Notes from Dr. Borkosky

Any noise emanating from the this region indicates a problem with the flexplate and/or torque converter-flexplate combination. A warped flexplate causes a vibration through all speed ranges, especially if the flexplate has thrown a balance weight. You can also manually shift from drive 1 to drive 2, then normal drive. If you are able to rock it, it is no longer serviceable and must be discarded. The most difficult part about troubleshooting clutch problems is that several different types of failure can manifest similar symptoms. A warped flexplate can make metal-to-metal contact with the inspection plate cover, or the starter drive mechanism, and can also make a knocking noise once the vehicle is put in forward or reverse gear.

Here are some of the most common signs of a bad flywheel. How do I Troubleshoot a Transfer Case ... Hemera Technologies/AbleStock.com/Getty Images, Copyright 2020 Leaf Group Ltd. / Leaf Group Media, Jasper Engines and Transmissions: Diagnosing Flywheel/Flexplate Failures. If you do NOT smell the facings burning up when this is happening, it is your dual mass flywheel that is slipping and it needs to be replaced. The internal springs are packed in grease.

*Gear Rollover Noise (aka Gear Rattle): The sound that a manual transmission makes when the gears in the gear box are in neutral and are shaken ever so slightly by the engine. Clutches are complex mechanisms and can fail in any number of ways. Check the friction surface for excessive heat checks and scoring. Sitemap. Slide under the vehicle with a stethoscope, and place the stethoscope probe against the underside of the bell housing. The flexplate can become cracked over time.

A good flexplate does not wobble. Diagnosing a warped flexplate requires some keen observation and process of elimination. A flexplate consists of a steel, circular disk with perforated holes and, depending on the model, teeth on the outside ring which engage the starter. Clutch chatter can come from burned or glazed clutch disc friction material, a worn pilot bearing or bushing, or damaged or distorted clutch disc.

It sounds like a light knocking or growling sound, and has absolutely no negative effect on the transmission’s performance or durability. Replace the OE dual mass fly wheel with an OE-spec replacement.*. Start the engine and let it idle.

We also work hard to ensure these single mass kits don't negatively impact drivability...our testing procedure and metrics for success are reliability, smooth shifting, no increased pedal effort, and as little noise as possible compared to the OEM dual mass units.

Again, if you have any of these problems, it's time to visually inspect the clutch and flywheel. On the negative side, dual mass flywheels are expensive and more prone to failure than simpler, single mass systems (especially if a vehicle is modified to have increased torque). There are specifications for each individual dual mass flywheel, but if the left to right "play" is more than an inch, it’s almost always time to replace it. A certain amount of warpage or "run out" is normal, a result of constant heating and cooling. Move the secondary plate (the one the pressure plate bolts up to) all the way to the left and mark the gear tooth. Listen for any rhythmic clunking or grinding noise while the engine idles in park or neutral, or idling in gear with a foot on the brake pedal. Diagnosis isn't exactly rolling the dice, but it certainly does require careful observation and some understanding of the mechanism. There's no hard and fast line between the flywheel with an acceptable run out, and one that's just warped; the distinction is in the symptoms. Even if the flexplate was old and re-used, the manufacture's specifications call for an exact torque pressure and tightening sequence. There's no hard and fast line between the flywheel with an acceptable run out, and one that's just warped; the distinction is in the symptoms.

On the plus side, dual mass flywheels reduce the torsional vibrations in the driveline and the other related vibration and noises. The vibration will be heavy, although not quite as heavy as a failing U-joint. This article was written by the It Still Works team, copy edited and fact checked through a multi-point auditing system, in efforts to ensure our readers only receive the best information. Use a socket and wrench to remove the bolts, then remove the inspection cover. Be aware of any starter spin that bogs, then picks up again, and bogs again in a rhythmic sequence.

Broken or loose bolts on the crankshaft end of the flexplate, or on the torque converter side, miss-align the flexplate, causing a high side of the plate to strike or rub against internal components. Drive the vehicle at normal speed, letting the transmission shift automatically from the lowest to the highest gear. At Phoenix Friction Products, we offer a variety of single mass flywheel conversion kits. The Gear rollover noise only occurs when the vehicle is idling and the transmission is in neutral. Clutch drag is the opposite of slippage, a phenomenon that occurs when the clutch fails to release completely. Raise the vehicle at both ends and place two jack stands under the rear frame, and two jack stands under the front frame. The most common of clutch problems isn't usually in the flywheel; it's in the clutch assembly itself.

A flexplate, as the name implies, serves as a flex-shock device between the torque converter and the engine crankshaft, and many flexplates have balancing weights to provide smooth engine RPM. Check the rotational free play. All clutches eventually wear out and begin to slip, but that's not the problem. These vibrations can usually be felt on the floor of the car and are due to the failure of the springs and other internal components. This usually happens first in the higher gears due to the higher gear ratios and increased wind resistance. While a single mass system will be a bit noisier* than a dual mass system, it will also be more reliable, especially in high torque/low idle rpm applications.

Noise.

Single mass conversion kits replace a dual mass flywheel with a simpler, more robust system. Discard if excessive.

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A definitive assessment will involve visual inspection of all components, but if you have any of these issues, then your flywheel could be the culprit. Once you've converted, your clutch will last longer, be less costly to service in the future, and will be far less likely to be discontinued than dual mass flywheel setups (some of which have reached obsolescence now and are increasingly difficult to replace). Check for visible damage including the ring gear, and other parts found inside the bellhousing. A warped flywheel will cause a steadily worsening pulsation in the brake pedal, accompanied by an intermittent rise and fall in engine rpm in later stages of warping. Because flywheel and clutch assemblies are similar in function to disc brake assemblies, they'll also exhibit similar symptoms after warpage. It was then that the vehicle was brought to our shop for diagnosis. Vibrations. The smaller flywheel engages the larger one via a set of springs. If you have increased the horsepower of your engine or tow heavy or you are interested in long term flywheel durability and minimal repair costs, it is a good idea to convert your dual mass flywheel to a single mass flywheel. If you have modified your vehicle's engine to produce more power - or if you are using your vehicle for heavy hauling or towing - you should convert your dual mass flywheel to a single mass. Listen for any rhythmic clunking or grinding noise while the engine idles in park or neutral, or idling in gear with a foot on the brake pedal. A warped flywheel will cause a steadily worsening pulsation in the brake pedal, accompanied by an intermittent rise and fall in engine rpm in later stages of warping. This will start out as mild grinding when shifting and may eventually result in a failure to engage first gear when starting. These noises can be very loud and it should be replaced as a soon as possible. Even slippage because of oil, grease or water contamination can damage the flywheel. Flexplates serve a very important function in vehicles equipped with an automatic transmission. Clutch chatter is what happens when the clutch "skips" on the flywheel, rapidly grabbing and releasing instead of engaging smoothly. *Gear Rollover Noise (aka Gear Rattle): The sound that a manual transmission makes when the gears in the gear box are in neutral and are shaken ever so slightly by the engine. A soft pedal and a delay in engagement after release are the basic signs of slippage. This article was written by the It Still Works team, copy edited and fact checked through a multi-point auditing system, in efforts to ensure our readers only receive the best information. A failing dual mass flywheel will first rattle when depressing or releasing the clutch, then proceed to exhibit symptoms similar to clutch chatter even after full engagement. This malfunction will typically occur during initial engagement and while shifting through the lower gears.

2. Diagnosing a failing dual mass flywheel can be a little tricky since most of the symptoms could also mean issues with the clutch itself. Grooves in the flywheel and missing or damaged flywheel dowel pins can also cause chatter, but flywheel-related symptoms also mimic the symptoms of a bad engine mount. Check for excessive grease loss due to overheating.

Set the vehicle in park and apply the emergency brake.

A smaller-diameter flywheel bolts to the engine and sits inside of a drum-brake-like outer flywheel.

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