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DIY: Do It Yourself
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Old 04-18-2011, 10:10 AM   #1
dlucy
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Join Date: Feb 2011
Location: Aston, PA
Posts: 6
My Ride: 1999 E46 328i sedan
Dual mass flywheel - too much movement?

Following the excellent DIY articles here and at pelicanparts.com, I'm halfway through a clutch replacement... but I've run into a dilemma.

My 1999 328i sedan has just over 250,000 miles, so when the clutch pedal started vibrating and the clutch started shuddering, I wasn't surprised. Happy, actually that it had lasted so long. By the time I could put the car up on jacks to start the replacement, I could hear slipping/grinding/sliding noise when in neutral.

Looks like I have a self-adjusting LUK clutch, so ordered a clutch super kit from Pelican. I get everything pulled out only to find the clutch is fine: the pressure plate looks good, there is 1/16" of material left both sides of the clutch plate and the flywheel surface looks fine.

So where is the shuddering and noise coming from? The throwout bearing is kaput; its internal bearing are noisy and roaring when you spin it by hand. But the thing that really threw me was the flywheel. It moves. The two halves of the flywheel rotate a bit. I thought they actually clicked as I was spinning them on the crankshaft, but that turned out to be wrong.

So, I've got this flywheel with a good surface and no indication of problems other than it moves some. Everything tells me this is a dual mass flywheel and it SHOULD move some.

How do I tell if it's OK? That its movement is tolerable? I don't want to buy a new one, but I don't want to button this all back up only to have to pull it apart again.

Help!
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Old 04-21-2011, 11:41 AM   #2
Eric Giles
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Yes, a dual mass flywheel is made of two pieces that are joined together, and they are designed so that there is some movement between them. I cannot remember the exact amount allowed, but I have seen around a 1/4" or so before with no issues-even a touch more and it would be fine. However, the surface of your flywheel does not look good. Take some relatively fine grit sandpaper and go to work on it, roughing it up some and removing the buildup that is there. You very likely could do that and use it again and it would be fine-however, after 250k miles, it would probably be a good idea to just bite the bullet and replace it to be safe. As you said, you don't want to have to do this job twice. The general rule is that a flywheel will last thru two clutch replacements. At 250k miles, that would probably be same time period relatively speaking.
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