Pinpoint Test D: Dual Mass Flywheel Visual Tests
- D1: VISUAL TEST 1 CHECK CLUTCH DISC FOR WEAR
- Remove the clutch and inspect the clutch disc for wear and damage
Is the clutch disc worn or damaged?
Yes : Inspect the dual mass flywheel for thermal overload GO to D2.
No : 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
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.
No : 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
Is there any scoring on the face of the dual mass flywheel?
Yes : Install a new dual mass flywheel and clutch assembly.
No : 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.
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
No : 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
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.
No : 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
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.
No : 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
Is the bearing worn or damaged?
Yes : Install a new dual mass flywheel and clutch assembly.
No : 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 0.04 mm with an admissible increase throughout its service life up to 0.17 mm.- Check the radial bearing clearance
Is the radial bearing clearance above 0.17 mm?
Yes : Install a new dual mass flywheel and clutch assembly
No : 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
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.
No : 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
Is there evidence of scoring on the primary mass flywheel?
Yes : Install a new dual mass flywheel and clutch assembly
No : 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
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.
No : 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
Is there evidence of excessive grease leakage?
Yes : Install a new dual mass flywheel and clutch assembly if the grease leakage is excessive.
No : 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
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
No : 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
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
No : 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
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.
No : 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
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.
No : 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
Is the friction surface slightly discoloured gold/yellow?
Yes : This indicated a low thermal load.
No : GO to PINPOINT TEST E .