VW TDI Dual Mass Flywheel DMF Nightmare
Dual Mass Flywheel(DMF) on a 2003 VW Golf TDI ALH 1.9L. The Flywheel was more then 15deg off (Twisted) and off-centered. That caused a horrible and unexplainable off balance wobble in the rpm range of 0-2000 rpm. The sound was similar to a helicopter. Apparently the DMF is only rated to 100k miles and have been know to fail in as little as 50k miles. Some have said that it is designed to fail.
The flywheel removal was impossible because the center mounting bolts were inaccessible. The VW experts said that you should be able to force the flywheel back into alignment to remove the 12 point mounting bolts. I tried that for about 30 mins. I was told that if you drill out the rivets that the assembly will separate. After drilling out the 8 rivets for almost an hour, only the surface that makes contact with the clutch came off. The center hub that was covering the mounting bolts remained. The last option was to cut the center hub to allow access to the mounting bolts. This worked like a charm and only took about 15 mins to complete.
Now if you were wondering the DMF and SMF have different bolts. The DMFs bolts are a 12 point Triple Square 12mm bolts. I used Lisle(tm) 4 piece Triple Square set part no. 60750 to remove the 6 DMF bolts with a 13mm socket and moly. The Lisle(tm) set has 4 sized (6mm, 8mm, 10mm & 12mm). The 8mm is needed to remove the 12 bolts from the left and right inner driveshafts to remove the transmission to access the clutch and flywheel.
Side Note: Always support you engine when you doing a clutch or timing job. In this video I was unaware that the engine had slide out of the passenger-side mount and was only being held up but the Exhaust manifold. This is not a good thing.
Dual mass play
Dual Mass flywheel in 2004 CTS-V. Unreal how much play is actually in these stock turds!
ZF Services Self Adjusting Clutch Fitting Procedure
AUTOiNFORM http://www.autoinform.co.uk is a FREE bi-monthly, online publication that offers the automotive aftermarket a fresh, exciting new platform using high quality video and interactive page layouts. This clip demonstrates the use of the correct tools for fitting self adjusting type clutches.
2000 Volkswagen Beetle 1.9L Turbo Diesel Clutch and Flywheel Installation
This video covers a 2000 Volkswagen Beetle 1.9L turbo Diesel clutch and solid flywheel conversion with Gary Croyle. The car was a donated for the simple purposes of doing a clutch installation. The clutch set used was a MU72211-1SK (Brute# 92692SK). An image of the clutch set can be found at the following link:
Buyers Guide for a MU72211-1SK Clutch Set:
Make Model Engine Year Remarks/Options
AUDI TT L4 1.8L GAS T C 2001 From Ch. # 8N1006001
AUDI TT L4 1.8L GAS T C 2001 5spd.; From Ch. # 8N1006001
AUDI TT L4 1.8L GAS T C 2002-04 5spd.
AUDI TT L4 1.8L GAS T X 2001 5spd.; From Ch. # 8N1006001
AUDI TT L4 1.8L GAS T X 2002 5spd.
AUDI TT QUATTRO L4 1.8L GAS T 2003-04 5spd.
AUDI TT QUATTRO L4 1.8L GAS T C 2002 5spd.
AUDI TT QUATTRO L4 1.8L GAS T T 2002 5spd.
AUDI TT QUATTRO L4 1.8L GAS T X 2002 5spd.
VOLKSWAGEN BEETLE L4 1.8L GAS T 1999-01
VOLKSWAGEN BEETLE L4 1.8L GAS T 2001-05
VOLKSWAGEN BEETLE L4 1.9L 116ci DIESEL T 1999-04
VOLKSWAGEN BEETLE L4 1.9L 116ci DIESEL T F 1998
VOLKSWAGEN BEETLE GLS TDI L4 1.9L 116ci DIESEL T 2005
VOLKSWAGEN BEETLE TDI L4 1.9L 116ci DIESEL T 2006
VOLKSWAGEN BEETLE turbo S L4 1.8L GAS T 2002-04
VOLKSWAGEN GOLF L4 1.8L GAS T 2000-01
VOLKSWAGEN GOLF L4 1.9L 116ci DIESEL T 2000-05
VOLKSWAGEN GOLF GL L4 1.9L 116ci DIESEL T 1999
VOLKSWAGEN GOLF GLS TDI L4 1.9L 116ci DIESEL T 2006
VOLKSWAGEN GOLF GLS TDI L4 1.9L 116ci DIESEL T 2006
VOLKSWAGEN GOLF GTI L4 1.8L GAS T 2000-05
VOLKSWAGEN GOLF GTI 1.8T L4 1.8L GAS T 2006
VOLKSWAGEN GOLF TDI L4 1.9L 116ci DIESEL T 1999
VOLKSWAGEN JETTA L4 1.8L GAS T 2004-05 5spd.
VOLKSWAGEN JETTA GL L4 1.8L GAS T 2003 5spd.
VOLKSWAGEN JETTA GLS L4 1.8L GAS T 2000-01
VOLKSWAGEN JETTA GLS L4 1.8L GAS T 2002-04 5spd.
VOLKSWAGEN JETTA TDI L4 1.9L 116ci DIESEL T 1999-05 Engine Code ALH, BEW
VOLKSWAGEN JETTA WOLFSBURG EDITION L4 1.8L GAS T 2001
Dual Mass Flywheel met radiale veren
http://www.amt.nl Het Valeo-DMF heeft radiale veren, waar het origineel van LuK gebruik maakt van boogveren. Het nadeel van die boogveren is dat de wrijving tussen glijschaal en boogveer varieert met het toerental. Dat probleem loste Valeo op met deze variant. Valeo leverde dit type aan PSA voor eerste montage. De constructie was te duur en ging in 2006 uit productie. Sinds 2008 produceert Valeo DMF's volgens de LuK-constructie.
TDI Dual Mass Flywheel / Clutch Noise
2004 VW TDI 5 Speed DMF/Clutch noise.
You can see the longer start at the beginning.
When I press in the clutch it gets much louder. It got a lot louder just yesterday where I can hear it in the car.
Audi S3 8P LUK DMF & Clutch
I was getting clutch slip after going Revo Stage 1 my car had only covered 19000 miles at the time. I upgraded my clutch & DMF for a Sachs Performance Clutch Plate,Disc & OEM LUK DMF. The DMF had lots of rotation on it and had collapsed, the disc was also just about into the rivets.
AUTOINFORM ONLINE MAGAZINE: LUK DUAL MASS FLYWHEELS DMF DIAGNOSTIC ADVICE
Dual Mass Flywheels are now being fitted to an increasing number of vehicles. AutoInform magazine asked
LuK to give them an overview of the technology and provide some diagnostic advice
Subscribe to Autoinform online magazine for FREE at www.autoinform.co.uk for more great videos and technical information for the professional automotive technician - delivered directly to your inbox every issue.
ECS Tuning: Audi RA4 Flywheel Clutch Kits DIY
RA4 Clutch Kits Available At: http://www.ecstuning.com/News/Audi_B6A418T_RA4_FlywheelRedesign/?utm_source=Youtube
Give your B6 A4 1.8T the clutch it deserves. We've assembled three very special clutch packages built around the ECS Tuning RA4 lightweight flywheel.
Mate our new, low mass flywheel to a bigger 240mm clutch. Choose S4, RS4, or Clutch Masters Fx300 clutch kits for a smooth, powerful clutch/flywheel package that revs faster but won't forget its manners in traffic.
No modifications required. Bolt them on and go, with complete kits that include everything you need, right down to fresh bolts and a clutch alignment tool.
(Our tests have clocked these at 100 smiles per hour.)
This tutorial is provided as a courtesy by ECS Tuning.
Proper service and repair procedures are vital to the safe, reliable operation of all motor vehicles as well as the personal safety of those performing the repairs. Standard safety procedures and precautions (including use of safety goggles and proper tools and equipment) should be followed at all times to eliminate the possibility of personal injury or improper service which could damage the vehicle or compromise its safety.
Although this material has been prepared with the intent to provide reliable information, no warranty (express or implied) is made as to its accuracy or completeness. Neither is any liability assumed for loss or damage resulting from reliance on this material. SPECIFICALLY, NO WARRANTY OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE OR ANY OTHER WARRANTY IS MADE OR TO BE IMPLIED WITH RESPECT TO THIS MATERIAL. In no event will ECS Tuning, Incorporated or its affiliates be liable for any damages, direct or indirect, consequential or compensatory, arising out of the use of this material.
Dual Mass Flywheel Noise
Vectra 1.9 CDTI 150. Dual Mass Flywheel is knackered. Normally more noisy than this on tickover, has the typical scraping noise, and makes a banging noise about twice a second.
The loud noise you hear when I'm in the car is when I depress and release the clutch slowly.
When I'm revving the engine you hear the scraping noise which is quite prominent when I'm driving along with the throttle fully up. Very embarrasing at traffic lights.