Hi,

The van is a Ford transit Tdci 125hk 2004 Model.
I am in a middle of a clutch replacement job and I need urgent help!

I have questions regarding the flywheel with the spring plate in front of it:

The flywheel has a moving plate ( I don`t mean the clucth plate) in front that seems too loose but i really don`t have the expertise to judge that, so I ask you
1. Is it normal that I can rotate the plate a couple of cm counter clockwise before the flywheel itself begins to rotate?

2. And when I rotate the plate counter clockwise it has a spring tension feeling til the flywheel itself begins rotating but when i rotate the plate the other way the spring tension isn`t there, should it be like this?

3. The plate also seems too loose in and out, like its too big of a movement, please see the pictures.
is this too big of a difference?



and I also got a stupid noob question regarding the clutch plate...
it has been some weeks since I disassemble the clutch system and I am just wondering wich way the clutch plate should be fitted...
Picture 1 or picture 2?
1.
2.

The reason I need to replace the clutch is that the tags in the center of the clutch plate has totally been worn down so the transmission axle and the clutch have not had any grip, you can see it in the last picture.
do you know how this could have happened ?

I would really appreciate any replies regarding this problem!

btw.. sorry about the english...

Thank you,
Leon

 

Looks to me like you might have had a bad clutch assembly from the beginning. The splines on the clutch are gone. I'd check the pilot shaft on the transmission real good before it went back together. Make sure the spline are not rolled (rounded on the edges) or twisted. You might need a new pilot shaft on the trans if they are.

 

Hi Leon..

That flywheel type is 'generally' called a dual mass flywheel.

Its design is to control engine torque and shudder on take off and kind of a cushion.. I'm not really familiar with the TD Transit, but in other trucks the outer portion of the plate rotates on a center bearing, and springs control and limit driveline load and the rotational travel. Some lateral play should be ok, but if excessive may need some inspection.

Clutch disc install with the larger/taller hub face towards the pressure plate..

 

As ususal, our Moderator is compeltely right. This IS a dual mass flywheel, which was pioneered on the 94.5 powerstroke diesel. They had a lot of problems with these.
Ford is comming back to this design, becuase it does reduce slip and cushions the takeoff. These flywheels are NOT resurfacable to us 'little people' in the outside world. Unless the surface is absoultely perfect (no burns, marks, gooves, etc.), AND the bearing is very smooth, I'd replace it.
And I realize it's NOT cheap. But it sure beats doing it twice.