KEP Flywheel problem -What other than porsche uses the same 9 bolt crank pattern

[RichHawk]

I have a KEP (Kennedy Engineering products) problem.
I have a brand new 9 bolt KEP custom flywheel that was made for mating a 3.2L to 901 transmission.
But when it's bolted to a 3.2 or to a 3.0L it hits the cases, and you can't turn the crank due to interference between the back of the flywheel and the engine case.

I don't want to cry foul to KEP just yet. Since I did not originally buy this I want to make sure there isn't any other possible explanation other than the flywheel being incorrectly manufactured.

Two Questions:
1) Is there any VW or Audi or Subaru that uses the same 9 bolt crank pattern that this flywheel could have potentially been made to fit?

2) In your Opinion, Because I did not buy this, but instead bought it brand new from the original purchaser, Does that lessen KEP's liability on their product? It's now more than a year old, but never installed until the initial "hitting the case" problem was found.

All I want is the right flywheel, and this one is just not right. What's your thoughts?

Thanks,
Richard

[vmax]

I would suggest calling KEP.
I know when you use some Aluminum flywheels they rub the engine case. The fix might be as simple as removing a little material from it.

Link on flywheel rubbing.
New Flywheel - Engine not turning

[KTL]

Call KEP. They specialize in specialty components, so they understand when things don't mate togther as desired and a workaround has to be created. Plus I suspect they'd like a chance to stand behind their product. Especially if the flywheel is supposed to be a direct fit for the configuration you have?

[RichHawk]

Intersting. We can't actually make a proper flywheel, so modify your engine???

Ok, I'll play a long. Does this look like a minor inconsistency of casting?

This is how much had to come off the cases to get the flywheel to turn. Happily this is not my case, and I did not do the grinding, the owner did. I'm just on the hook for the flywheel.

Here's some drawings the owner and I did to confirm what we suspected. It just ain't right....


Richard

[BURN-BROS]

It's common to have to modify the case for the aluminum flywheels. I suspect Kennedy cannot make the flywheel thin enough due to the material. Any thinner and the flywheel can bend when the clutch is depressed. Good luck!

Edit:
The one I had a problem with only had interfearence between the rivets and the case. A slight massaging of the case fixed the issue.

[RichHawk]

Ahhhh.... I glossed over the whole Aluminum Flywheel bit.

No this is a custom steel flywheel. There's plenty of material and strength left in the KEP design. It's just cut wrong.
No relief on the backside for the case bulges (Like my stock 3.2 has)
Plus it's too short overall, so the starter can't engage. (Otherwise the case grinding would have worked)

Richard

[RichHawk]

Oh,
And initial calls to KEP have not yielded a solution. KEP is acting a bit apathetic since we did not buy it directly from them. But it's not used, it was just the typical long time between purchase and install game, plus it changed hands once.

I'm personally going to call them today. I think I've got a pretty solid case both commercially and technically that I can present to them.

Richard

[RichHawk]

Update:
KEP is happily fixing it.

Once I had my ducks in a row, and track the paperwork correctly it becomes pretty easy.

Flywheel is going back for clearance on the back side, and for the proper ring gear.

Thanks to Dave at TRE for assisting on the paperwork trace, and for Brett at KEP for reviewing all the documentation.

Richard (A KEP and TRE Happy customer)

[BURN-BROS]

Originally Posted by RichHawk

Ahhhh.... I glossed over the whole Aluminum Flywheel bit.

No this is a custom steel flywheel. There's plenty of material and strength left in the KEP design. It's just cut wrong.
No relief on the backside for the case bulges (Like my stock 3.2 has)
Plus it's too short overall, so the starter can't engage. (Otherwise the case grinding would have worked)

Richard

Woops! I agree with your assesment then.