Fretting wear on output shaft flange


I pulled the OM616 engine & 4 spd manual out of a benz 240D.

The flange on the output shaft showed fretting wear in the hole on one of the 3 tabs that the flex disc mounts to. The bolt was necked to ~70% original diameter, the hole in the tab was worn out of round & size.

A friend of mine welds & has worked as a weld R&D engineer. I figured I’d ask him to plug the hole w/ weld, then redrill using the driveshaft as a template.

Anyone have a better idea?


Obtain new parts. The output shaft is not a readily weldable material, either inductioned hardened C50 or case carburized 20MnCr5 or similar.

Above is a snippet.