General Flywheel locking

[Wwhaitesm]

Hi I am a newbi looking for some help
I have a 1999 ducato 2.8d motorhome with the sofem engine gearbox 20le22
I have changed the timing belt and struggling to tighten the 36mm bolt to 200nm as I can't find how to lock the flywheel
Can't seem to find the hole it put the locking pin in
Any help would be greatly appreciate
Thanks
Mark

 

[bugsymike]

Don't know if this will help, it's for the later common rail engine that doesn't need the injector pump timed, but is basically the same engine.
It shows a hole in bottom of gearbox.
Other Forum Members may have more specific advice.
Most of my Sofim 2.8s were in Iveco Daily's and I used to put in around third gear and chock the wheels to torque pulley bolt.
In the past a last resort was to remove the starter and just insert a 10mm spanner in the teeth and move the flywheel until it jammed which works quite well.
If using these methods only do so for final tightening and with other timing/locking devices removed so as not to bend anything. Then recheck timing etc . and as always after fitting cambelts, turn engine by hand at least two full revolutions to ensure no damage.
Don't forget to remove afterwards.

 

[Communicator]

Hi I am a newbi looking for some help
I have a 1999 ducato 2.8d motorhome with the sofem engine gearbox 20le22
I have changed the timing belt and struggling to tighten the 36mm bolt to 200nm as I can't find how to lock the flywheel
Can't seem to find the hole it put the locking pin in
Any help would be greatly appreciate
Thanks
Mark

Hi Mark,

Welcome to the forum.

I had the same problem when replacing the timing belt on my 2006 2.8jtd.

I mainly followed Free Spirit's guide, which is available via the downloads section at the top of the page.

Free Spirit made a locking device to mount on two of the starter bolts with a welded part to engage with the flywheel teeth. Not being so proficient in welding, I opted to use a surplus high tensile 3/8" UNF set bolt locked into the monting plate, and filed to an approximation of the tooth profile. I was rather wary as to whether the single tooth would be sufficient. In the event no problem, but I did have to buy a larger torque wrench.

To obtain the flywheel tooth profile, I used a piece of card to make a rubbing, see attached photo.

I realise that you would rather find the elusive hole, but now you have alternative methods.

Perhaps the 10mm spanner in the works, as suggested by @bugsymike, would be easier, but make sure that it cannot disappear into the clutch housing.

 

[bugsymike]

Hi Mark,

Welcome to the forum.

I had the same problem when replacing the timing belt on my 2006 2.8jtd.

I mainly followed Free Spirit's guide, which is available via the downloads section at the top of the page.

Free Spirit made a locking device to mount on two of the starter bolts with a welded part to engage with the flywheel teeth. Not being so proficient in welding, I opted to use a surplus high tensile 3/8" UNF set bolt locked into the monting plate, and filed to an approximation of the tooth profile. I was rather wary as to whether the single tooth would be sufficient. In the event no problem, but I did have to buy a larger torque wrench.

To obtain the flywheel tooth profile, I used a piece of card to make a rubbing, see attached photo.

I realise that you would rather find the elusive hole, but now you have alternative methods.

Perhaps the 10mm spanner in the works, as suggested by @bugsymike, would be easier, but make sure that it cannot disappear into the clutch housing.

There are several options available to buy, some with a matching set of ring gear teeth to spread the load evenly, many of these are model specific.
Apart from the hassle of removing the starter and as @Communicator mentions re losing the spanner into the clutch housing , the advantage of my suggestion is it is not model specific, is readily available in most toolboxes and best of all it works without slipping once it is located correctly.
I have seen garages where tyre levers and large screwdrivers have been held in, though often it is a two person job to prevent it jumping out and damaging the teeth.

 

[Communicator]

There are several options available to buy, some with a matching set of ring gear teeth to spread the load evenly, many of these are model specific.
Apart from the hassle of removing the starter and as @Communicator mentions re losing the spanner into the clutch housing , the advantage of my suggestion is it is not model specific, is readily available in most toolboxes and best of all it works without slipping once it is located correctly.
I have seen garages where tyre levers and large screwdrivers have been held in, though often it is a two person job to prevent it jumping out and damaging the teeth.

I looked at some of those with several teeth. I did not find a model specific one online, and could not convince myself that the multi model ones, with a long fixing slot would fit correctly.

 

[bugsymike]

I looked at some of those with several teeth. I did not find a model specific one online, and could not convince myself that the multi model ones, with a long fixing slot would fit correctly.

I was thinking of where I have been at auctions in the past where Dealerships have closed down and I have been looking at their specialist tools.
Not in this case, but as an example I went to a Renault Dealership in Exeter many years ago and bought a metal trumpet of steel rods which was for fitting stretching CV boots to fit over driveshafts on Renault Masters etc. I have used it many times over the years on multiple makes before the advent of the plastic ones they include in large CV boot kit supplies. Also numerous odd shaped press tools to use on my hydraulic press.
Mind you equally so I have bought odd tooling and never found a use for it.