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Single Mass Flywheel Conversion

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  • Single Mass Flywheel Conversion

    Right, after my balls up of fitting a single mass flywheel on my ABY linky I thought it correct to do some sort of parts list and rough guide to help others do what should be a decent conversion when all finished. Perhaps someone doing this conversion in the future might be able to take pics?

    I would suggest getting most of the parts from the 3B or 7A engine donating it's flywheel so that you know it's all correct but if not then here goes (sorry, no P/No's).

    Parts required:-
    • 3B flywheel (or 7A but it's approx 1kg heavier).
    • Clutch for 3B flywheel (ABY stuff won't fit).
    • Flyhweel center roller bearing (to attach to 'box).
    • Flywheel to engine bolts (with threadlock pre-applied) x 8.
    • Pressure plate retaining screws.
    • Replacement bellhousing to engine bolts (new or from a 3B) (CGR retaining bolts are approx 10mm longer due to DM flywheel spacer).
    • Replacement dowels (either new, turned-down originals or from a 3B) 2 different ones.
    • Clutch release bearing (optional).
    • Rear crank seal (optional).
    • Rear crank seal paper gasket (optional).

    Specialist tools required:-
    • Alignment tool.
    • Crank locking too (or flywheel locking tool like DJones').

    Method:-
    • Remove the gearbox, clutch and flywheel
    • Replace the rear crank seal if required.
    • Remove the dowels from the engine and 'box.
    • Replace the dowels with the new shorter ones.
    • throw the 'box spacer plate in the same pile as the original clutch and flyheel.
    • Replace the 'box and check it all bolts up, be especially careful of the bracket that is held in place by one of the bellhousing bolts, I think this might have played a part in my downfall.
    • Replace all relevant bellhousing bolts with shorter (shortened) items and do it all up.
    • Replace the gearbox

    Useful links:-
    My original thread
    Thread mentioning dowels no. 1 (05/04)
    Thread mentioning dowels no.2 (07/05)
    Josh's thread about snapping the block!

    ABY dowels left, 7A right:-


    Hope I've not missed anything, please post if I have.

    Mods, please sticky so that noone else ends up with a knackered block or 'box like me or Josh.
    Cheers'en, AndyC
    1994 ABY Coupe - Projekt Alpinweiss

  • #2
    I'm sure that the bolts used to attach 3B or 7A flywheel to the crank are DIFFERENT than those from the ABY... So be sure to have the right ones for SM flywheel- N902 061 03

    Great info here from Andy... I'll try to add other part numbers to this thread.

    Paul
    Paul Nugent
    Webmaster http://S2central.net
    Administrator http://S2forum.com

    1994 S2 Coupe ABY - aka Project Lazarus
    2001 A6 allroad 2.5TDi - family tank
    2003 S4 Avant 4.2 V8 - daily burble

    Purveyor of HomeFries and Exclusive agent for Samco hose kits (S2/RS2)

    There are only 10 kinds of people that understand binary - those that do, and those that don't

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    • #3
      They are shorter. EVERYTHING needs to be for a 3B!
      Cheers'en, AndyC
      1994 ABY Coupe - Projekt Alpinweiss

      Comment


      • #4
        Here goes with the parts list of bolts & dowels required to convert 01E transmission for use with SM flywheel. All from parts system - ACOQ-3-00 (300-70) 5-cyl pages. 1-off each item below:

        The bolts listed will be approx 10mm shorter than those originally fitted to 01E gearbox with DM flywheel. There are other bolts common of course. Really needs a picture from family album here to explain it. Will do that later...

        03 - N904 957 03 (M12x100)
        05 - 014 301 153 (Dowel)
        06 - N904 954 04 (M12x67)
        08 - N904 956 04 (M12x90)
        09 - 012 301 153 (Other Dowel)
        10 - N904 955 03 (M12x80)
        11 - N906 682 01 (M10x48)
        14 - N034 773 1 (M10x38)

        If someone else can confirm this it would be great - I dont wanna be blamed for bad info. Note there are a few other bolts with 5mm difference that goes with chassis number - nothing to do with flywheel or gearbox type.

        Paul
        Paul Nugent
        Webmaster http://S2central.net
        Administrator http://S2forum.com

        1994 S2 Coupe ABY - aka Project Lazarus
        2001 A6 allroad 2.5TDi - family tank
        2003 S4 Avant 4.2 V8 - daily burble

        Purveyor of HomeFries and Exclusive agent for Samco hose kits (S2/RS2)

        There are only 10 kinds of people that understand binary - those that do, and those that don't

        Comment


        • #5
          -Add a note to check the timing pin on the back side of the 3B flywheel. I think its part of the DM flywheel so i never noticed it missing at first, very easy to snap off.
          91CQ20v - Gone to a new home
          93UR-S4 - The Magic Carpet
          94S2Bus - The Emerald Express

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          • #6
            Originally posted by Andy_Casey View Post
            Mods, please sticky so that noone else ends up with a knackered block or 'box like me or Josh.
            By your command *star fleet*

            Comment


            • #7
              It should also be mentioned that not all 'single mass flywheels' are alike, in that some of the more bespoke versions may need custom length flywheel to crank bolts, and accurate measuring should be recommended if in doubt.

              For example my (very good) aluminum flywheel made by Cees and Jeffer, needed bolts to be made up to the correct length, as 3b bolts were too short and ABY bolts were too long.

              In the end I had some ABY bolts machined down to the correct length.
              Mark - Modded

              Comment


              • #8
                Originally posted by S2central.net View Post
                Here goes with the parts list of bolts & dowels required to convert 01E transmission for use with SM flywheel. All from parts system - ACOQ-3-00 (300-70) 5-cyl pages. 1-off each item below:

                The bolts listed will be approx 10mm shorter than those originally fitted to 01E gearbox with DM flywheel. There are other bolts common of course. Really needs a picture from family album here to explain it. Will do that later...

                03 - N904 957 03 (M12x100)
                05 - 014 301 153 (Dowel)
                06 - N904 954 04 (M12x67)
                08 - N904 956 04 (M12x90)
                09 - 012 301 153 (Other Dowel)
                10 - N904 955 03 (M12x80)
                11 - N906 682 01 (M10x48)
                14 - N034 773 1 (M10x38)

                If someone else can confirm this it would be great - I dont wanna be blamed for bad info. Note there are a few other bolts with 5mm difference that goes with chassis number - nothing to do with flywheel or gearbox type.

                Paul
                Paul, I agree with your parts list but there is a discrepancy between the dowel ODs (as detailed on the album) so I might be tempted to re-work the ABY dowels on a lathe to the correct length (No's 05 and 09).

                Originally posted by Mark Halligan View Post
                It should also be mentioned that not all 'single mass flywheels' are alike, in that some of the more bespoke versions may need custom length flywheel to crank bolts, and accurate measuring should be recommended if in doubt.
                Good point.

                I have two family tree pics to show what's what:-

                Cheers'en, AndyC
                1994 ABY Coupe - Projekt Alpinweiss

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                • #9
                  Version 7 pic
                  Attached Files

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                  • #10
                    2nd Dowel
                    Attached Files

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                    • #11
                      get you!
                      Cheers'en, AndyC
                      1994 ABY Coupe - Projekt Alpinweiss

                      Comment


                      • #12
                        Careful now - Jamo's snapshot is NOT from the gearboxes used on I5 engines... Its the V6 application. I'm confident the part numbers I posted are correct !

                        Its an easy mistake to make with the dopey family album software - you click on the part in question and the system gives you the 1st option in the list - which is for V6 in this case.

                        Paul
                        Paul Nugent
                        Webmaster http://S2central.net
                        Administrator http://S2forum.com

                        1994 S2 Coupe ABY - aka Project Lazarus
                        2001 A6 allroad 2.5TDi - family tank
                        2003 S4 Avant 4.2 V8 - daily burble

                        Purveyor of HomeFries and Exclusive agent for Samco hose kits (S2/RS2)

                        There are only 10 kinds of people that understand binary - those that do, and those that don't

                        Comment


                        • #13
                          See attached PDF with the view of 5-cyl application...
                          Attached Files
                          Paul Nugent
                          Webmaster http://S2central.net
                          Administrator http://S2forum.com

                          1994 S2 Coupe ABY - aka Project Lazarus
                          2001 A6 allroad 2.5TDi - family tank
                          2003 S4 Avant 4.2 V8 - daily burble

                          Purveyor of HomeFries and Exclusive agent for Samco hose kits (S2/RS2)

                          There are only 10 kinds of people that understand binary - those that do, and those that don't

                          Comment


                          • #14
                            I think it's OK Paul as there seem only to be special parts for the CGR and everything else is common for the 5 speed 'boxes. Also, from my experiences last weekend, the bolt lengths seem to make sense.
                            Cheers'en, AndyC
                            1994 ABY Coupe - Projekt Alpinweiss

                            Comment


                            • #15
                              What is the correct part number for the center roller bearing? I plan to use a lightened 7A FW in combination with my 6-speed 01E gearbox. Is there just one size or type?

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