Flywheel Inspection

SPECIAL TOOL DESCRIPTION

Holding Tool, Flywheel 303-103 (T74P-6375-A)

CAUTION: Do not clean the dual mass flywheel with any kind of fluid, use a dry cloth only.

CAUTION: Do not clean the gap between the primary and secondary mass. Only clean the bolt connection surface and the clutch surface.

Check the transaxle fluid level and fill to the correct level as necessary.
With the engine operating at idle and the transaxle in NEUTRAL, listen and check for unacceptable noise. Determine if any unacceptable noise is reduced when the clutch pedal is depressed.
If unacceptable noise is identified, remove the transaxle. For additional information, refer to MANUAL TRANSAXLE/TRANSMISSION .
Inspect the clutch slave cylinder for leaks. If a leak is identified, install a new clutch slave cylinder. For additional information, refer to MANUAL TRANSAXLE/TRANSMISSION .
Inspect the sliding surfaces of the clutch release hub and bearing. Any scoring or burr should be removed with a fine grade of emery paper.
Inspect the transaxle input shaft for spline wear, scoring or burrs. Any scoring or burr should be removed with a fine grade of emery paper. If spline wear is identified, install a new transaxle. For additional information, refer to MANUAL TRANSAXLE/TRANSMISSION .

NOTE: The clutch disc should be discarded due to possible hub spline wear or friction material wear.

Remove the clutch disc and pressure plate. For additional information, refer to CLUTCH article .
- Discard the clutch disc.
Inspect the clutch pressure plate and diaphragm spring segments and discard as necessary.
- Inspect the clutch pressure plate for scoring, cracks or discoloration. Any minor scoring or discoloration should be removed with a fine grade of emery cloth.
- Inspect the clutch diaphragm spring segments for damage, uneven height, scoring, cracks or discoloration. Any minor scoring or discoloration should be removed with a fine grade of emery cloth.

NOTE: The flywheel cannot be machined.

With the dual mass flywheel installed on the engine, inspect the dual mass flywheel surface for scoring, cracks, discoloration or damage. If any of these conditions exist, install a new flywheel.
With the dual mass flywheel installed on the engine, inspect the dual mass flywheel internal spring operation using the following Steps 11-13.
Install the special tool.

Fig 1: Installing Special Tool (303-103) On Flywheel
Courtesy of FORD MOTOR CO.
Using a suitable long screwdriver or bar, firmly rotate the secondary mass clockwise. The secondary mass should begin to engage the internal spring past the freeplay movement of 19 mm (0.750 in) maximum. The secondary mass should continue to rotate and engage the internal spring with increasing spring pressure. If the secondary mass does not rotate, install a new dual mass flywheel.

Fig 2: Rotating Secondary Mass Clockwise Using Suitable Long Screwdriver Or Bar
Courtesy of FORD MOTOR CO.
Using a suitable long screwdriver or bar, firmly rotate the secondary mass counterclockwise. The secondary mass should begin to engage the internal spring past the freeplay movement of 19 mm (0.750 in) maximum. The secondary mass should continue to rotate and engage the internal spring with increasing spring pressure. If the secondary mass does not rotate, install a new dual mass flywheel.

Fig 3: Rotating Secondary Mass Counterclockwise Using Suitable Long Screwdriver Or Bar
Courtesy of FORD MOTOR CO.
Using a suitable long screwdriver or bar, firmly rotate the secondary mass clockwise and counterclockwise until the dual mass flywheel friction control plate is centered between the secondary mass notches.

Fig 4: Centering Dual Mass Flywheel Friction Control Plate Between Secondary Mass Notches
Courtesy of FORD MOTOR CO.
Inspect the dual mass flywheel friction control plate for damage or melting and install a new dual mass flywheel if necessary.

NOTE: The dual mass flywheel rotational freeplay inspection cannot be carried out if the friction control plate is off center or damaged.

With the dual mass flywheel installed on the engine, inspect the dual mass flywheel rotational freeplay using the following Steps 17-21.
Check that the dual mass flywheel friction control plate is centered between the secondary mass notches.

Fig 5: Checking That Dual Mass Flywheel Friction Control Plate Is Centered Between Secondary Mass Notches
Courtesy of FORD MOTOR CO.
Place a reference mark on the secondary mass of the dual mass flywheel.

Fig 6: Placing Reference Mark On Secondary Mass Of Dual Mass Flywheel
Courtesy of FORD MOTOR CO.
Using light hand pressure, rotate the secondary mass clockwise to the end of the freeplay. Place a reference mark on the primary mass of the dual mass flywheel, in line with the reference mark on the secondary mass.

Fig 7: Placing Reference Mark On Primary Mass Of Dual Mass Flywheel, In Line With Reference Mark On Secondary Mass
Courtesy of FORD MOTOR CO.
Using light hand pressure, rotate the secondary mass counterclockwise to the end of the freeplay. Place a second reference mark on the primary mass of the dual mass flywheel, in line with the reference mark on the secondary mass.

Fig 8: Placing Second Reference Mark On Primary Mass Of Dual Mass Flywheel, In Line With Reference Mark On Secondary Mass
Courtesy of FORD MOTOR CO.
Measure the rotational freeplay XX between the 2 reference marks on the primary mass of the dual mass flywheel. If the rotational freeplay exceeds 19 mm (0.750 in), install a new dual mass flywheel.

Fig 9: Measuring Rotational Freeplay XX Between 2 Reference Marks On Primary Mass Of Dual Mass Flywheel
Courtesy of FORD MOTOR CO.
Inspect the dual mass flywheel when removed from the engine and placed on a bench, using the following Steps 23-24.

NOTE: Blocks must be placed under the dual mass flywheel to make sure it is level and stable.

Fig 10: Removing Dual Mass Flywheel Retaining Bolts And Special Tool

Courtesy of FORD MOTOR CO.

Remove the dual mass flywheel and place it on a firm and level surface.
- Discard the dual mass flywheel retaining bolts and remove the special tool

NOTE: Axial movement of the secondary mass flywheel is normal and the dual mass flywheel should not be discarded based on this movement.

Fig 11: Using Suitable Dial Indicator Gauge And Holding Fixture To Inspect Dual Mass Flywheel Hub Bush For Wear

Courtesy of FORD MOTOR CO.

Using a suitable dial indicator gauge and holding fixture, inspect the dual mass flywheel hub bush for wear and install new as necessary.
- Place a dial indicator gauge at a point on the outer upper surface of the secondary mass.
- Using light hand pressure, press downward at the opposite point on the outer upper surface of the secondary mass and note the deflection on the dial indicator gauge.
- Repeat this measurement at 120 degree intervals around the dual mass flywheel and note any deflection. If the deflection exceeds 1.5 mm (0.060 in) at any point, install a new dual mass flywheel.
Inspect the rear face of the engine block.
1. Make sure that the 2 engine dowel pins are correctly installed and are not damaged, install new dowel pins as necessary.
2. Inspect the upper and lower engine block rear face plates for damage or warping and install new plates as necessary.
3. Inspect the crankshaft flange for residual thread locking compound or rust, and clean as necessary.
Fig 12: Inspecting Rear Face Of Engine Block
Courtesy of FORD MOTOR CO.
Inspect the transaxle mounting face.
- Make sure that the 2 dowel pin holes are not elongated or damaged.
Inspect the dual mass flywheel crankshaft mounting flange for residual thread locking compound or rust and clean as necessary.

NOTE: Install new dual mass flywheel retaining bolts.

Loosely install the dual mass flywheel.
Install the special tool.

Fig 13: Installing Special Tool (303-103)
Courtesy of FORD MOTOR CO.
Tighten the dual mass flywheel retaining bolts in the sequence shown to 112 Nm (83 lb-ft).

Fig 14: Tightening Dual Mass Flywheel Retaining Bolts In Sequence
Courtesy of FORD MOTOR CO.

NOTE: A new clutch disc should be installed due to possible hub spline wear or friction material wear.

Install the clutch disc and pressure plate. For additional information, refer to CLUTCH .
Install the transaxle. For additional information, refer to MANUAL TRANSAXLE/TRANSMISSION .