Flywheel Inspection

SPECIAL TOOL(S) / GENERAL EQUIPMENT

	100-002 Holding Fixture with Dial Indicator Gauge
	303-103 Holding Tool, Flywheel TKIT-2009TC-F

NOTE: Do not clean the dual mass flywheel with any kind of fluid, use a dry cloth only or damage to the dual mass flywheel may occur.

NOTE: Do not clean the gap between the primary and secondary mass. Only clean the bolt connection surface and the clutch surface or damage to the flywheel may occur.

NOTE: The dual mass 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 dual mass flywheel.
Inspect the dual mass flywheel friction control plate for damage or melting. If any of these conditions exist, install a new dual mass flywheel.

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

Fig 1: Placing Reference Mark On Secondary Mass Of Dual Mass Flywheel

Courtesy of FORD MOTOR CO.

Place a reference mark on the secondary mass of the dual mass flywheel.
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 2: Rotating Secondary Mass Clockwise To End Of Freeplay Using Light Hand Pressure
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 secondary mass of the dual mass flywheel, in line with the reference mark on the primary mass.

Fig 3: Rotating Secondary Mass Counterclockwise To End Of Freeplay Using Light Hand Pressure
Courtesy of FORD MOTOR CO.
Measure the rotational freeplay between the 2 reference marks on the secondary mass of the dual mass flywheel. If the rotational freeplay exceeds 19 mm (0.750 in), install a new dual mass flywheel.

Fig 4: Measuring Rotational Freeplay Between 2 Reference Marks On Secondary Mass Of Dual Mass Flywheel
Courtesy of FORD MOTOR CO.
Install the Special Tool(s) : 303-103 (Holding Tool, Flywheel)

Fig 5: Identifying Special Tool - 303-103 Holding Tool, 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 6: 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 7: Rotating Secondary Mass Counterclockwise Using Suitable Long Screwdriver Or Bar
Courtesy of FORD MOTOR CO.

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

Fig 8: Locating Dual Mass Flywheel Bolts

Courtesy of FORD MOTOR CO.

Remove the dual mass flywheel and place it on a firm and level surface.
- Using the Dial Indicator Gauge with Holding Fixture, inspect the dual mass flywheel hub bushing for wear.
  Special Tool(s) : 100-002 (Holding Fixture with Dial Indicator Gauge)
- 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.
Fig 9: Inspecting Dual Mass Flywheel Hub Bushing For Wear Using Dial Indicator Gauge With Holding Fixture
Courtesy of FORD MOTOR CO.
- Verify that the 2 engine dowel pins are correctly installed and are not damaged, install new dowel pins as necessary.
- Inspect the crankshaft flange for residual thread locking compound or rust, and clean as necessary.
Fig 10: Inspecting Crankshaft Flange For Residual Thread Locking Compound Or Rust
Courtesy of FORD MOTOR CO.

NOTE: 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(s) : 303-103 (Holding Tool, Flywheel)

Fig 11: Identifying Special Tool - 303-103 Holding Tool, Flywheel
Courtesy of FORD MOTOR CO.
Torque : 112 Nm

Fig 12: Identifying Dual Mass Flywheel Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
Remove the Special Tool(s) : 303-103 (Holding Tool, Flywheel)

Fig 13: Identifying Special Tool - 303-103 Holding Tool, Flywheel

Courtesy of FORD MOTOR CO.