388.7769WWW.TURNERMOTORSPORT.COMTable of Contents13
N54 LIGHTWEIGHT 8-BOLT FLYWHEEL INSTALLATIONT#553672TRANSMISSION REMOVALStep 11:13mm Socket & RatchetRemove the four nuts securing the center exhaust pipes to thecatalytic converter flanges (two on each flange). If you have a sleeved system, remove both center exhaustsections at this time, then proceed to step 13. You do notneed to remove the rear exhaust system. If you have a one piece system, continue with step 12.Step 12:Exhaust Hanger Removal ToolThere are six rubber hangers (arrows) holding the exhaust system up.Request the help of an assistant to support the exhaust, then removeeach of the hangers and lower the complete system from the car.The picture on the right shows an exhaust hanger removal toolbeing used on one of the hangers.CAUTION: The exhaust system is very heavy. Be sureto request assistance to prevent personal injury and/ordamage to the exhaust. 2020 TURNER MOTORSPORT16 HUNT RD SOUTH AMESBURY, MA 019131.978.388.7769WWW.TURNERMOTORSPORT.COMTable of Contents14
N54 LIGHTWEIGHT 8-BOLT FLYWHEEL INSTALLATIONT#553672TRANSMISSION REMOVALStep 13:8mm, 10mm Sockets & RatchetRemove the center heat shield by removing the securing screwsaround the perimeter.Step 14:Paint MarkerMake reference marks on the front of the driveshaft, the rubber flexcoupler, and the transmission output flange so you can re-indexthem during reassembly. This will lessen the risk of developingunwanted driveline vibration.DriveshaftFlex coupler 2020 TURNER MOTORSPORT16 HUNT RD SOUTH AMESBURY, MA langeTable of Contents15
N54 LIGHTWEIGHT 8-BOLT FLYWHEEL INSTALLATIONT#553672TRANSMISSION REMOVALStep 15:18mm Open/Boxed End WrenchesRemove the three bolts holding the driveshaft to the flex coupler.Step 16:Transmission JackRemove the two bolts holding the driveshaft center support bearingto the body tunnel.The driveshaft center support bearing is offset. Note theinstallation position so you do not install it upside downduring reassembly. The majority of the bearing will fit upinto the tunnel when properly installed. 2020 TURNER MOTORSPORT16 HUNT RD SOUTH AMESBURY, MA 019131.978.388.7769WWW.TURNERMOTORSPORT.COMTable of Contents16
N54 LIGHTWEIGHT 8-BOLT FLYWHEEL INSTALLATIONT#553672TRANSMISSION REMOVALStep 17:Flat Blade ScrewdriverSlide the driveshaft rearward off the rubber flex coupler. You mayneed to lever slightly between the driveshaft and flex coupler toseparate the two.Step 18:Allow the driveshaft to hang down and off to the side, but secure itwith mechanics wire so the weight of it is not on the rear driveshaftCV joint. 2020 TURNER MOTORSPORT16 HUNT RD SOUTH AMESBURY, MA 019131.978.388.7769WWW.TURNERMOTORSPORT.COMTable of Contents17
N54 LIGHTWEIGHT 8-BOLT FLYWHEEL INSTALLATIONT#553672TRANSMISSION REMOVALStep 19:Flat Blade ScrewdriverDisconnect the turbo outlet hose from the intercooler so it will notbe stretched when lowering the transmission (aftermarket style ofhose shown here).Step 20:Transmission Jack, 13mm Socket & RatchetPosition a transmission jack underneath and raise it up until itcontacts the transmission, approximately in the center. Remove thefour transmission crossmember bolts and lower the transmission sothe cross member drops away from the body by about 2”. 2020 TURNER MOTORSPORT16 HUNT RD SOUTH AMESBURY, MA 019131.978.388.7769WWW.TURNERMOTORSPORT.COMTable of Contents18
N54 LIGHTWEIGHT 8-BOLT FLYWHEEL INSTALLATIONT#553672TRANSMISSION REMOVALStep 21:18mm Open/Boxed End WrenchesRemove the three bolts holding the rubber flex coupler to thetransmission output flange, and pull the coupler off the flange.You may need to gently lever the flex coupler off ofthe output flange due to three dowels which keep italigned and sometimes cause it to be “stuck”.Step 22:With the flex coupler removed, you will be able to access the shifterfor removal. Locate the two clips that hold the main shift console inplace.ShiftconsoleClip 2020 TURNER MOTORSPORT16 HUNT RD SOUTH AMESBURY, MA le of Contents19
N54 LIGHTWEIGHT 8-BOLT FLYWHEEL INSTALLATIONT#553672TRANSMISSION REMOVALStep 23:Small Flat Blade Screwdriver or Small Pick ToolFirst, pry the clips up off of the ribs on the transmission, then slidethem to the sides and pull them completely out.2.2.1.Step 24:1.Small Flat Blade Screwdriver or Small Pick ToolRemove the two clips holding the shift rod in place, then slide theshift rod out and remove it.ClipShiftrodClip 2020 TURNER MOTORSPORT16 HUNT RD SOUTH AMESBURY, MA 019131.978.388.7769WWW.TURNERMOTORSPORT.COMTable of Contents20
N54 LIGHTWEIGHT 8-BOLT FLYWHEEL INSTALLATIONT#553672TRANSMISSION REMOVALStep 25:Pull the wiring harness clip off the harness bracket on the side of thetransmission.Step 26:Small Flat Blade ScrewdriverUnplug the oil level sensor electrical connector, then pull bothoxygen sensor connectors out of their support brackets anddisconnect them. Move the main harness assembly off to one sideand secure it out of the way.Oil levelsensorUse colored tape or zip ties to mark the matchingsides of the oxygen sensor connectors. 2020 TURNER MOTORSPORT16 HUNT RD SOUTH AMESBURY, MA 01913Oxygen .COMTable of Contents21
N54 LIGHTWEIGHT 8-BOLT FLYWHEEL INSTALLATIONT#553672TRANSMISSION REMOVALStep 27:E10 Socket & RatchetRemove the two securing bolts (#3 and #4 on the bell housing boltchart) and remove the lower wiring harness bracket from the bottomof the bell housing.Step 28:13mm Socket & RatchetRemove the securing bolt and remove the wiring harness bracketfrom the side of the transmission. 2020 TURNER MOTORSPORT16 HUNT RD SOUTH AMESBURY, MA 019131.978.388.7769WWW.TURNERMOTORSPORT.COMTable of Contents22
N54 LIGHTWEIGHT 8-BOLT FLYWHEEL INSTALLATIONT#553672TRANSMISSION REMOVALStep 29:Disconnect the reverse light switch and pull the harness out of theclips on the top of the transmission (see component locations onPage 7).Step 30:13mm Socket, Ratchet & ExtensionUnbolt the slave cylinder from the side of the transmission, thensecure it off to the side so it does not hang its weight on the hose.SlavecylinderCAUTION: DO NOT depress the clutch pedalonce the slave cylinder has been removed. 2020 TURNER MOTORSPORT16 HUNT RD SOUTH AMESBURY, MA 019131.978.388.7769WWW.TURNERMOTORSPORT.COMTable of Contents23
N54 LIGHTWEIGHT 8-BOLT FLYWHEEL INSTALLATIONT#553672TRANSMISSION REMOVALStep 31:Insert two 2x4 blocks in between the front sway bar and the bottomof the oil pan. You may have to lower the transmission jack slightlyand pull down on the back of the transmission to slip them inplace. These will keep the engine from falling forward when thetransmission is removed.Step 32:E14 or E18 Torx Socket & RatchetRemove bell housing bolts #5 and #6 on the bolt location chart.These bolts will also secure a downpipe bracket to the bell housing.If you have OE downpipes, you will need to remove the bracket fromthe downpipes as well.The original bell housing bolts in these locations arealuminum and require an E18 Socket. Replacement boltsare steel and require an E14 socket. Your vehicle may beequipped either way depending on past service. 2020 TURNER MOTORSPORT16 HUNT RD SOUTH AMESBURY, MA 019131.978.388.7769WWW.TURNERMOTORSPORT.COMTable of Contents24
N54 LIGHTWEIGHT 8-BOLT FLYWHEEL INSTALLATIONT#553672TRANSMISSION REMOVALStep 33:E10, E14, E18 Sockets & RatchetMake sure the transmission jack is located securely underneath thetransmission. Remove bell housing bolts #7, #8, #9, and #10. Youwill generally have to use a number of different extensions and auniversal joint in order to access these bolts, but you’ll find thatoverall it’s not too difficult.78910You are almost ready to remove the transmission. Besure to enlist the help of a friend. The transmissionis very heavy and you will need help to steady it andtransfer it to a work surface.Step 34:E14 or E18 Socket & RatchetRemove bolt #11. Slide the transmission rearward just far enoughfor the input shaft to clear the clutch assembly, then lower thetransmission down and transfer it to a work surface.Locating dowels between the bell housing and engineblock may require you to lever the two apart using alarge flat blade screwdriver or pry bar. 2020 TURNER MOTORSPORT16 HUNT RD SOUTH AMESBURY, MA 019131.978.388.776911WWW.TURNERMOTORSPORT.COMTable of Contents25
N54 LIGHTWEIGHT 8-BOLT FLYWHEEL INSTALLATIONT#553672REMOVING THE ORIGINAL FLYWHEEL AND CLUTCHStep 1:6mm Hex Bit Socket, Ratchet & Flat Blade ScrewdriverDREAD ENTIRE STEP FIRSTLoosen, but do not remove all six pressure plate bolts (arrows). Next,keep a flat blade screwdriver within reach, then place one hand onthe pressure plate to keep it in place and remove all six bolts in analternating pattern. Now, using both hands, slowly pull the pressureplate off of the flywheel dowel pins (D). As you pull it off, make surethat you grab the clutch disc so it does not fall and remove it alongwith the pressure plate. You may have to pry the pressure plate offthe dowel pins (D) using a flat blade screwdriver. Depending onwhether the pressure plate bolts are original or not, the socket sizerequired for removal may vary.Step 2:DDT60 Torx Socket & RatchetLoosen all eight flywheel bolts, then remove seven of them. Firmlygrip the flywheel and remove the last bolt, then pull the flywheel offthe end of the crankshaft.An impact can be used to easily remove the flywheelbolts. If you do not have an impact, thread two ofthe old pressure plate bolts back into place and levera pry bar between them to keep the engine fromturning while you break the flywheel bolts loose. 2020 TURNER MOTORSPORT16 HUNT RD SOUTH AMESBURY, MA 019131.978.388.7769WWW.TURNERMOTORSPORT.COMTable of Contents26
N54 LIGHTWEIGHT 8-BOLT FLYWHEEL INSTALLATIONT#553672CLEANING THE ENGINE BLOCKStep 1:Thoroughly clean the end ofthe crankshaft and engineblock. Closely inspect therear main seal for any signsof leakage, replacing it ifnecessary. Make sure thatboth alignment dowelsare located in the block inthe locations shown. If not,they are probably stuck inthe bell housing. Locatethem and reinstall them inthe block.AlignmentdowelRear mainsealAlignmentdowel 2020 TURNER MOTORSPORT16 HUNT RD SOUTH AMESBURY, MA 019131.978.388.7769WWW.TURNERMOTORSPORT.COMTable of Contents27
N54 LIGHTWEIGHT 8-BOLT FLYWHEEL INSTALLATIONT#553672PREPARING THE TRANSMISSION FOR CLUTCH/FLYWHEEL INSTALLATIONStep 1:Remove the release lever and throwout bearing together using thefollowing procedure:1. Pinch the ends of the clutch release arm pivot spring togetherwith your thumb and forefinger.2. Slide the release arm and throwout bearing off of thethrowout bearing guide sleeve.3. Pull the release arm out of the pivot spring.ThrowoutbearingReleaseleverPinch springends togetherStep 2:Thoroughly clean the inside of the bell housing, the throwoutbearing guide sleeve, and the input shaft splines.GuidesleeveInputshaft 2020 TURNER MOTORSPORT16 HUNT RD SOUTH AMESBURY, MA 019131.978.388.7769WWW.TURNERMOTORSPORT.COMTable of Contents28
N54 LIGHTWEIGHT 8-BOLT FLYWHEEL INSTALLATIONT#553672PREPARING THE TRANSMISSION FOR CLUTCH/FLYWHEEL INSTALLATIONStep 3:The retaining spring for the release arm should remain installed onthe ball pin as shown. If it came off with the release arm, reinstall itonto the ball pin.Also closely inspect the ball pin for wear. Compare the end of yourball pin to the picture of the new one. If yours is worn down, now is agood time to replace it. Step 4:A new ball pin can be found HERE.A new release lever retaining spring can be found HERE.Pilot Bearing PullerReplace the pilot bearing in the end of the transmission input shaft.A new one is included with the kit. This is easily accomplished ifyou have a pilot bearing puller. Proceed to the next page for moreinformation.InputshaftPilot bearingpullerPilotbearing 2020 TURNER MOTORSPORT16 HUNT RD SOUTH AMESBURY, MA 019131.978.388.7769WWW.TURNERMOTORSPORT.COMTable of Contents29
N54 LIGHTWEIGHT 8-BOLT FLYWHEEL INSTALLATIONT#553672PREPARING THE TRANSMISSION FOR CLUTCH/FLYWHEEL INSTALLATIONPilot Bearing Removal:Remove the old bearing with a pilot bearing removal tool attached to the end of a slide hammer. Insertthe puller jaws into the old bearing, then spread them apart until they grip the inside of the bearingsecurely. Then slide hammer the old bearing from the bore. Use a bearing driver or appropriately sizedsocket to drive in the new bearing.slide hammerinputshaftpuller jawspilot bearingroundpunchIf you don’t have a puller, try filling the insideof the bearing bore with grease. Then inserta round punch, slightly smaller in diameterthan the bearing bore. Strike the punch with ahammer. This forces the grease under pressurethrough the small hole in the bearing cap intothe blind hole. The pressure will push the oldbearing out of the bore. 2020 TURNER MOTORSPORT16 HUNT RD SOUTH AMESBURY, MA 01913pilot eTable of Contents30
N54 LIGHTWEIGHT 8-BOLT FLYWHEEL INSTALLATIONT#553672PREPARING THE TRANSMISSION FOR CLUTCH/FLYWHEEL INSTALLATIONStep 5:Inspect the input shaft and guide sleeve for wear, lubricate the ballpin with a light grease, then sparingly lubricate the input shaft withclutch spline grease.BallpinGuidesleeveInputshaftStep 6:Being very careful not to get any grease or oil onto the frictionface, test fit the clutch disc onto the input shaft. Slide it in and outa few times to make sure it moves freely without any sticking orbinding. Any sticking or binding here can lead to engagement ordisengagement issues, and must be corrected now.When you are satisfied the disc moves freely on the input shaft,remove it and lay it aside in a clean place until the new flywheel isinstalled. 2020 TURNER MOTORSPORT16 HUNT RD SOUTH AMESBURY, MA 019131.978.388.7769WWW.TURNERMOTORSPORT.COMTable of Contents31
N54 LIGHTWEIGHT 8-BOLT FLYWHEEL INSTALLATIONT#553672PREPARING THE TRANSMISSION FOR CLUTCH/FLYWHEEL INSTALLATIONStep 7:Install the new throwout bearing onto the new clutch release arm,then slide them over the guide sleeve and install the release armthrough the pivot retaining spring and onto the ball pin. Push inon the release arm at the ball pin to hold it in place, then pivot therelease arm in and out to make sure it slides freely.Step 8:One final thing to check here: Take a look at the back of thetransmission where the shifter selector shaft enters the case. Thisseal is a common place for leaks. Inspect forleaksA replacement is available on our website by clicking HERE. 2020 TURNER MOTORSPORT16 HUNT RD SOUTH AMESBURY, MA 019131.978.388.7769WWW.TURNERMOTORSPORT.COMTable of Contents32
N54 LIGHTWEIGHT 8-BOLT FLYWHEEL INSTALLATIONT#553672INSTALLING THE NEW FLYWHEEL AND CLUTCHStep 1:Inspect the end of the crankshaft and the center hub of the newlightweight flywheel. The crankshaft will have a locating dowel inone of the bolt holes. The flywheel will have a recess to mate upwith this dowel.Step 2:T60 Torx Socket & RatchetInstall the flywheel into place on the end of the crankshaft, theninstall all eight bolts by hand in an alternating fashion to draw theflywheel down evenly onto the crankshaft. Continue to thread t
dual mass flywheel mated to a non-damped clutch disc, and a self adjusting pressure plate that maintains pedal feel and free play as the clutch wears. Once we remove the original components, we’ll bolt up our lightweight single mass flywheel, followed up by a new sp
5mm bolt, nut 4.5-6 6mm bolt, nut 8-12 8mm bolt, nut 18-25 10mm bolt, nut 29-34 12mm bolt, nut 49-59 4mm screw 1.5-2.6 5mm screw 3.5-5 6mm screw 7-11 5mm flange bolt 3.6-6.9 6mm screw 7-11 5mm flange bolt 3.6-6.9 6mm flange bolt 10-14 8mm flange bolt 20-26 Bolt and nut 10mm flange bolt
Fig.5.Dual Mass Flywheel System The dual mass flywheel system is as shown above. The flywheel comprises of the flywheel hub which is keyed to the engine shaft,. Hub carries the flywheel body, on which the flywheel gear
of conventional flywheel and compact flywheel using inertia augmentation mechanisms. A. Trial on Conventional Flywheel and Compact Flywheel Engine Speed 1300 rpm Engine Power 205 watt Radius of dyno- brake pulley 0.032 m Table 1 Observation Table of Conventional Flywheel Sr
hand, bring the bolt carrier with bolt to the rear as far as possible, and moving the bolt carrier forward a distance of 1 to 2 mm. Lift the rear portion of the bolt carrier and remove it together with the bolt from the receiver. 8. Remove the bolt from the bolt carrier. Take the bolt
parker lubed. The flywheel can be machined to take 8 1/2” and 7 1/4” clutch sizes. In addition to the standard lightweight flywheel, a milled ultra-lightweight item is also available. ARP heavy duty flywheel bolts must be used. Uses AP fast road cover and organ-ic driven plate. We
1. Place flywheel on the crankshaft and attach with washers and bolt. Torque bolt to 14-16 LB-FT. Verify correct flywheel rotation. CAUTION: Do not force flywheel onto the crankshaft. 2. Position and assemble air compressor to the platform. This air compressor pump was shipped without oil
1. Place flywheel on the crankshaft and attach with washers and bolt. Torque bolt to 14-16 LB-FT. Verify correct flywheel rotation. CAUTION: Do not force flywheel onto the crankshaft. 2. Position and assemble air compressor to the platform. 3. Attach air filters to the pump heads. This air
Araling Panlipunan . 2 Araling Panlipunan 2 Ma. Ther Inilimbag sa Pilipinas ng _ Department of Eduction-Instructional Materials Council Secretariat (DepEd-IMCS) Office Address: nd 2 Floor Dorm G, PSC Complex Meralco Avenue, Pasig City Philippines 1600 Telefax: (02) 634-1054 or 634-1072 E-mail Address: imcsetd@yahoo.com Mga Bumuo ng Kagamitan ng Mag-aaral Consultant: Zenaida E. Espino .
