The flywheel is a massive metal disc and serves to stabilize the torque transmitted from the engine crankshaft to the gearbox. It is equipped with a toothed ring for engagement with the starter when starting the engine.
Low-power engines are equipped with a solid conventional flywheel. The breakdown of such a part includes the destruction of individual teeth of the rim, as a result of which it becomes problematic to start the engine at certain positions of the crankshaft.
More powerful motors are equipped with dual-mass flywheels to reduce vibration and damp torsional vibrations. Structurally, the dual-mass version consists of two disks. One of them is mounted on the crankshaft of the engine and has a toothed ring. The second disc is mounted on the clutch mechanism. The discs can rotate relative to each other. An angular contact bearing and a spring damping system are installed between them.
The damper springs are located on the outer circumference of the disc and are separated by cages to evenly distribute the load. Usually, a two-stage damping system is used when springs of different stiffness are present in the mechanism. Softer springs work during engine start and when starting off. Rigid springs smooth out torsional vibrations during uniform motion. The damper is filled with grease to reduce friction and ease the operation of the assembly.
The most frequent breakdowns in dual-mass flywheels are caused by shock loading or metal fatigue that breaks the damper springs. Bearings fail more rarely. Increased loads also lead to the drying out of the lubricant and the loss of its lubricating properties, as a result of which there is a subsequent destruction of the loaded elements - springs and bearings.
The most common cause of damage to a dual-mass flywheel is when the vehicle is running at minimum engine speed. With this operating mode of the motor, it has large torsional vibrations and increases the load on the damper springs. Breakdown can be caused by starting off in overdrive, clutch pedal jerks and aggressive driving style.
The reason for checking the flywheel may be extraneous knocks at low speeds, which are especially significant when idling a cold engine, characteristic clicks when starting and stopping it, and increased housing heating.
To find a malfunction, first of all, you need to inspect the outer surface of the case. It must be free from cracks and grease leaks. The flywheel installed on the car should turn in both directions at a small angle using your hands or a small pry bar and not make loud sounds. Small shocks are acceptable as a result of play in the damping mechanism. When trying to rotate, the force of the springs should be felt. If the part rotates freely in any direction, or is jammed, or has a distinct ringing of destroyed springs, then it definitely needs to be repaired or replaced.
Repairing a dual-mass flywheel can be difficult due to the fact that there are no separate parts of the mechanisms on sale. It is advisable to repair the device only in cases where it is possible to take defective parts from a similar one. The second problem is that the assembled flywheel after repair requires careful balancing, which is possible only with special equipment.
For repair, the part is first removed from the engine.The fastening bolts that secure the drive and driven discs with the motor and clutch cannot be reused, only new ones are required that have not been in use.
Usually, the parts of the assembly are interconnected by rivets that need to be drilled out without violating the integrity of the parts being fastened. After connecting the driven and driving discs, access to the damper springs is opened. If the flywheel is removed soon after suspicions of its breakdown, then several springs are broken, which change to the same ones exactly. Ideally, the springs should be changed all at once.
The damper elements are also inspected and changed, after which the inner space is filled with grease, and the unit is assembled in the reverse order.
Bearings with increased play are removed using a puller and replaced with new ones.
After assembling the assembly, you need to check its balance. At home, this can only be done by car through a test drive.
Increased vibrations, jerking when starting and stopping indicate a poor quality of repair.
Instead of repairing a dual-mass flywheel, most cars will accept a regular solid flywheel. At the same time, starting off slightly worsens and vibrations increase, especially when the engine is running at low speeds.
Repairing a flywheel instead of replacing it is a forced measure caused by the high cost of original spare parts, which often amounts to several tens of thousands of rubles.
Caution should be exercised against installing lightweight flywheels. Engines with such parts are unstable at low speeds and may stall.
Another type of repair - converting a two-mass flywheel into a solid one - cannot be recommended for use, since you still need to purchase a clutch for a single-mass flywheel, and the reliability of such a conversion is very low. The essence of the repair is that the entire internal filling of the faulty flywheel is thrown away, and the driven and driving discs are welded together. The biggest problem here will be balancing, which cannot be dispensed with in such a repair.
The flywheel of an internal combustion engine is used to store energy. It helps the pistons go through bottom dead center (especially when starting the engine). The flywheel transmits engine torque to the gearbox. There are three types of flywheels:
The flywheel resource is usually 120-150 thousand km. It all depends on how intensively and in what modes the engine worked. Usually, a new flywheel is installed after two sets of clutch friction linings have worn out, so the flywheel is changed complete with the clutch.
Flywheel malfunctions are obvious. This part is subjected to constant dynamic loads and friction, which leads to physical abrasion of the contact surfaces. As a result, vibrations or beats appear, and the clutch can "slip". Simple flywheels must be replaced, damper ones are restored in special workshops.
VIDEO Another typical malfunction is damage or wear of the rim teeth. If the flywheel is still serviceable, the crown is changed, if not, the entire assembly is changed.
Repairing damper flywheels is more complicated. They are repaired and refurbished in specialized workshops. Troubleshooting, accurate measurements, balancing machines, the services of a professional welder will be required. The essence of the process is that the worn surfaces are ground, the springs and the plain bearing are changed. The flywheel is balanced and tested under load. After repair, the flywheel planes should "fall" within the tolerances of backlash and runout.
Replacement will require a car lifter, transmission rack, and standard locksmith tools.
The engine of classic Zhiguli has a conventional single-mass flywheel. Consider how to remove the flywheel and the technological sequence for replacing it:
First you need to get access to the flywheel.If the engine is removed, there will be no problems, if not, you need to dismantle the gearbox and clutch basket;
Next, you need to keep the flywheel from turning. To do this, use a special lock, but an ordinary screwdriver is also suitable;
Having removed the gearbox, it is necessary to unscrew the six bolts of the fastener, then remove the flywheel;
Installing a new flywheel. Mount the flywheel in the reverse order of dismantling. The flywheel bolts are tightened crosswise with a force of 60.1-87.4 N.m.
Repair of flywheels is almost the main part of adjusting elements of a complex design of an internal combustion engine. The flywheel performs the most important tasks, is responsible for the uniform functioning of the motor, extinguishing excessive vibrations, avoiding unnecessary jerks and floating revolutions.
ATTENTION! Found a completely simple way to reduce fuel consumption! Don't believe me? An auto mechanic with 15 years of experience also did not believe until he tried it. And now he saves 35,000 rubles a year on gasoline! Read more"
What is a flywheel? This wheel has a diameter of 40 centimeters. Thanks to this design, there is an accumulation of internal combustion engine energy. As a result, a smooth recursion of the crankshaft is ensured at the time of passing the so-called MT phases (dead points).
Conventionally, the flywheel is referred to as diverse elements, because in fact it is included in almost every system of the car. Let's take a closer look at its function.
In the transmission, the flywheel acts as a multi-plate clutch. When transmitting torque from the starter, it is the flywheel that transfers energy to the crankshaft, as an element of the gearbox. Also, the flywheel is part of the KShM, since it directly participates in the moment of rotation of the crankshaft and minimizes the irregularity of rotation of the latter.
In order for the element to withstand such loads, it is made of a special alloy - gray cast iron (such material will damage the friction material of the clutch less). On the one hand, such production is not too expensive financially.
The main trump card is hidden in the flywheel design. It is obvious that only cast iron is not able to withstand heavy loads. For this reason, a steel rim with teeth having the same pitch is worn on the flywheel. This outer rim transmits rotation from the starter to the crankshaft when the internal combustion engine is installed.
The middle of the flywheel is lightweight. The emphasis is on the edges to increase the element's inertia.
The flywheel is fixed to the crankshaft through six holes and a flange. But besides this, there are other holes for fixing the clutch.
Like any other mechanism, the flywheel deteriorates over time. The types of possible element failures include wear of the teeth of the steel outer edge, the occurrence of cuts on the surface that is close to the clutch disc, breakage of the spring, etc.
If the teeth of the steel rim wear out (grind off), then the repair is reduced to the replacement of the product, although restoration is possible if professional equipment is available. You can also emboss the bezel (more details below). The old rim is simply updated, a new one is refueled instead.
If slots and scoring appear on the flywheel, it is recommended to use the product grinding method. For these purposes, professional equipment is also intended, a machine that is able to remove the thinnest layer of metal (up to 0.3 mm). If there is no equipment, the product is replaced with a new one.
Finally, a breakage of the spring on a dual-mass flywheel already necessarily leads to the replacement of the entire product.
During the operation of the flywheel, the latter may also require partial repair.
A steel crown is present on all flywheels, regardless of the type. The teeth of the rim are involved, as mentioned above, in important processes of transmission of rotation.
So, a steel rim can be pressed onto a cast iron flywheel element. In the process of wear of the teeth or the occurrence of cracks, the bezel is changed.This operation is justified by the fact that the cost of a new flywheel is several times higher than the price of a new steel ring with teeth.
The algorithm for carrying out the operation to replace the rim looks like this:
first, the flywheel removed from the car is placed on a flat surface;
a heavy hammer and a chisel are taken, which should be applied uniform blows around the entire circumference of the wheel;
after a few strokes, the bezel should fly off.
Advice. Masters recommend to warm up the product a little before doing this. This will make the task of removing the steel crown somewhat easier.
To fit the new steel ring onto the flywheel without any problems, it will need to be expanded in diameter. But how to do it? Take advantage of the physical properties of metals, or in other words, heat the rim in an oven.
The product is placed in the oven for half an hour, setting the heater mode to 250 g.
If there is no special oven, then you can prepare several supports, put a rim on them, hang a rag soaked in fuel over the entire diameter of the crown and set it on fire.
In both cases, it is not recommended to heat the metal to redness.
After heating, the bezel must be quickly transferred to the flywheel and inserted. It is recommended to use a hammer to achieve an accurate alignment.
Attention. The flywheel is put into place only after the steel rim has completely cooled down.
It will also be interesting to know that in some cases the crown is damaged by the teeth of the starter. In this case, only the front of the bezel will be damaged, and in this case there is no need to change it completely. It will be enough just to turn the steel rim to the other side.
If low-power automobile internal combustion engines can be equipped with a solid conventional flywheel, then modern engines are necessarily dual-mass. Such a product is less prone to breakage of the rim teeth and other wear. That there are only reviews about such flywheels posted on autoforums.
The versatility of the dual mass flywheel lies in its design. It consists of 2 discs: one is placed on the crankshaft, the other on the clutch mechanism. The discs are capable of revolving independently of each other, and a RADU bearing and a whole system with damping springs are used to eliminate friction.
However, whatever one may say, but the dual-mass flywheel is prone to breakdowns. The springs of the damping system are most often destroyed. This is due to excessive stress, shock, etc. Bearings can also fail, although this happens less frequently.
In general, increased loads lead to other consequences. The lubricant dries faster, its original properties are lost. As a result, the metal elements of the entire system are destroyed - bearings, springs, etc.
Attention. Incorrect driving style is considered to be one of the most common causes of wear on a dual-mass element. When the car often moves at low speed, this is very critical for a dual-mass flywheel. The torsional vibrations increase several times, the load on the springs increases, etc.
Components of improper driving also include improper starting, an overly sharp lowering of the transmission clutch, or simply an aggressive manner of entering corners and overtaking.
How to check a flywheel of this type for malfunctions? First of all, an experienced motorist recommends paying attention to sounds and extraneous noises.
So, if non-native engine sounds are heard at low engine speeds, then this is most likely evidence of flywheel wear. The noise is necessarily amplified in XX mode, in cold mode, when the engine is started, etc.
Diagnostics is carried out as follows:
initially it is recommended to inspect the flywheel from the outside (there should be no traces of grease, cracks and other things);
then try to turn the flywheel in both directions using a small pry bar (the flywheel should not squeak loudly when rotating, only minor impacts caused by the damping mechanism are permissible).
Attention.When the flywheel is turned, force should also be felt. It is caused by the operation of the springs, and this is normal. If the element rotates too freely on either side or is jammed, the flywheel needs to be replaced.
Adjustment of the improved flywheel can be done by hand, but you should be able to find separately sold flywheel parts in stores, including various small parts. In some cases, it is possible to transfer small parts from an old dual-mass flywheel, where another part is damaged, and the rest of the parts are normal.
Another difficulty in self-repairing a dual-mass flywheel is the need for careful balancing of the flywheel. And this is done only on professional equipment.
So, in order to repair such a flywheel, it must be removed from the car. The bolts with which it was fixed to the motor and clutch must be replaced with new ones, they will no longer be reused (this cannot be done).
The prefabricated parts of a dual-mass flywheel are interconnected, as a rule, with rivets.
Here's how to repair such a product:
the springs are being checked (on a damaged flywheel, several springs are necessarily damaged, although ideally it is better to replace all of them);
all damping elements are carefully inspected, after which the entire space inside is filled with grease with a special composition;
bearings are diagnosed, especially those that have an increased backlash (they are dismantled using a removable tool);
at the end, the unit is adjusted (in garage conditions, it will be possible to check this only by a test trip).
Attention. An unsuccessful level of repair will be indicated by vibrations of an increased quality, twitching of the motor during the factory process and at the start.
The flywheel is by far the easiest to replace rather than repaired. This refers to the installation of a conventional solid flywheel. Yes, some indicators will deteriorate. For example, starting from a place will deteriorate slightly, vibrations will increase, especially when the internal combustion engine is operating at low speeds.
Repairing a flywheel, not replacing it, is a forced measure caused by the high cost of the part, the prohibitively high price of original auto parts, etc. As a rule, the amount of replacement of some models can reach 20-50 thousand rubles.
I would like to warn motorists against installing lightweight flywheels. The fact is that motors equipped with these components are characterized by unbalanced operation. The engine stalls easily, does not start well.
Forget about fines from cameras! An absolutely legal novelty - NANOFLENKA, which hides your numbers from IR cameras (which are in all cities). More details on the link.
Absolutely legal (Article 12.2.4).
Hides from photo and video recording.
Installs independently in 2 minutes.
Not visible to the human eye, does not deteriorate due to the weather.
2 year warranty,
Cars change, friends and the forum remain. [my.housecope.com/wp-content/uploads/ext/1209]
Message Victor Mers. »19 Jan 2014, 01:01
.
we replace the bearing with a new one or grease it, put it in place. put the moving part of the flywheel on the bearing, having previously combined the holes for 6 rivets. after welding, the diesel will not start otherwise.
Message Oleg vito »19 Jan 2014, 10:29
Message 550th »19 Jan 2014, 20:22
Since in the case of a damper flywheel, its design is not so simple, then, consequently, the concept rebuilding a two-mass flywheel assumes, like the repair of any unit, the replacement of faulty elements with new ones. Of course, for this, the master must have the appropriate spare parts.
In general, first you need to figure out why many car owners prefer to replace the two-mass flywheel with its repair.
First of all, the price affects here, since the cost of buying a new two-disk flywheel is much more impressive than the cost of restoration.
However, it should be remembered that it is quite difficult to observe the technological process of restoring a flywheel of this type, therefore, it will not be possible to restore a two-mass flywheel with your own hands. As a result, experts do not recommend removing and disassembling a flywheel with two housings on their own.
Many services undertake the restoration of a two-mass flywheel, however, they do not give any guarantee for the result.
And we recall that a malfunctioning and broken two-disk flywheel can lead to very serious destructive consequences, the costs of eliminating which can exceed all conceivable values.
Still, many car owners are tempted by the prospect of fully returning the original two-disc flywheel to work without heavy costs.
Of course, in general, it is theoretically possible to qualitatively repair a two-mass flywheel, but in Russia this practice is rare. Therefore, many professionals immediately advise not to save money, but to buy a new part.
If we talk directly about the restoration process, then the repair of a two-mass flywheel involves not only a bulkhead, but also measures that are standard for all-metal flywheels.
How to rebuild a two-body flywheel?
replace defective parts;
pierce damage;
balance.
After all, it is only first that the flywheel must be disassembled and re-arranged, and only then, as in the case of conventional flywheels, a groove is made, which allows you to eliminate external defects and level the contact surfaces, as well as the mandatory balancing of the part.
The balancing of the dual-mass flywheel is carried out on a special stand after all the repair work, being their technologically correct completion.
In the technical centers from the catalog from our website, you can always get advice on whether it is possible, in your case, to do with the repair of a two-disk flywheel and how much will it cost to restore it, as well as what guarantees are provided after repair.
Specialists of good car services will always say for sure whether it is worth repairing a dual-mass flywheel after the diagnostics.
The transmission of a car is a rather complex system, it includes many different parts and assemblies (it is a mistake to think that this is just a gearbox). There is an opinion that the mechanics (manual transmission - a manual transmission and its attachments) are very reliable, "indestructible", the repair costs "a penny" and can work for a VERY long time. Previously, this was indeed the case, but now with the advent of such a unit as a dual-mass flywheel, things are getting a little sadder. On the one hand, it gives comfort and removes parasitic vibrations, on the other hand, its repair or replacement is very expensive! Today we will analyze everything in detail, there will also be a video version, so we read - we are watching ...
THE CONTENT OF THE ARTICLE
To begin with, I propose to think about what it is?
Dual-mass flywheel crown with teeth with which the starter engages), creates inertial rotation of the crankshaft, and also smoothes vibration and torsional vibrations from the power unit.
As it becomes clear this flywheel is different from the usual one. Previously, they put a simple one, which was a piece of cast disc-shaped metal, on top with a crown (with teeth). He had only two tasks to start the motor and keep momentum. For not powerful cars, this was enough, but now there are different times, different moments and powers.
This is not a simple "piece of iron" here, the structure is much more complex. The structure of flywheels with two masses is different. As it becomes clear here, as it were, two disks, which are combined into one device (two masses). Each of the masses is fixed to its source - one to the motor, the other to the gearbox. Moreover, these two discs can rotate freely from each other, they are connected only by a bearing
However, this way we will not "move" the car from its place, we need to torque transmitted from the power unit to the box and then to the wheels. That is, these two masses need to be somehow connected with each other. THIS is what the internal parts of the structure are doing, namely springs, flanges (they are of many types - an asterisk, a polygon, a gear). All this is closed with a sealed sealing cover. It should be noted that the springs and the inner cavity are often filled with grease.
This is one of the most common types, there are others, however, the principle is the same for all of them.
As I said above the power, the revs and speeds of cars are growing (15 years ago, a 1.6 engine produced less than 80 hp, now often 110 - 120 hp). Also, drivers demand from new cars - both acoustic and vibration comfort. And to do it is REALLY DIFFICULT! A powerful engine does NOT always work evenly, it often transmits large vibrational and torsional vibrations to the body, if for a sports car this is all the same, then the owner of a business class is unlikely to tolerate it, give comfort here.
Another point is robotic gearboxes, especially the old ones (one clutch disc), which are electronically controlled. For them, vibrations are GENERALLY NOT ACCEPTABLE, it was on them that dual-mass flywheels were first installed. However, now they are increasingly found on conventional mechanical boxes.
The principle of operation is very simple
It is worth noting that there is a spring damper in the clutch disc, but it can no longer cope with the increased loads on it.
The service life is now about 150 - 200,000 km. After that, the first signs of the failure of this node begin to appear:
Squeaking noise when starting or stopping the motor. Sounds like the starter keeps on spinning
Strong vibrations, which have not been encountered before (for example, at idle), many confuse them with "triple" of the engine. And after the revolutions increase, the vibrations go away. The thing is that such flywheels work on a two-stage principle, some elements (so-called soft) work at idle, others (hard) at high speeds. This is why vibrations can be at different speeds.
Clicks at start or when picking up speed
If you show at least one of the listed points, then most likely it either fails or has already gone out.
What problems does this element have and can you determine them yourself?
Defects are mainly associated with the leakage of a special lubricant, scratches, dents or even creases and cracks on surfaces. All this a master at the service station will be able to diagnose without removing it from the car, for example, when replacing the clutch disc.
If there are no visible signs of a malfunction (but sounds and vibration remain), the damper mechanism, springs may be broken, there are seizures inside, etc. You need to shoot and diagnose.
When removed, it can be checked on special stands, where its fluctuations are read, and then a verdict is issued.
REPAIR is possible or not? By the way, many write that the masters at the service station recommend buying a new one than repairing the old one.
In general, why do many people want to restore, and not buy a new one? Yes, all because the cost of an original spare part sometimes just goes off scale, for example, on a Volkswagen, the original costs about 50,000 - 80,000 rubles (it all depends on the brand) from 15 to 20,000 analogs (20-30000)
Nevertheless, repairs are possible, the main thing is to find the right specialists (who are really few).
It is worth remembering that restoration is not always possible, sometimes it happens that there are cracks or dents on the case, then only a new one or an analogue
The restoration process involves more than just a bulkhead (replacement of entrails). BUT and other activities that are simply necessary.
Replacement of damaged, broken parts. Everything changes, even the mount (the bolts that were installed on the new one are not used)
Groove workings (sometimes from the springs from the inside)
Balancing after bulkhead is a must
Changing grease
The process looks like this - initially, the disassembly process takes place, then all the broken elements are thrown out, rewound, a groove is performed (mainly to eliminate external defects and level the contact surface) - the last balancing (which is performed by high-class craftsmen, at special stands).
It is worth noting that you should not save on spare parts, because the bulkhead is not a cheap process and if you put in poor quality parts (say springs), it will not live long!
Another question - how long can you walk after renovation? If the work is well done, then the original minimum of 150,000 km (250,000 at the maximum) can be walked.
Now we are watching the video version.
VIDEO
In conclusion, I would like to say that some drivers (including German cars) are sure that an automatic transmission (automatic transmission) to be repaired is more expensive and more capricious! Friends of the automatic transmission, if you change the oil (filter) in it correctly and do not ruin it with your own hands (for example - skid on it for a long time ) can walk 250 - 350,000 km without repair. But on mechanics, in 150,000, in any case, you will change the clutch disc, and in 80% of cases the master will offer you to change your dual-mass flywheel - AND IT IS VERY EXPENSIVE, often comparable to repairing an automatic transmission.
This concludes, sincerely your AUTOBLOGGER
As an example - ignition malfunction, failure of engine mounts (cushions), plunger pairs, throttle valve, high pressure fuel pump and other factors.
It is necessary to change or repair the dual-mass damper flywheel only after isolating all the other reasons indicated.
In order to eliminate the illegal replacement of the damper, we recommend that you inspect it and check its operation.
The dual-mass damper flywheel should only be replaced in the following cases:
When cracks are found on the surface of one working mass of the flywheel, which can appear under the influence of high temperatures.
Loss of lubrication. Detection of grease on the crankcase of the manual transmission housing.
The damper flywheel does not rotate around the axis in any direction, or it is blocked (inability to dismantle due to blocked holes).
It is required to very accurately determine the angle of displacement of one mass relative to another in different directions.
1. Try turning the dual-mass flywheel clockwise and counterclockwise by hand or a pry bar.
Modern diesel engines have an additional friction ring, so when testing the flywheel, you need to apply more force than for gasoline engines.
To do this, you must use a crowbar or pry bar.
If the resistance of the damper springs is felt, this means that it is in good working order and there is no reason to replace it.
The damper must be replaced when it rotates around its axis freely, without resistance, until the springs stop against the bump stop, or if noises are heard similar to the ringing of springs.
These symptoms indicate deformed or broken springs or a lack of lubricant.
2. Check the rotation of the dual-mass flywheel - clockwise or counterclockwise in different directions.
The angular play of one damper mass in relation to another mass increases with engine operation, and may also be a consequence of a certain driving style of the driver.
3. Checking the angular backlash of the mass displacement in the flywheels of the SACHS company - measured on the engine at rest.
The damper disc must be secured against rotation by the tool.
The offset rate is 0 to 3 teeth.
4 and above teeth - repair is required.
4. Checking the angular play of the LUK clutch - measured on the vehicle at rest.
The damper flywheel disk must be locked against rotation.
The flywheel of an internal combustion engine is used to store energy. It helps the pistons go through bottom dead center (especially when starting the engine). The flywheel transmits engine torque to the gearbox. There are three types of flywheels:
usual;
lightweight;
damper (springs are installed inside the damper).
The flywheel resource is usually 120-150 thousand km. It all depends on how intensively and in what modes the engine worked. Usually, a new flywheel is installed after two sets of clutch friction linings have worn out, so the flywheel is changed complete with the clutch.
Flywheel malfunctions are obvious. This part is subjected to constant dynamic loads and friction, which leads to physical abrasion of the contact surfaces. As a result, vibrations or beats appear, and the clutch can "slip". Simple flywheels must be replaced, damper ones are restored in special workshops.
VIDEO Another typical malfunction is damage or wear of the rim teeth. If the flywheel is still serviceable, the crown is changed, if not, the entire assembly is changed.
Repairing damper flywheels is more complicated. They are repaired and refurbished in specialized workshops. Troubleshooting, accurate measurements, balancing machines, the services of a professional welder will be required. The essence of the process is that the worn surfaces are ground, the springs and the plain bearing are changed. The flywheel is balanced and tested under load. After repair, the flywheel planes should "fall" within the tolerances of backlash and runout.
Replacement will require a car lifter, transmission rack, and standard locksmith tools.
The engine of classic Zhiguli has a conventional single-mass flywheel. Consider how to remove the flywheel and the technological sequence for replacing it:
First you need to get access to the flywheel. If the engine is removed, there will be no problems, if not, you need to dismantle the gearbox and clutch basket;
Next, you need to keep the flywheel from turning. To do this, use a special lock, but an ordinary screwdriver is also suitable;
Having removed the gearbox, it is necessary to unscrew the six bolts of the fastener, then remove the flywheel;
Installing a new flywheel. Mount the flywheel in the reverse order of dismantling. The flywheel bolts are tightened crosswise with a force of 60.1-87.4 N.m.
The Masterturbo company was founded in 2006 as a specialized company for the repair and sale of turbochargers. In the process of dynamic development of our company, the list of services we provide has significantly expanded. At the moment we are a highly qualified unified enterprise and have two equipped repair plants in Moscow and St. Petersburg.
Currently, the specialized areas of work of our company are:
Repair and sale of turbochargers for cars, special. equipment, small vessels, gas piston, gas turbine and other power plants.
Repair and sale of two-mass flywheels.
Repair of automatic transmissions, variators, DSG.
Caliper repair
Engine overhaul
CAR SERVICE
In the process of repairing a high-mileage engine, the repairer will inevitably face flywheel wear. The rim teeth wear out, and the clutch rubs a deep ditch. It is deeply mistaken if the repairer considers the flat wear surface under the clutch to be “normal” and installs such a flywheel without restoration. Clutch slippage is the inevitable result of this attitude towards repairs.
Instead of buying an expensive flywheel, it is advisable to restore your own one.
The worn crown is repressed, and the starter will operate on the other, unworn side. At the next repair, when the second side of the crown is worn out, the crown should be replaced with a new one.
We must grind the flywheel planes under the clutch, removing the worn surface. The groove should be made along two planes (the plane of the basket mounting and the plane of the clutch disc).
The photo below shows an example of a remanufactured flywheel with a range of more than 100 thousand km. - the planes are machined, the crown is repressed. The resource of such a flywheel is not inferior to the new factory flywheel, and high-quality restoration of the planes guarantees correct and durable clutch operation.
In a workshop K-POWER it is possible to restore the flywheels of various engines. The possibility of repair and restoration is assessed only during inspection and troubleshooting of the flywheel.
ATTENTION Cargo Flywheels and Cracks - Not Repairable. Dual-mass flywheels of foreign cars (if the damper is destroyed) - we also do not accept for repairs.
The cost of repressing and grooving a plane - see the price list.
Video (click to play).
Article written: June 9, 2009
