Flywheel Inspection - 5.2L 32V Ti-VCT

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Special Tool(s) / General Equipment

Courtesy of FORD MOTOR COMPANY	100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge
Courtesy of FORD MOTOR COMPANY	303-103 (T74P-6375-A) Holding Tool, Flywheel T74P-77000-A TKIT-2009TC-F

Inspection

NOTE: Do not clean the dual mass flywheel with compressed air.

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 dual mass flywheel may occur.

NOTE: The dual mass flywheel normally has up to a total of 16 degrees (7 ring gear teeth) maximum rotational freeplay between the primary (bolted to crankshaft) and the secondary mass (clutch disc face).

NOTE: The dual mass flywheel cannot be machined.

- Inspect the pilot bearing for excessive wear and heat damage. If the pilot bearing has excessive wear or heat damage, install a new dual mass flywheel.
- Check the pilot bearing for smooth operation. If the pilot bearing operation is not smooth, install a new dual mass flywheel.
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NOTE: The dual mass flywheel should be replaced if it has been scored by the clutch or if it has large cracks. Minor heat cracks and heat discoloration do not effect the function of the dual mass flywheel. The dual mass flywheel can be re-used if it has minor heat cracks or heat discoloration.

NOTE: The dual mass flywheel cannot be machined.

Inspect the clutch contact surface for damage.
1. If large cracks or scoring are found on the clutch contact surface, install a new dual mass flywheel. Refer to: Flywheel .
2. Minor heat cracks on the clutch contact surface is acceptable wear. Do NOT install a new dual mass flywheel.
3. Minor heat scoring on the clutch contact surface is acceptable wear. Do NOT install a new dual mass flywheel.
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Inspect the dual mass flywheel hub bushing for wear and install a new dual mass flywheel if necessary.

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Rotate the secondary mass counterclockwise and place a reference mark on the primary and secondary mass of the dual mass flywheel.

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Using light hand pressure, rotate the secondary mass clockwise to the end of the freeplay. Place a 2nd reference mark on the primary mass of the dual mass flywheel, in line with the reference mark on the secondary mass.

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Measure the rotational freeplay between the 2 reference marks on the primary mass of the dual mass flywheel. If the rotational freeplay exceeds 16 degrees (7 ring gear teeth), install a new dual mass flywheel.

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Install Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel.

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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 16 degrees 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.

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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 16 degrees 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.

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- Remove the bolts and the dual mass flywheel. Discard the flywheel bolts.
- Inspect the dual mass flywheel crankshaft mounting flange for residual thread locking compound or rust and clean as necessary.
- NOTE: Blocks must be placed under the dual mass flywheel to make sure it is level and stable.
  
  Place the flywheel on a firm and level surface.
- Remove Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel.
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1. Position the special tool on the clutch mounting surface 130 mm (5.12 in) from center. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
2. Apply a load of 50 N (11.24 lb) on the opposite point on the outer upper surface of the secondary mass and zero the dial indicator.
3. Move the 50 N (11.24 lb) load to the opposite side.
- If the peak to peak displacement exceeds 2.8 mm (0.11 in), install a new dual mass flywheel.
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Remove the CKP sensor ring.

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1. Inspect the rear face of the engine block. Make sure that the 2 engine dowel pins are correctly installed and are not damaged, install new dowel pins as necessary.
2. Inspect the engine block rear spacer plate for damage or warping and install a new plate as necessary.
3. Inspect the crankshaft flange for residual thread lock compound or rust, and clean as necessary.
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Inspect the transmission mounting face. Inspect the 2 dowel pin holes so that they are not elongated or damaged.
Install the CKP sensor ring.

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Install the dual mass flywheel and new bolts finger tight.

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Install Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel.

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- Tighten the bolts in the sequence shown.
  Torque: Stage 1: 89 lb.in (10 Nm) Stage 2: 177 lb.in (20 Nm) Stage 3: 59 lb.ft (80 Nm)
- Remove Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel.

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