Clutch kit replacement
A clutch kit consists of the flywheel, clutch disc, pressure plate (basket) and the release bearing. There are two types of flywheel: solid and dual-mass flywheel (DMF).
A solid flywheel is rarely replaced, only when its plate warps due to overheating. Some flywheels contain a small ball or needle bearing (pilot bearing) that is also replaced together with the clutch kit. It is located either in the flywheel or on the crankshaft. The bearing keeps the clutch shaft aligned — if it is not replaced, it disintegrates and damages the new clutch kit.
The dual-mass flywheel is the most common issue on modern diesel vehicles. Some manufacturers also use DMFs in petrol engines. Other DMF-related issues include knocking and rattling during driving, ignition/turn-off, sudden acceleration, etc.
The DMF consists of multiple components, the two main ones being the fixed flywheel section and the floating flywheel section (the plate that transfers force from the engine to the clutch kit and onto the gearbox). The DMF can also have a "pilot bearing" supplied with the flywheel; if it is on the crankshaft it is purchased separately. The job of the DMF is to absorb vibrations and shocks during driving, gear changes and engine braking, and to direct them onto the crankshaft and gearbox, allowing smooth gear changes.
What is the most common cause of DMF failure?
The most common cause is the driver's style.
The clutch kit also includes a clutch cover that may have an automatic adjustment system. The most common clutch-kit issues are: disc wear, damage or leakage of the release bearing, weakening of the pressure plate. The lifespan of the clutch system mostly depends on the driving style. Expected service life is 100,000–150,000 km.
Hydraulic release-bearing leakage occurs due to irregular bearing-system fluid changes (clutch/brakes), increased clutch cover stiffness, or driving for a long period with a faulty DMF.
When replacing the clutch kit, replacing the DMF is mandatory. This ensures the clutch system works correctly and lasts longer.
Some vehicles with automatic transmissions also have a DMF that is replaced — the symptoms of a bad DMF are similar to manual transmissions.
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