Flywheel Removal

[busboy]

Is there an alternative to the $80.00 Mercury flywheel removal tool on the 60's and 70's 4 cylinder motors? Any ideas on making one? Any help would be appreciated. Mike

 

[KCLOST]

Re: Flywheel Removal

Not much of one, but I can tell you what I'm doing to get around spending the money. <br /><br />I've having a machinist (with the company I work for), cut 1-1/2" x 16tpi threads in a piece of 1-1/2" bar. After that I'm going to drill through the center and tap for a bolt to go through, also counter bore the bottom side to make clearance around the flywheel nut. This will work both as a flywheel puller (with a bolt) and as a lifting eye (if I use an eye bolt instead).<br /><br />Wait, I just thought of something.... You can probably buy a lifting eye from your parts dealer (they cost around $35), Then maybe, you can drill and tap through the top of it to add the puller bolt. Might work...

 

[MercMark]

Re: Flywheel Removal

I went through this already with my 850. I ended up buying the puller. I tried many other ways but nothing worked. Some of them very bad techniques that involve rapping the end of the crank with the nut leveled at the top. I wouldn't do it.<br /><br />I looked at having something made, but it cost the same as buying the purpose built puller.<br /><br />$150 candaian dollars. 30 seconds of usefullness. It hurt a bit but was so much easier. <br /><br />Yours is like mine was? insider thread on the fly wheel only and no holes for a universal puller?<br /><br />If you search the forums, you will find my old posts. Search "mercury 850 lifting eye puller" that should bring them up. Maybe adding flywhell to the searh list. Do "Mercury 850 [word here]" for each. What you should find is some photos of homebuilt pullers people suggested but wouldn't work for me.

 

[KCLOST]

Re: Flywheel Removal

I'm kind of proud of this... A standard lifting eye, modified to also be a flywheel puller... Drilled out center hole and tapped with 1/2"x13 threads for puller bolt...<br /><br />Photos....<br /><br /> http://groups.msn.com/_Secure/0XADY...cpQYj*jcOsG4hs*ANxdyzlo4uK5V2rvRmrew/DSC00026. JPG?dc=4675463942984899372<br /><br /> http://groups.msn.com/_Secure/0WADR...KqFpfONrDXH7Ffeyh8RFyZLAJWAAAAP****8/DSC00027. JPG?dc=4675463942991484988

 

[ZmOz]

Re: Flywheel Removal

Be careful, I think the end of the bolt on a merc puller is rounded or something, to sit better in the crank...

 

[KCLOST]

Re: Flywheel Removal

I got a grinder, I'll check out the crank when I remove the flywheel nut. But it shouldn't matter, as there is no play for it to become misaligned.

 

[MercMark]

Re: Flywheel Removal

The merc flywheel puller has a thrust bearing that sits on the end of the crankshave so you can't damage it.

 

[Chris1956]

Re: Flywheel Removal

Busboy, I have taken off my 1977 Merc 1500 flywheel several times, by myself, using the wedge and tap method. It wasn't too hard. The flywheels are flexible (stamped steel). If yours is really stuck, take off the nut and washer, put some penetrating oil onto the spline, put the nut back on upside down (or ger a regular nut), even with the top thread. Now get a friend to pry up on the flywheel's edge and you do the same on the outer side, and tap the flywheel nut. It should break loose. This ain't no Johnson motor after all, those never came loose!

 

[AMD Rules]

Re: Flywheel Removal

Bringing up an old topic. Need to make one of these tomorrow.<br /><br />What size is the counter bore on the inside, that provides clearance for the nut on the end of the crank?<br /><br />1-1/2 - 16 OD straight thread<br /><br />1/2" - 13 thru tap<br /><br />? Counter bore x ? deep

 

[achris]

Re: Flywheel Removal

Originally posted by Chris1956:<br /> Busboy, I have taken off my 1977 Merc 1500 flywheel several times, by myself, using the wedge and tap method. It wasn't too hard. The flywheels are flexible (stamped steel). If yours is really stuck, take off the nut and washer, put some penetrating oil onto the spline, put the nut back on upside down (or ger a regular nut), even with the top thread. Now get a friend to pry up on the flywheel's edge and you do the same on the outer side, and tap the flywheel nut. It should break loose. This ain't no Johnson motor after all, those never came loose!

This is asking for DISASTER!!!<br />If you really want to make your own 'non-merc' puller, get a piece of 1/2" steel, drill a 7/16" hole in the centre and three 1/4" hole with the same spacing as the bolts that hold the flexplate to the hub, then set it up the same as a standard gear puller. Oh, you'll need some 7/16" threaded rod and a 7/16" nut as the driver. I use fine thread.<br /><br />Chris...........

 

[AMD Rules]

Re: Flywheel Removal

I'll answer my own question, for the benefit of the group. ID c'bore would be 1.125" diameter to clear the nut on the end of the shaft. I used 1.375" depth, but anything over an inch would be adequate.<br /><br />Suitable as a lifting ring, and a puller.<br /><br />