Pinpoint Test D: Dual Mass Flywheel Visual Tests

WARNING: This page is about a different car, the 2019 Jaguar XE. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: The following dual mass flywheel tests are performed after removing the manual transmission and clutch.

D1: VISUAL TEST 1 CHECK CLUTCH DISC FOR WEAR

Remove the clutch and inspect the clutch disc for wear and damage

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Is the clutch disc worn or damaged?

Yes

Inspect the dual mass flywheel for thermal overload GO to D2.

GO to D6.

D2: VISUAL TEST 2 CHECK DUAL MASS FLYWHEEL FOR THERMAL OVERLOAD

NOTE:

Dual mass flywheels cannot be refaced.
Dual mass flywheel heat damage is not claimable under warranty.
The image is for reference only and is not the vehicle specific dual mass flywheel.

NOTE: Residue of the abraded friction material can penetrate into the arc spring channel and cause dual mass flywheel malfunction.

Inspect the dual mass flywheel for abraded clutch facing sticking up around the edge of the dual mass flywheel or in the ventilation holes

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Are burnt residues of abraded clutch facing sticking up around the edge of the dual mass flywheel or in the ventilation holes?

Yes

This indicates a very high thermal load. Install a new dual mass flywheel and clutch assembly.

GO to D3.

D3: VISUAL TEST 3 CHECK DUAL MASS FLYWHEEL FOR SCORING

NOTE:

Dual mass flywheels cannot be refaced.
Dual mass flywheel heat damage is not claimable under warranty.
The image is for reference only and is not the vehicle specific dual mass flywheel.

NOTE: Scoring on the dual mass flywheel can cause limited power transmission capability, the clutch is unable to generate the required torque.

Inspect the face of the dual mass flywheel for scoring

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Is there any scoring on the face of the dual mass flywheel?

Yes

Install a new dual mass flywheel and clutch assembly.

GO to D4.

D4: VISUAL TEST 4 CHECK DUAL MASS FLYWHEEL FOR HOT SPOTS

NOTE:

Dual mass flywheels cannot be refaced.
Dual mass flywheel heat damage is not claimable under warranty.
The image is for reference only and is not the vehicle specific dual mass flywheel.

Inspect the face of the dual mass flywheel for localised dark hot spots, sometimes in large number.

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Are there localised dark hot spots on the face of the dual mass flywheel?

Yes

This indicates a low thermal load. No further action is required

GO to D5.

D5: VISUAL TEST 5 CHECK DUAL MASS FLYWHEEL FOR CRACKS

NOTE:

Dual mass flywheels cannot be refaced.
Dual mass flywheel heat damage is not claimable under warranty.
The image is for reference only and is not the vehicle specific dual mass flywheel.

NOTE: Cracks on the face can cause loss of the dual mass flywheels operational reliability.

Inspect the face of the dual mass flywheel for cracks

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Are there cracks on the face of the dual mass flywheel

Yes

This indicates a very high thermal load. Install a new dual mass flywheel and clutch assembly.

GO to D6.

D6: VISUAL TEST 6 CHECK DUAL MASS FLYWHEEL BALL BEARING

NOTE:

Dual mass flywheels cannot be refaced.
Dual mass flywheel heat damage is not claimable under warranty.
The image is for reference only and is not the vehicle specific dual mass flywheel.

NOTE: Insufficient bearing lubrication will cause the dual mass flywheel to fail.

Inspect the dual mass flywheel ball bearing for grease egress, seized bearing sealing cap missing or brown discolouration due to thermal overload

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Is there evidence of any of the listed faults?

Yes

This indicates a thermal overload or mechanical damage. Install a new dual mass flywheel and clutch assembly.

GO to D7.

D7: VISUAL TEST 7 CHECK DUAL MASS FLYWHEEL PLAIN BEARING

NOTE:

Dual mass flywheels cannot be refaced.
Dual mass flywheel heat damage is not claimable under warranty.
The image is for reference only and is not the vehicle specific dual mass flywheel.

Inspect the dual mass flywheel plain bearing for wear or damage

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Is the bearing worn or damaged?

Yes

Install a new dual mass flywheel and clutch assembly.

GO to D8.

D8: VISUAL TEST 8 CHECK DUAL MASS FLYWHEEL RADIAL BEARING CLEARANCE

NOTE:

Dual mass flywheels cannot be refaced.
Dual mass flywheel heat damage is not claimable under warranty.
The image is for reference only and is not the vehicle specific dual mass flywheel.

NOTE: The maximum radial bearing clearance for a new part is 0.04mm with an admissible increase throughout its service life up to 0.17mm.

Check the radial bearing clearance

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Is the radial bearing clearance above 0.17mm?

Yes

Install a new dual mass flywheel and clutch assembly

GO to D9.

D9: VISUAL TEST 9 CHECK DUAL MASS FLYWHEEL FRICTION DISC

NOTE:

Dual mass flywheels cannot be refaced.
Dual mass flywheel heat damage is not claimable under warranty.
The image is for reference only and is not the vehicle specific dual mass flywheel.

Inspect the dual mass flywheel for any evidence of a melted friction control disc

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Is there any evidence of a melted friction control disc?

Yes

This indicates a high thermal load. Install a new dual mass flywheel and clutch assembly.

GO to D10.

D10: VISUAL TEST 10 CHECK DUAL MASS FLYWHEEL FOR SCORING

NOTE:

Dual mass flywheels cannot be refaced.
Dual mass flywheel heat damage is not claimable under warranty.
The image is for reference only and is not the vehicle specific dual mass flywheel.

NOTE: Scoring on the primary mass flywheel can be caused by wear of the plain bearing friction ring causing noise emission.

Inspect the primary mass of the dual mass flywheel for scores caused by the secondary mass flywheel

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Is there evidence of scoring on the primary mass flywheel?

Yes

Install a new dual mass flywheel and clutch assembly

GO to D11.

D11: VISUAL TEST 11 CHECK DUAL MASS FLYWHEEL RING GEAR

NOTE:

Dual mass flywheels cannot be refaced.
Dual mass flywheel heat damage is not claimable under warranty.
The image is for reference only and is not the vehicle specific dual mass flywheel.

NOTE: Worn teeth on the ring gear can cause noise on engine start.

Inspect the dual mass flywheel ring gear teeth for wear

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Are any of the ring gear teeth worn?

Yes

Check the function of the starter motor. Install a new dual mass flywheel and clutch assembly.

GO to D12.

D12: VISUAL TEST 12 CHECK DUAL MASS FLYWHEEL FOR GREASE LEAKAGE

NOTE:

Dual mass flywheels cannot be refaced.
Dual mass flywheel heat damage is not claimable under warranty.
The image is for reference only and is not the vehicle specific dual mass flywheel.

NOTE: A small amount of grease egress is allowed. Excessive grease leakage approx 20g/flywheel housing covered with grease.

Inspect the dual mass flywheel for leakage of grease around the openings or seal caps

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Is there evidence of excessive grease leakage?

Yes

Install a new dual mass flywheel and clutch assembly if the grease leakage is excessive.

GO to D13.

D13: VISUAL TEST 13 CHECK DUAL MASS FLYWHEEL BALANCE WEIGHTS

NOTE:

Dual mass flywheels cannot be refaced.
Dual mass flywheel heat damage is not claimable under warranty.
The image is for reference only and is not the vehicle specific dual mass flywheel.

NOTE: If the dual mass flywheel is out of balance a loud humming noise can be heard

Inspect the dual mass flywheel balance weights

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Are the dual mass flywheel balance weights loose or missing? (Indicated by clearly visible welding spots)

Yes

The dual mass flywheel is out of balance. Install a new dual mass flywheel and clutch assembly

GO to D14.

D14: VISUAL TEST 14 CHECK DUAL MASS FLYWHEEL SECONDARY FLYWHEEL

NOTE:

Dual mass flywheels cannot be refaced.
Dual mass flywheel heat damage is not claimable under warranty
The image is for reference only and is not the vehicle specific dual mass flywheel

Inspect the secondary flywheel

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Is the entire secondary flywheel discoloured blue/purple or are cracks visible?

Yes

This indicates a very high thermal load. Install a new dual mass flywheel

GO to D15.

D15: VISUAL TEST 15 CHECK DUAL MASS FLYWHEEL SECONDARY FLYWHEEL

NOTE:

Dual mass flywheels cannot be refaced.
Dual mass flywheel heat damage is not claimable under warranty
The image is for reference only and is not the vehicle specific dual mass flywheel

Inspect the secondary flywheel

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Is the friction surface discoloured blue and the flywheel tarnished at the outer edge or in the rivet area?

Yes

This indicates a high thermal load. The dual mass flywheel may become defective.

GO to D16.

D16: VISUAL TEST 16 CHECK DUAL MASS FLYWHEEL SECONDARY FLYWHEEL

NOTE: The image is for reference only and is not the vehicle specific dual mass flywheel

Inspect the secondary flywheel

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Is the friction surface discoloured blue, with no discolouration at the outer edge or in the rivet area?

Yes

This indicates a moderate thermal load.

GO to D17.

D17: VISUAL TEST 17 CHECK DUAL MASS FLYWHEEL SECONDARY FLYWHEEL

NOTE: The image is for reference only and is not the vehicle specific dual mass flywheel

Inspect the secondary flywheel

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Is the friction surface slightly discoloured gold/yellow?

Yes

This indicated a low thermal load.

GO to PINPOINT TEST E .