'Evening all, I've got a Mondeo ST200 flywheel that I was hoping to bolt up to my AJ-30 engine (Jag S-type V6), however whilst the bolt pattern is the same the flywheel is much thinner than the S-type dual mass and has a different ring gear tooth pitch. The thickness issue can be solved with a machined spacer (which would also solve a couple of other issues), however the ring gear is a bit of a bugger.

The way I see it is I either need to swap the ring gear from the S-type over or swap over the pinion from a Mondeo starter to the S-type one (I can't just swap starters as they mount completely differently).

Does anyone have any experience of doing either of the above as I have none!

Does your dual mass have a welded ring gear?
If not, and the flange the ring gear fits on is the same outside diameter on both, gently and evenly heating the ring gear you want to use will expand it enough for it to drop off, and repeat for your single mass flywheel.
Preheat the chosen ring gear and drop over the flywheel, allow to cool and all should be good.

If this doesn't sound like an option, then read on.

I used a third option when i needed a higher torque starter for my zetec.
I cut out the mounting flange from the t9 starter, and cut off the mondeo starter so that it slid inside t9 flange, and was operating the pinion correctly.
I then got the 2 halves tigged together to make 1 complete starter.
It did take a fair bit of measuring up to get everything fitting on the first go, but well worth it.

You may find that the motor case fits in the same way on both your starters, so just swapping the case and armature may be possible, so long as the nose bearing and solenoid fork slot are in similar positions to give a full engagement when starting, and clearance while disengaged.

Dave

I have given up on the ST200 flywheel and reverted to the Jag dual mass, easier in the long run
A guy on RHOCAR has successfully fitted an AJ30 in a 2B, using the ST flywheel. "The dual mass flywheel from the 3.0l manual s-type arrived and has the right teeth but when removed the inside diameter was about 4mm too big to fit onto the mondeo solid flywheel. So I have picked up another mondeo flywheel and machined the ring gear down to form a sleeve. I have then heat shrunk the dual mass ring gear onto the mondeo flywheel. Happy days. It is now parcelled up and ready to be lightened and balance checked. (pictures in the original link) So after a 3month delay progress will start again soon i hope"

Heres a link to his build: http://www.rhocar.org/index.php?s=f017254d2ea6ad9b9b424df7aba5d993&showtopic=31973&st=15
Page 2. Post number #27

Thanks for the replies guys, it looks like the ring gear swap is a bit of a PITA. I'll have a look tonight if I can easily swap the pinion on the Jag starter over to a suitable alternative... if I can find a suitable alternative! Barring that the ST200 flywheel idea is completely dead, which is a shame as it would be quite cool to do.