Mercury F77Z-6375-AA Flywheel Assembly

Raise the vehicle and support it securely on jack stands, ensuring that if equipped with Automatic Ride Control (ARC), the air suspension switch is turned to the OFF position before raising to prevent damage to the system components. For vehicles with manual transmission, remove the pressure plate and clutch disc. Apply alignment marks on the flywheel/drive plate and crankshaft to ensure correct alignment during reinstallation. Remove the bolts securing the flywheel/drive plate to the crankshaft, supporting the heavy flywheel during removal; if the crankshaft turns, wedge a screwdriver through the starter opening to jam the flywheel, noting that 1997 and later models have eight flywheel bolts while earlier models have six. Carefully remove the flywheel/drive plate from the crankshaft, supporting it while removing the last bolt. Clean the flywheel to remove grease and oil, inspecting the surface for cracks, rivet grooves, burned areas, and score marks, with light scoring removable using emery cloth. Check for cracked and broken ring gear teeth, laying the flywheel on a flat surface to check for warpage with a straightedge. Clean and inspect the mating surfaces of the flywheel/drive plate and crankshaft, replacing the crankshaft rear seal if leaking before reinstalling. Position the flywheel/drive plate against the crankshaft, aligning the marks made during removal, and noting that some engines have an alignment dowel or staggered bolt holes for correct installation. Apply thread locking compound to the bolt threads before tightening, using a screwdriver through the starter motor opening to prevent the flywheel/drive plate from turning as the bolts are torqued. The remainder of the installation follows the reverse of the removal procedure.

Put your car on jack stands while following this rule. Before you lift it, turn off the vehicle's Automatic Ride Control option to stop air suspension damage. To service a manual transmission vehicle, you need to take off the two parts that press the clutch together. Make marks on the flywheel/drive plate and crankshaft that will help you get the pieces exactly right when you put them back together. Take off the flywheel/drive plate's bolts from the crankshaft, holding the heavy flywheel securely when you remove it. If the crankshaft turns while you work, put a screwdriver through the starter opening to lock the flywheel. Pay attention that newer cars (model year 1997 and later) have eight bolts on their flywheels, while older models have six. Slowly take off and hold the flywheel/drive plate, then remove the last bolt from its crankshaft position. Scrub the flywheel clean of grease and oil, then check the surface for cracks, failed rivets, burnt patches, and shallow scars, with shallow grooves that you can remove by sanding. Put the flywheel flat on a ground surface, and check for cracked ring gear teeth by running a ruler over its back. First, carefully clean and check both the flywheel/drive plate and crankshaft for damage. Reinstall the rear seal when the crankshaft shows signs of leakage. Combine the flywheel/drive plate with the crankshaft, match the marks you made while taking it apart, and remember some vehicles need a special alignment tool or slight bolt hole differences for right assembly. Before installing the bolt, apply a thickening liquid onto its thread. At the same time, push your screwdriver into the hole where the starter is located to stop the flywheel/drive plate from spinning when you tighten the bolts. The rest of the installation process works in the exact opposite way we removed the components earlier.

On 2011 automatic transmission-equipped models, the driveplate is known as a flexplate by the manufacturer. To remove it, first take out the transmission and the clutch if equipped. If any clutch components show wear or the vehicle has high mileage, replacement is recommended. Mark the flywheel/driveplate to the crankshaft with paint or a center-punch for proper reinstallation. To prevent the flywheel/driveplate from turning, install one transmission mounting bolt into the cylinder block and have an assistant hold a prybar against the mounting bolt while loosening the bolts. Remove all bolts except one, leaving it installed halfway, then pull the flywheel/driveplate away from the crankshaft flange, using a mallet if necessary. Support it while removing the last bolt and carefully take it out, noting that it is heavy and has sharp edges, so gloves and caution are advised. If the rear oil seal shows leakage or the vehicle has high mileage, replacing the seal is highly recommended before reinstalling the flywheel/driveplate. For inspection, clean the flywheel/driveplate to remove grease or oil and check for cracks, rivet grooves, burned areas, and score marks, with light scoring removable using emery cloth. Check for cracked and broken ring gear teeth and use a straight-edge to check for warpage, as resurfacing by a professional machine shop may be necessary for severe wear or damage, along with clutch replacement if resurfacing occurs. Clean and inspect the mating surfaces of the flywheel/driveplate and the crankshaft. For installation, if the engine/transmission adapter plate was removed, reinstall it, then place the flywheel/driveplate on the crankshaft ensuring all bolt holes align, and install the proper bolts, tightening them by hand. Torque the mounting bolts in a crisscross pattern and in three stages, with the remainder of the installation being the reverse of removal.

The flywheel should be visually inspected for signs of cracking, warpage, scoring, or heat checking.

Raise the vehicle and support it securely on jackstands, then remove the transmission. If it's leaking, now would be a very good time to replace the front pump seal/0-ring (automatic transmission only).

Raise the vehicle and support it securely on jackstands, remove the transmission. If it's leaking, now would be a very good time to replace the front pump seal/O-ring (automatic transmission only).

Torque the flywheel/driveplate mounting bolts in a crisscross pattern and in three stages.

Clean and inspect the mating surfaces of the flywheel/driveplate and the crankshaft. If the crankshaft rear seal is leaking, replace it before reinstalling the flywheel/driveplate.

Remove the pressure plate and the clutch disc from the rear of the flywheel.