Grooves in the flywheel and missing or damaged flywheel dowel pins can also cause chatter, but flywheel-related symptoms also mimic the symptoms of a bad engine mount. A warped flexplate wobbles around the outside ring teeth, even if the warp is slight. Diagnosis isn't exactly rolling the dice, but it certainly does require careful observation and some understanding of the mechanism. Here are some of the most common signs of a bad flywheel. Use CHAT for product questions and assistance. A loose bolt on a flexplate or a crack between it’s bolt holes; can result in a knocking or rattling sound. *NOTE: Replacing one OE-spec dual mass flywheel with another is only a viable option if the vehicle's power output levels have remained stock (meaning you haven't modified the engine to produce more power). Clutches are complex mechanisms and can fail in any number of ways. After installing the remanufactured unit, the same code and symptoms returned. Any noise emanating from the this region indicates a problem with the flexplate and/or torque converter-flexplate combination. There's no hard and fast line between the flywheel with an acceptable run out, and one that's just warped; the distinction is in the symptoms. A flexplate, as the name implies, serves as a flex-shock device between the torque converter and the engine crankshaft, and many flexplates have balancing weights to provide smooth engine RPM. 2. If you are able to rock it, it is no longer serviceable and must be discarded. A flexplate bolts directly to the crankshaft flange, and connects to the torque converter with large mounting bolts. Use a socket and wrench to remove the bolts, then remove the inspection cover. This usually happens first in the higher gears due to the higher gear ratios and increased wind resistance. Feel for any unusual vibration that travels up through the chassis and into your driver's seat. It sounds like a light knocking or growling sound, and has absolutely no negative effect on the transmission’s performance or durability. A dual-mass flywheel is a two-part unit. An OE-spec replacement dual mass flywheel will restore the vehicle's stock performance and feel. Clutch drag will cause the clutch assembly to remain closer to engine rpm during shifting. Vibrations. It will look like a half-moon piece of sheet steel, connected to the bell housing with two or three bolts. The downside, of course, is the cost, as replacement DMFs are generally much more expensive that single mass flywheel conversion kits (if a conversion kit is available, of course). Allowing a clutch to slip excessively will affect your flywheel the same way that riding the brakes will affect your discs and rotors; it'll overheat the metal, weaken, warp and crack it. 1) Slipping Gears If you shift to a new gear and then notice that the engine speed (RPM) increases much faster than your ground speed, this is called gear slippage. Raise the vehicle at both ends and place two jack stands under the rear frame, and two jack stands under the front frame. The most common of clutch problems isn't usually in the flywheel; it's in the clutch assembly itself. *Gear Rollover Noise (aka Gear Rattle): The sound that a manual transmission makes when the gears in the gear box are in neutral and are shaken ever so slightly by the engine. A good flexplate does not wobble. Set the vehicle in park and apply the emergency brake. Grab the secondary plate on each side (180 degrees apart) and push one side in and see if the other side comes up. Determine from memory, or any past repair orders, if the flexplate has been replaced. A soft pedal and a delay in engagement after release are the basic signs of slippage. Broken or loose bolts on the crankshaft end of the flexplate, or on the torque converter side, miss-align the flexplate, causing a high side of the plate to strike or rub against internal components. Copyright 2020 Leaf Group Ltd. / Leaf Group Media, "Heavy Duty Drivetrains: System and Component Application"; Charles R. Jones; 1991. To submit your questions or ideas, or to simply learn more about It Still Works, contact us. ©2008-2020 Phoenix Friction Products. All Rights Reserved. You can also manually shift from drive 1 to drive 2, then normal drive. The vibration will be heavy, although not quite as heavy as a failing U-joint. At Phoenix Friction Products, we offer a variety of single mass flywheel conversion kits. Move the plate all the way to the right and mark that gear tooth. Check the friction surface for excessive heat checks and scoring. As a result, This can cause the flexplate to wobble. To submit your questions or ideas, or to simply learn more about It Still Works, contact us. These vibrations can usually be felt on the floor of the car and are due to the failure of the springs and other internal components. A certain amount of warpage or "run out" is normal, a result of constant heating and cooling. Because flywheel and clutch assemblies are similar in function to disc brake assemblies, they'll also exhibit similar symptoms after warpage. Single mass setups, while generally a little louder (due to gear rollover noise), are more durable and more affordable if they require replacement again in the future. This leads directly to the flywheel’s inability to dampen the tremors with use and it must be replaced. Broken or loose bolts on the crankshaft end of the flexplate, or on the torque converter side, miss-align the flexplate, causing a high side of the plate to strike or rub against internal components. This will start out as mild grinding when shifting and may eventually result in a failure to engage first gear when starting. Drive the vehicle at normal speed, letting the transmission shift automatically from the lowest to the highest gear. The smaller flywheel engages the larger one via a set of springs. If you have increased the horsepower of your engine or tow heavy or you are interested in long term flywheel durability and minimal repair costs, it is a good idea to convert your dual mass flywheel to a single mass flywheel. This article was written by the It Still Works team, copy edited and fact checked through a multi-point auditing system, in efforts to ensure our readers only receive the best information. Even slippage because of oil, grease or water contamination can damage the flywheel. On the negative side, dual mass flywheels are expensive and more prone to failure than simpler, single mass systems (especially if a vehicle is modified to have increased torque). Check for visible damage including the ring gear, and other parts found inside the bellhousing. The flexplate can become cracked over time. What's more, single mass conversion kits are less costly than dual mass flywheel replacements. A warped flexplate causes a vibration through all speed ranges, especially if the flexplate has thrown a balance weight. Once you’ve determined that your dual mass flywheel is bad, you have a couple of options: 1. Listen for any rhythmic clunking or grinding noise while the engine idles in park or neutral, or idling in gear with a foot on the brake pedal. When a clutch is slipping due to wear or otherwise not being up to capacity to the demand placed on it, you get a burning smell like that of burnt bread and gear oil mixed together. A warped flexplate can make metal-to-metal contact with the inspection plate cover, or the starter drive mechanism, and can also make a knocking noise once the vehicle is put in forward or reverse gear. Like a lot of the parts on the modern automobile, dual mass flywheels are a compromise. All clutches eventually wear out and begin to slip, but that's not the problem. This malfunction will typically occur during initial engagement and while shifting through the lower gears. Check for excessive grease loss due to overheating. A warped flywheel will cause a steadily worsening pulsation in the brake pedal, accompanied by an intermittent rise and fall in engine rpm in later stages of warping. Locate the inspection cover on the underside of the bell housing case. A warped flywheel will cause a steadily worsening pulsation in the brake pedal, accompanied by an intermittent rise and fall in engine rpm in later stages of warping. If you do NOT smell the facings burning up when this is happening, it is your dual mass flywheel that is slipping and it needs to be replaced. Such characteristics denote a warped flexplate, provided the starter functions properly and can be ruled out. Clutch chatter is what happens when the clutch "skips" on the flywheel, rapidly grabbing and releasing instead of engaging smoothly. Even if the flexplate was old and re-used, the manufacture's specifications call for an exact torque pressure and tightening sequence. Single mass conversion kits replace a dual mass flywheel with a simpler, more robust system. A smaller-diameter flywheel bolts to the engine and sits inside of a drum-brake-like outer flywheel. Over-torquing the flexplate stretches the metal, causing high and low spots. Flexplates serve a very important function in vehicles equipped with an automatic transmission. Check for secondary plate rock. There are specifications for each individual dual mass flywheel, but if the left to right "play" is more than an inch, it’s almost always time to replace it. These noises can be very loud and it should be replaced as a soon as possible. A failing dual mass flywheel will first rattle when depressing or releasing the clutch, then proceed to exhibit symptoms similar to clutch chatter even after full engagement. After verifying the concern and pulling codes, I did some basic tests to determine if the PCM was commanding the TCC solenoid correctly, and to make sure the TCC solenoid was functioning properly. It sounds like a light knocking or growling sound, and has absolutely no negative effect on the transmission’s performance or durability. Sitemap. On the plus side, dual mass flywheels reduce the torsional vibrations in the driveline and the other related vibration and noises. A flexplate consists of a steel, circular disk with perforated holes and, depending on the model, teeth on the outside ring which engage the starter. There's no hard and fast line between the flywheel with an acceptable run out, and one that's just warped; the distinction is in the symptoms. We also work hard to ensure these single mass kits don't negatively impact drivability...our testing procedure and metrics for success are reliability, smooth shifting, no increased pedal effort, and as little noise as possible compared to the OEM dual mass units. The internal springs are packed in grease. This design offers a bit of buffering between the engine and transmission to enhance smoothness during clutch engagement. Slipping. Replace the OE dual mass fly wheel with an OE-spec replacement.*. Under-torquing can cause a premature separation, causing the bolts to slam and break off, or jam the flexplate teeth into the starter gear teeth. Clutch chatter can come from burned or glazed clutch disc friction material, a worn pilot bearing or bushing, or damaged or distorted clutch disc. The Gear rollover noise only occurs when the vehicle is idling and the transmission is in neutral. Clutch drag is the opposite of slippage, a phenomenon that occurs when the clutch fails to release completely. Diagnosing a warped flexplate requires some keen observation and process of elimination. Be aware of any starter spin that bogs, then picks up again, and bogs again in a rhythmic sequence.

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