How to Resurface a Flywheel? The Beginner’s Guide

How to resurface a flywheel?” is a frequently asked question. Here, you can read about each step of the process in great detail.

A flywheel is an essential part of a car. It stores energy to keep the crankshaft spinning and regulates the rotating assembly. It supplies power by smoothly transferring energy to the transmission. The clutch assembly aids the engine’s ability to supply power to the transmission.

When the clutch disk meets the flywheel, there is a lot of friction. For the vehicle to move forward, it needs to be able to grip the road. When the lining wears, this grip begins to lose its sturdiness. You may face clutch slipping.

You can resurface it for better performance like before. Before resurfacing your flywheel, it’s crucial to realize what you’re throwing yourself into.

resurfacing flywheels

How to resurface a flywheel?

A flywheel is a wheel that is used to store rotational energy. It is self-regulating, which means that when it is used, it will keep going at the same speed. Flywheels are often used in cars and other vehicles to help them start up more quickly.

Here are two main ways to do the process.

  1. Cutting the Flywheel

You’ll need a brake lathe to start with this cutting process. Make sure you follow the steps correctly because adjusting a flywheel on a lathe is not an easy job. But this method may result in uneven areas.

People like to remove a lot of metal because the brake lathe doesn’t go over hard places. It is vital to know how to cut and grind when you are resurfacing a flywheel.

When it comes to hydraulically linked cars, bearings might not move very much. Understand that it doesn’t work well when too much metal is taken out of the clutch.

  1. Grinding the flywheel

It’s the most popular method of resurfacing flywheels. The task requires a block grinding machine for practical completion. Compared to dedicated grinders, grinding equipment for heads and blocks requires a high setup time.

You should verify whether a machine shop offers a dedicated grinder for stepped flywheels. Otherwise, you should look for a shop with the right tools for the job.

When the flywheel moves, keeping the clutch at the right height is important. It’s critical to take out the same metal on both sides. With the help of a depth gauge, you can find out how far down the part is.

A grinder can help you get the right level of flatness with the least amount of metal removal by removing hard spots and leaving a smooth surface. This process only takes about five minutes.

It is essential to have the right tools when you are fixing a flywheel. It provides a mounting point for the flywheel and allows it to be centered on the crankshaft. Wet grinding with silicon carbide stones is helpful.

How much is it to resurface a flywheel?

Surfacing a flywheel is relatively easy for most machine shops as long as they have the correct equipment. The cost of resurfacing a flywheel depends on the size of the machine and how much metal is removed.

Generally speaking, most consumers may expect to pay less than $50 for flywheel resurfacing. While the procedure is relatively straightforward, the cost depends on how long it takes the technician to remove the flywheel from the engine, examine, grind, and replace it.

Consider replacing the flywheel at the price is above the $40 To $65 range. New ones are frequently available for less than that. Of course, the precise cost is mostly determined by the brand and year of the car being repaired and the amount of time it will take.

Symptoms of the worn flywheel

Here are some symptoms of a worn flywheel:

  1. Unpleasant sounds when the vehicle is idling

Many modern cars have flywheels that have two separate parts. While idling, you may notice an excess noise from your transmission. Loud bangs are an excellent way to tell if this is the case. It is only possible with a car model equipped with dual-mass flywheels.

  1. Intense Smell of Burning

Even though improper clutch use is the most prevalent cause, a burning clutch can indicate a more serious mechanical issue if you’re doing everything correctly. A damaged part means you either need to change your driving style or replace the transmission assembly parts.

  1. Difficult to Shift Gears

If you find it challenging to shift gears, this can signify that your flywheel is worn out and needs to be replaced. When it loses its precision, it will become hard for the transmission shafts to align correctly with the gears of the car model. It may cause noise in the engine and transmission during regular operation.

  1. Failing transmission fluid level indicator

The transmission fluid level indicator will be empty if the system requires more fluid than it can hold. It usually happens when there is too much wear and tear in the flywheel or if it has been damaged by an accident or impact during normal operation. Changing the flywheel and replacing it with a new one is a solution.

  1. Poor running

When the flywheel is worn, it will not spin as well as it should. As a result, the engine may be more difficult to start at first. You may also notice a surging sound coming from the engine when you put your foot on the gas or press the brake pedal. You will hear a grinding sound when you shift between gears if you have an automatic transmission.

  1. No Start or Stalling Issue

If you have a broken flywheel, your car will not start or stall out. It is frequently caused by a damaged ignition coil or a clutch plate. If this happens, you need to get rid of any fluids in your engine and transmission system before you take your car in for repairs because these fluids can cause problems if they get into other parts of the engine or transmission system.


Is it worth it to resurface a flywheel?

The short answer is YES! The first point you must make is to look at the surface of the flywheel for cracks. If there are no cracks, it’s a good idea to resurface it because this will help to reduce friction in your engine and transmission system.

Can flat flywheels be resurfaced?

Flat flywheels can be resurfaced, but you must use a two-step method. If the surface is too rough, you will need to first use a surface preparation compound before resurfacing the flywheel. If the surface is smooth, you can repair or polish it with a diamond powder designed for this purpose without using any unique tool.

resurface flywheel

How often should a flywheel be resurfaced?

It’s best to purchase a new one if it’s cracked or has gashes, but you’re good to go 4 to 6 times if it’s only slipped on something.

Can you grind a flywheel?

Yes, you can grind a flywheel. You can use a rotary grinder or an impact grinder. To avoid harming the product, take your time and follow the manufacturer’s recommendations.

What does a damaged flywheel sound like?

A damaged flywheel will have a grinding sound when you start the engine. It may also make a knocking or clunking noise when it’s turning. If there are no cracks, it will still turn, but it may cause a clicking sound when the flywheel rotates.


Flywheels are a vital part of the car engine. They need to be kept in good shape to function accurately and efficiently. That is why you need to take care of them if you want to keep them for a long time. Hope now you can understand how to resurface a flywheel.


Mr. Rubel is an Engine Mechanic. He has more than 15 years’ experience on repair and maintenance of different kinds of vehicles. He is also providing training to mechanics and works as a Senior Mechanic of a well-known organization. He is sharing his knowledge to support the car lovers to solve the vehicle issues.

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