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Thread: Took my DMF apart to find out why they fail

  1. #1
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    Default Took my DMF apart to find out why they fail

    I'm an engineer and wanted to find out why these dual mass flywheels fail and what I could do to prolong their life so I set about dismantling the one that came off my cdti 120 and here are the pics. What appears to happen is that there is a little plastic bush that WAS on the boss I'm pointing to in the pictures that wears and disintegrates,( I removed the plastic bits when the flywheel came off the car.) As this disintegrates the clutch pressure plate then comes into contact with the flywheel itself and progressively wears away each time the clutch pedal is pressed, additional to this , the rivet heads holding the cluch together then begin to wear away, you can see one in the picture and as you can see there's not much head left, another 2 to 3k miles I reckon would have worn them through when the whole lot would then collapse, go out of balance and probably destroy the gearbox. Fewer clutch changes I beleive would prolong the life and this reduces the times axial force is applied to the plastic bush. God knows why it is plastic, this assembly could quite easily be made bullet proof with maybe a phosphur bronze bush for example. You can also see on the reverse of the pressure plate where metal to metal contact has been made and has worn it away. I now don;t even press the clutch when selecting neutral on the move when approaching lights etc., I just get the revs right and take it out of gear. I also avoid sitting in traffic with clutch pressed, hope this helps!!Attachment 24922Attachment 24922

  2. #2
    Regular Member ditchp's Avatar
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    Vehicle : Vectra cdti estate

    Trim : Get a

    Engine : Dirty diesel

    Year : 2006

    Default

    well i for one thankyou for going to the bother of stripping it down......looks like vx could do with you working for them in there dmf / clutch department...
    Midlands Mod Shop - NFFC.

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    Regular Member Penfold101's Avatar
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    Cool - so in a word, rubbish design... In theory I suppose the motorway cruisers should suffer a lot less than the round town cars, but then i suppose that's true for the clutch and the engine in general...

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    Regular Member mark_647's Avatar
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    Great write-up, very interesting...

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    Yep exactly right, the flywheel in the pictures did 105k miles, mostly motorway as it was a repmobile and started to rattle when pressing clutch over the last couple of thousand miles

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    Regular Member parsco's Avatar
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    top man, always good to have some knowledge on these things.

    (Does anyone else think this should be a sticky somewhere so that EVERYONE can be aware of it? )

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    They are unfortunately a 'necessary evil',without one your gearbox wouldn't last too long.

    Here's a link that tells you what can go wrong with them and why.

    http://www.standardtransmission.com/dmf.html

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    Regular Member Auto-Brite's Avatar
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    Thankyou mate for taking time to post your findings out on the flywheel! People like you keep the forums going with invaluable information like that!!

    Great report!!

    Thanks

    Mark

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    Great pictures!!!

    I'm also a mechanical engineer, and I too took my DMF apart to check it. I've taken some pictures (this was in may 2009) and put it on my website to inform the guys from a dutch forum. You can check the pictures of the clutch, flywheel and intake manifold on my website. Although it's in Dutch, the pictures will speak for itself.

    Intake maninold: http://members.quicknet.nl/arjan.koe...old_totaal.jpg and http://members.quicknet.nl/arjan.koe...fold_close.jpg

    Clutch: http://members.quicknet.nl/arjan.koen/plaat.jpg

    DMF: http://members.quicknet.nl/arjan.koen/DMF.jpg

    regards, Arjan

  10. #10
    Regular Member john_k_sri's Avatar
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    Vehicle : Insignia Grand Sport

    Trim : DESIGN

    Engine : 1.5T (165)

    Year : 2018

    Mileage : 220

    Default

    Disintegrating plastic......sounds familiar. Reminiscent of the 90's problem affecting the entire range of 16v engines, where a plastic cambelt tensioner was disintegrating at high speed.....and yes, VX claimed it wasn't a safety issue when the cambelt was thrown off.

    VX have obviously done a cost/benefit analysis. They benefit from cheaper production costs and their customers bear the cost.

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