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Fretting wear on output shaft flange

Fretting wear on output shaft flange

(OP)
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?

RE: Fretting wear on output shaft flange

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

RE: Fretting wear on output shaft flange

get a new flange and new bolts. parts are readily available and do not cost that much. also inspect the rest of the driveshaft and the support bearing, because the imbalance may well have done some damage there too.

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