AJ-V6 Flywheel

AJ-V6 Flywheels

Like most modern domestic engines, the AJ-V6 uses a dual mass flywheel, the S-type variant weighing in at 12kg.
A normal single mass flywheel was available on the V6 Duratec powered Mondeo ST220 and I managed to get hold of one to see if it would fit. Whilst it will certainly bolt up to the crank there are some key differences that make it unsuitable when using the rear wheel drive gearbox.

Left - Mondeo ST220
Right - Standard Jaguar S-type

Note the removable spigot bearing carrier is still fitted to the S-type flywheel.

Difference in thickness means the clutch assembly sits much closer to the engine on the Mondeo flywheel...

So you would have to check the splines on the gearbox input/primary shaft extend far enough and you will likely need a spacer for the clutch release bearing.

But the real stopper is the starter ring gear. Although the outer diameter is the same there are two issue with the teeth.
1) They are of a different pitch to the S-type (or most other similar) starter motor.
2) They don't have a chamfered 'lead-in' to guide engagement of the starter pinion.

Mondeo left, S-Type right. Note subtle bevelled lead in on engagement side of S-type teeth.

Mondeo left, S-type right.

So why not just swap the ring gears over?
The problem here is that the internal diameter of the Mondeo ST220 ring gear is smaller than that of the S-type ring gear making the S-type ring gear effectively too big.

Mondeo flywheel,

Ring gear internal diameter 267mm

S-Type flywheel

Ring gear internal diameter 270mm

www.TTVRacing.com

Fortunately there is another option. UK based TTV Racing actually list a range of lightened flywheels purposely for the S-type version of this engine.
Click on the picture to be taken to their website.

TTV Racing

After saving up some pocket money I took the plunge and bought the TTV Racing single mass 'Lite' flywheel. At 6.1kg this is about half the weight of the standard 12 kg dual mass flywheel. Lighter flywheels are available from them but I want to retain some road manners.

As delivered, looking all shiny and fast.

The 'Lite' flywheel uses the standard S-Type clutch assembly.

The spigot bearing carrier is machined as an integral part of the flywheel,as is the starter ring gear.

Mondeo - S-Type - TTV Racing

A few items are required to fit the flywheel regardless of what you end up with:
Spigot Bearing - P/N: 410 0015 10 (LUK)
Bolts (8. off) - P/N: C2S5392 (Jaguar), 4 107 081 (Ford)
Rear crank seal - P/N: AJ89510 (Jaguar), 4 605 210 (Ford)
The rear crank seal isn't a necessity but unless your engine is freshly rebuilt it makes sense to replace it whilst you are there rather than risk it leaking once you start using it again. The genuine parts price is a bit steep but it is up to you if you want to take the risk on this item with a cheaper aftermarket alternative. Having had an aftermarket seal fail on me before (front crank seal on the Zetec) I bit the bullet and bought genuine as I really don't want to have to pull the gearbox and flywheel off again six months later.

Fitting

To be continued...

Image Caption and Link

The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

AJ-V6 Flywheels

Left - Mondeo ST220Right - Standard Jaguar S-type

Note the removable spigot bearing carrier is still fitted to the S-type flywheel.

Difference in thickness means the clutch assembly sits much closer to the engine on the Mondeo flywheel...

So you would have to check the splines on the gearbox input/primary shaft extend far enough and you will likely need a spacer for the clutch release bearing.

But the real stopper is the starter ring gear. Although the outer diameter is the same there are two issue with the teeth.1) They are of a different pitch to the S-type (or most other similar) starter motor.2) They don't have a chamfered 'lead-in' to guide engagement of the starter pinion.

Mondeo left, S-Type right. Note subtle bevelled lead in on engagement side of S-type teeth.

Mondeo left, S-type right.

So why not just swap the ring gears over?The problem here is that the internal diameter of the Mondeo ST220 ring gear is smaller than that of the S-type ring gear making the S-type ring gear effectively too big.

Mondeo flywheel,

Ring gear internal diameter 267mm

S-Type flywheel

Ring gear internal diameter 270mm

TTV Racing

After saving up some pocket money I took the plunge and bought the TTV Racing single mass 'Lite' flywheel. At 6.1kg this is about half the weight of the standard 12 kg dual mass flywheel. Lighter flywheels are available from them but I want to retain some road manners.

As delivered, looking all shiny and fast.

The 'Lite' flywheel uses the standard S-Type clutch assembly.

The spigot bearing carrier is machined as an integral part of the flywheel,as is the starter ring gear.

Mondeo - S-Type - TTV Racing

Fitting - Preparation

Fitting

To be continued...

Image Caption and Link

Image Caption and Link

Image Caption and Link

Image Caption and Link

Left - Mondeo ST220
Right - Standard Jaguar S-type

But the real stopper is the starter ring gear. Although the outer diameter is the same there are two issue with the teeth.
1) They are of a different pitch to the S-type (or most other similar) starter motor.
2) They don't have a chamfered 'lead-in' to guide engagement of the starter pinion.

So why not just swap the ring gears over?
The problem here is that the internal diameter of the Mondeo ST220 ring gear is smaller than that of the S-type ring gear making the S-type ring gear effectively too big.