Hello everyone looking for a bit of advise if you can all help.

I got myself a 2002 ford mondeo 2.0 tdci at car auction the other day as a non runner. Spoke to garage about it and they reckon the dual mass flywheel has started breaking up as crank sensor was damaged, new one was fitted briefly and it started but was banging and rattling so stopped before any more damage done.

Does anyone know where to get a replacement flywheel at a reasonable price and also a clutch kit? Going to tackly myself. also heard that a solid flywheel can be fitted but dont know if it will affect running of the car?

Many thanks
Paul

 

I'm about to take on one of these myself. Same car, same age, same problem- only mine is still running, for now. For the parts try eurocarparts.com or buypartsby.co.uk. Probably a good idea to change the slave cylinder too because it will burst immediately after the repair otherwise.
Hope that's some help.
Graham

 

thats good advice cheers, was looking at buying a kit which includes fluwheel clutch and slave cylinder anyway even though they are kind of pricy. keep me informed of how you get on maybe can givce each other advice if we get stuck. These dual mass flywheels seem to be headaches to everyone the more i look into it.

 

Dual mass dual trouble!!, convert to normal if you can.
tabetha

 

DMF on MK3 diesel mondys are a fooking nightmare. they always go, its just a matter of time, same with the injectors.

 

Hi there thanks for the reply, i was looking into the solid flywheel swap but have heard that they put more strain on crank, gearbox etc as the dual mass relieves some strain from torque, so is this a 50/50 move or is it reaslly worth it???

 

the solid flywheels are fine but just find the driving a bit harsher then with the dual mass i changed mine for a dual mass about a year ago no problems with it

 

It's interesting to see us all go through the same thought process... I was wondering about solid flywheels too but the stories about smashed gearboxes and even more worryingly broken crankshafts scared me too much. No choice for me now because I've got most of the parts (dual mass etc)- just need the new flywheel bolts and for it to stop snowing/raining/freezing etc so that I can get to work on the driveway. Fiddy, don't even mention injectors / fuel pumps! So far so good. I'd rather fix the flywheel twice!

 

I will be towing a fairly heavy boat often so would a solid flywheel be better for towing or worse???

 

fitted loads of solid flywheels to transits with no problems at all but not mondeos.cant see any problems as both same engines.

 

I've heard horror stories about fitting solid flywheels to mondeos , personally i'd stick with what its made with so if mine goes before i get rid then it'll get a dual mass replacement .

Mines done 150,000 , 54 plate 130bhp and one previous owner , lease company so its had what it needed but i think its ready for the odd injector now .

Good cars but toooooooo many problems i've read about so would never have another .

 

The dmf is the weak link in the drive chain and the torque from the engine is what kills it. If you make the flywheel stronger then something else has to be the weak point. People have gone solid flywheel without a problem and some have had one. I guess it's down to luck but for sure the harder the car is driven the more likely the 'next weakest' point will snap. That's why I stuck with the dmf.

 

What a bloody day i had today, ok heres the progress managed to get gearbox out of mondeo tdci today, although in doing so i had to drop the complete subframe is this normal i could not see another way for it to get out otherwise.

Anway after all that grief i removed clutch, and flywheel only to find them looking near brand new. the only damage i could see was that the startet motor gear had collapsed and bits were falling out of it.
Found a few small springs in bellhousing tho
Oh yeh and it snowed all day so soaked, freezing, and skinned knuckles galore !

 

I'v done four mondeo flywheels 3 dual mass and 1 soiled.With the DM flywheel you have problems with the starter motors when the flywheel give up.I'v had no bother with the soiled flywleel as the clutch plate is spring loaded. I got it of transitparts.Take off the flywheel and stand on it and do the twist.If there any play in it it fucked.And that subframe is a bastard

 

Way hay some else agrees yes that sub frame was causing a few fuck sakes to fly about earlier, what a ballake !
yes my flywheel has a bit of sideways and rotaitional clockwise / anticlockwise slack so this isnt normal? does the new unit have no play then at all

thanks folks

 

It should be like a spongey affect like no slaping about and no metal grit on the flywheel.Check the starter too, clean it out well but i don't think its a good idea to put oil on it as grit would stick to it.Hope this helps

 

Sorry to hear about your troubles. Taking out the subframe is a bloody pain and I'm not lokking forward to mine but it has to go. I just looked at my new flywheel and it has no sideways movement at all. It rotates 2 or 3 degrees either way but very very little. More than a couple of degrees and it's toast for sure. The dmf is full of springs and my guess is that the ones you see are from inside there. I think I'm going to have to start swearing at mine, and swear I will, because the rain looks set to stay so I think I'm gonna have to bite the bullet and go for it too. Did you have any stuck bolts to free and did the driveshafts come out of the hubs easily?

 

Sounds like its worth Ł350 for mr clutch to do it with the slave inc and any warrenty no labour charges !

 

the nearsdie driveshaft was a bit tough but a good pull and push with some pry bars got it out the offside one was no probem at all just disconnected bracket attached to the block and pulled it and it came out, the only stubbord nut i has were the very font offside bolts which hold the radiotr pipe to subframe, ended up snapping them off as really stubbord buggers and they are only 10 mil x 2 of them

 

bugger it made a decision gona by a solid flywheel tommorow off ebay

 

A mate told me that the reason for the dmf is to stop the timing chain breaking but i don't know

 

speak to ginge! For the solid flywheel kit

 

If you get a sprung clutch with the solid fly you will be fine, this will give the flex that the old 2 piece dual mass fly did, it will be fine. I swapped a dual mass fly on my focus to solid fly and its been great. The solid fly will no doubt be lighter too which will give you an even more fun drive with much improved acceleration

 

ok i hope all will be well. timing chains go forever do they not??? life of the engine i heard?

 

apparently Euro car parts have stopped selling the solid flywheel conversion due to a few cranks snapping on the tdci models

 

They vary rarely fail, infact, ive never heard of mondy one failing. the tensioners can ware, but with regular oil changes, that shouldnt happen either. trust me, you would hear it, the rattle would be unmissable.

 

does anyone know if you can get a solid flywheel kit for petrol cars that have dmf's

 

I don't think petrol cars have dmf

 

yeah thats what i thought untill i bought a 2.0l oetrol that needed a clutch

Ł600 later it was fixed

 

Jes thats dear,600 pound. They stay the reason for the dmf is to prolong the life of the timing belt.Has yours got one?

 

that was just over 500 for the dmf and juat under 100 for 2 piece clutch kit, lifted the engine and box out the top as i prefer doing it that way rather than lying under it for a day

the tumbler flaps were also rattling in the end so it was sold on again

was looking at another mk3 mondeo but just got the chance of another mk2 so should be getting that tomorow

 

I had the usual probs with my 2.0 petrol 03 reg mondy. bought from new 60thou on clock new clutch with mr clutch gave out after 6thou replaced along with new dmf which caused the prob . now I find all this about the dmf being crap etc - tooooo late but question , does the focus st170 bought same time as mine 03 reg , have the same clutch etc and is it likely to suffer same problems

 

my 53 plate 20tdci zetec s has clutch just got had someone to look at it he said its fxxxxx daul mass flywheel how much for a job like this he said about 500 gutted as the car only has 80000 on the clock

 

There is a better DMF available

Sachs planetary type