Flywheel and flywheel housing service procedures for 2001 2002 2003 2004 2005 and 2006 MerCruisers. Note, procedures may differ depending on year and model. See repair manual for additional instructions and pictures for additional repair procedures.
Models Covered in This Manual
Sterndrive (MCM
5.0L MPI Alpha and Bravo
350 MAG MPI Alpha and Bravo
350 MAG MPI Alpha and Bravo Horizon
MX 6.2 MPI
MX 6.2 MPI Horizon
Inboard and Tow Sports (MIE)
350 MAG MPI Inboard
350 MAG MPI Horizon Inboard
MX 6.2 MPI Inboard
MX 6.2 MPI Horizon Inboard
350 MAG MPI Tow Sports
Flywheel Housing Removal
1. Extract the motor from the boat.
2. Extract the transmission for MIE models.
NOTE: Pay special attention to ends of power steering cooler when taking off the water hoses, avoid bending.
1. Take off the water hoses from the power steering cooler.
2. On some MIE models, a rear mounted starter may be equipped. Remove the starter.
3. Take off the power steering cooler.
4. Take off the flywheel housing cover, should be two bolts needed to remove the cover.
5. Detach any ground wires from the flywheel housing.
NOTE: Upon reinstalling, be sure to place the same flywheel housing bolts in the same exact location removed from
6. Take off the bolts and studs from the flywheel housing.
7. Take off the flywheel housing.
Cleaning
1. Always use eye protection when cleaning parts.
2. Use a suitable cleaning solvent to clean all parts.
3. Use compressed air to dry parts after cleaning.
Inspection
1. Inspect the flywheel housing for possible damage, cracks or excessive wear to bolt holes or studs. Replace if needed.
2. Check guide dowels for correct placement, repair if needed.
Installation
1. Position flywheel housing on guide dowels on engine.
NOTE: Reinstall the flywheel housing fasteners in the exact same location as was upon removal.
2. Reinstall the bolts and studs in the exact locations as was upon removal.
3. Tighten the flywheel housing studs and bolts to factory specifications.
Flywheel Housing Studs and Bolt Torque Specifications: 41 Nm (30 lb-ft)
4. Reinstall the flywheel housing cover.
Flywheel Housing Cover Torque Specifications: 9 Nm (80 lb-in.)
5. Reinstall the ground wires to the flywheel housing.
6. Reinstall the power steering cooler.
7. Reinstall the water hoses.
8. For MIE models, reinstall the transmission and rear mounted starter. This is only needed if your MIE model is equipped with this.
9. Reinstall the motor in the boat.
Flywheel Removal
1. Remove the motor from the boat.
2. Remove the transmission from the boat on MIE models.
3. Take off the flywheel housing.
4. Take of the drive plate or coupler.
NOTE: The coupler or drive plate differs for Alpha, Bravo, MIE models. Refer to your repair manual for pictures.
5. Take off the flywheel.
Cleaning and Inspection
1. Clean the mating surfaces on to bare metal of flywheel and crankshaft. Eliminate any burrs.
2. Inspect the flywheel ring gear for excessively worn teeth or damaged and missing teeth.
3. Check splines in drive plate or coupler for signs of wear.
Installation
1. position the dowel hole in flywheel making sure the dowel is in crankshaft.
2. Reinstall the flywheel.
3. Reinstall the flywheel bolts and tighten bolts in correct sequence. See repair manual for sequence illustration.
Engine Flywheel Bolt Torque Specifications: 100 Nm (74 lb-ft)
Inspect the flywheel runout in the following order:
4. Obtain a dial indicator and attach the indicator to the block. Measure the outer edge of the flywheel.
5. Apply force inward on the flywheel to eliminate crankshaft end play.
6. Rotate the flywheel and take a measurement of the runout.
Specifications of Runout on 5.0L (305), 5.7L (350), 6.2L (377): 0.023 mm (0.0080 in. Maximum
7. Be sure to install the 3 rubber bumpers prior to reinstalling the flywheel, this pertains to the Alpha model only.
8. Reinstall the drive plate and tighten the bolts.
Couple-to-Flywheel Bolts Torque Specifications (MCM): 48 N-m (35 lb-ft)
Drive Plate-to-Flywheel Bolts Torque Specifications (MIE) 48 N-m (35 lb-ft)
9. Reinstall the flywheel housing.
10. Reinstall the transmission MIE models.
11. Reinstall the motor in the boat.
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