Ford Mondeo MK4 TDCI DMF Failure - Dual Mass Flywheel Noise / Issue

Рет қаралды 61,597

6 жыл бұрын

Ford Mondeo TDCI 2.0 DMF Failure - This video was created to give a guide to the experience I had replacing the clutch and Flywheel on a 2009 MK4 TDCI.
The video gives an overview of the issue, stripping and assembly of car etc. All work was carried out by using a Haynes manual by a non qualified person.
I take no responsibility for any damage cause to your own vehicle by following anything detailed in my video. Everything you do is at your own risk. Seek professional qualified advice if required. Always have a mobile phone and/or family / Friend / Colleague close by to assist as and when required!

Пікірлер: 73

@PurpleHelmet 5 жыл бұрын

Just gearing up to do this job myself, great video - thanks for taking the time to put it together!

@adamjosey 5 жыл бұрын

Purple Helmet no problem, glad to hear the video is useful to you, hope it the job goes smoothly for you!

@sopissedoff 3 жыл бұрын

That's a lot of work man, I bought the clutch and flywheel kit and the local garage changed it for 200quid on tdci focus

@pete9b 5 жыл бұрын

Great informative video Adam, thanks very much. 👏🏻

@adamjosey 5 жыл бұрын

pete9b no problem, glad to hear it is of use!

@wilfadams7173 5 жыл бұрын

Great. Thanks for recording. Really helpful.

@adamjosey 5 жыл бұрын

Wilf Adams no problem, glad it was helpful to you

@Badgertronix 6 жыл бұрын

Fantastic job. Bit of a pain having to remove the subframe, you did well 👍

@adamjosey 6 жыл бұрын

Badgertronix many thanks! The two winch straps I used really helped control the dropping and in particular the refitting of the subframe!

@SpannerAT34 5 жыл бұрын

Great video. Just reading Haynes now and then I'm off to garage to hand car over because that work is well beyond my confidence. Well done. It's great to see comparisons between worn and new parts. WW reg and "see what the craic is",,,, you're in The Garden of Ireland?

@adamjosey 5 жыл бұрын

ZbgZ yep over in ireland, glad the video gave you what you needed to decide if you could do it yourself or hand off to garage, looking back it was a bit of a nightmare job!

@ciogon 5 жыл бұрын

replace the seal!!!!!!!!my mechanic didnt replaced it when he changed my dual mass flywheel on my volvo v50 2.0 tdci...and after some months it started leaking oil.....now i have to take out the gearbox again to replace it!and its a very cheap parts...and easy to replace....damn!!!

@adamjosey 5 жыл бұрын

After over a year there is no residue oil coming out of the bottom of the gearbox, I would say the seal was ok and the vibration of the knackered flywheel that was causing the seal to weep oil. Car is going strong since.

@georgigeorgiev1300 6 жыл бұрын

Hello i have a question was there any vibrations when you accelarste under 2000 rpm ?

@darrethmorgan1561 4 жыл бұрын

great vid mate ive got the 1.8tdci mk4 Mondeo can i ask how much the clutch flywheel costs been told mine needs changing

@chrispapp4606 5 жыл бұрын

What an awesome tutorial! My clutch has started to make an odd sound when pedal is being pressed, with or without gear engaged. If my local garage confirm it's the clutch assembly or DMF that's at fault I will try to follow your video and do it myself....What could go wrong???

@adamjosey 4 жыл бұрын

Chris Papp how did you get on?

@oskarbarsk9421 5 жыл бұрын

What is the torque specs for dmf and clutch plate??

@user..Aa..Bb.. Жыл бұрын

Great video. Am in the same boat, mine sounds like a spanner in a washing machine and the someone taking a hammer to the bonnet. Horrible. What's did the parts cost and how much labour would I expect to pay. Any info would be great

@MrZimmaframe 4 жыл бұрын

I was thinking of buying a 2007 Mondeo 2.0tdci with 112,000miles which needs a new clutch and flywheel for £600-700. Do you think that is a good deal? Is there anything else I could do while it’s taken apart like seals or anything else like that? Also which are some clutch kits so much more expensive? £400 then it jumps to £1000.

@JoseCarvalho-ge3mn 6 жыл бұрын

Hello, Congratulations for the good video, i'm thinking to do the same for my Smax 2.0 TDCI. Before doing the job did you took out the gearbox engine oil? Did you replace the rear crankshaft seal, how it was?

@adamjosey 6 жыл бұрын

Hi Jose Carvalho, thank you for your feedback. Yes after removing the plastic under covers and before removing the draft shafts you need to remove the gearbox oil. Apologies for that not being clear in the video. Best of luck with you smax!

@adamjosey 6 жыл бұрын

Regarding the crank seal, in the end I decided not to replace it, i cleaned up the whole area and I have been monitoring. I have had no drop in oil level nor oil showing under the car or on gearbox. The risk of getting the crank seal wrong was too high, to do it correctly you need a dedicated removal / refit tool that ford uses. Plus too many people have put up they have a worse oil leak after doing a diy job on it.

@MasterrOwns 2 жыл бұрын

Hi man, Did you install the dualmasswhell and the clamp, what about the movie? I am asking because I also have a 2008-2009 pre-lift, and just like you, my original dualmasswheel is slightly different than the polift one. Is everything okay with what you put on the pre-lift? Theoretically, the dualmasswheel you have installed (new) was from after-lift mondeo. Sory for bad english....

@andrecastro6821 4 жыл бұрын

Hi there. May I ask how heavy is the gearbox for two people to take it off? Is it easy enough to remove the gearbox on jackstands? Great job on this one mate and thanks for an awesome tutorial. Regards.

@adamjosey 4 жыл бұрын

André Castro it is manageable with two people, you could do it with axle stands and a jack. I would still recommend putting a strap around box to give you something to grip on to with your hands though. Thank you for your feedback, hope the video helps with your own job

@alanjm1234 Жыл бұрын

The automatic doesn't have a DMF. (Of course it has its own suite of problems) It's quiet and smooth enough. Is the DMF really necessary?

@TheTopper2010 6 жыл бұрын

Hello Adam, wondering you might be able to advise. I have a ford Mondeo 2L tdci 2008 ghia. Last yr in January 2017 first issue was Slave cylinder, had it replaced but I reckon should have changed clutch & flywheel then. Two months later in March had clutch failure, so had clutch & dual mass flywheel replaced, then in November (6month later) flywheel rattling just like in your video, had flywheel replaced again but supplier hasn’t paid the mechanic back under warranty which is still an ongoing issue. Car was running fine from November but then in March 2018 unable to put into gear when ignition on, so clutch failure, took to same mechanic & he says the flywheel gone again & he cannot understand what else could be causing this. What else from your knowledge could be causing recurring DMF failure on this? Frustrating as I’m not sure whether to replace these again & buying LUK clutch & flywheel brand new are really expensive

@adamjosey 6 жыл бұрын

gul sorry for late reply, if the bolts holding the clutch plate onto the DMF are not torqued to right setting it can cause issues. Also if the flywheel is not on the crank straight it will be unbalanced and cause early failure from my understanding. Hope you got yours sorted in the end?

@Robyrama76 5 жыл бұрын

Nice video congratulations, but I have only a doubt, for the installation of the pressure plate manufacturers recommend the use of the special tool for fixing the pressure plate flange without the contact with the clutch! do you find this thing?

@gaynordaykin9979 5 жыл бұрын

Mistake I made not using this tool... I had a hard pedal and then a failed CSC cylinder as a result of following this vid

@granadadr 4 жыл бұрын

how long time did the job take? :)

@Mudam666 5 жыл бұрын

I have a similar problem with my mondeo. When the gearbox is cold it will make a klonking noice every other second and it dissapears when I press down the clutch. Did your also start doing that? Or was is just staring making that noice out of the clear blue sky?

@adamjosey 5 жыл бұрын

It started with a bit of rumble and not running as smooth, in particular in the lower gears (1st / 2nd), it got worse and worse. It I had left it any longer the flywheel would of broken up and knackered the bell housing / gearbox.

@arturmi100 6 жыл бұрын

Hi I need your advise mate. I've got mondeo mk4 titanium x 2008 TDCI DURATORQUE 140 BHP. about a weak ago I've started to hear a noise like worn bearing when I drive on low gears with no acceleration on. after when I press the clutch there is no noise at all. I don't think that this is DMF because engine run quiet , with out any noise like on your video. It's quiet on neutral as well. have you got any ideas please ? regards Artur

@malcolmyoung7866 6 жыл бұрын

Artur, Your problem does sound like a clutch release bearing but as mentioned above this video does not pertain to that. Hope you managed to solve the issue?

@adamjosey 6 жыл бұрын

Hi Arthur, Malcolm is right that the video is for a DMF issue however I did have a noisy release bearing. There is a test to see which it is, this test should help you determine which is the issue / generating the bearing noise. If you hear bearing / grinding noise with clutch pressed its more likely the release bearing. If there is no noise with clutches presses in but when you release clutch and or driving in 1st / 2nd gear you hear the grinding / bearing noise then it is more than likely the bearing on mainshaft / input shaft inside the gearbox. So if its the first, replace release bearing, you should always replace this on any clutch changes. If it is the second, the you need to check and replace both bearings inside gearbox, there should be two inside. Plus you should replace release bearing on clutch regardless as it is so cheap. For stripping gearbox I would recommend a gearbox specialist unless you have the skill and confidence to do it.

@boost351 3 жыл бұрын

Hi Arthur how did you get on with the bearing type noises . I have a 2013 Ford C-Max 2.0 tdci 103 kw that has also developed a bearing type noise. Very noticeable around 20 - 30 km/ on and off the accelerate pedal. Was yours inputshaft or outputshaft bearings?

@potluckfishing 3 жыл бұрын

Running cold is a classic mk4 mondeo problem, almost as if by design

@adamjosey 6 жыл бұрын

Hi Georgi, yes very much so, it was until a couple of days later I realised how different the car drove, sounded, handled and performed. Before doing the DMF there was vabriation and rattling through out the car, in paricular under load and below 2,000 rpm. You could not use 6th gear below 60 mph without it shaking the car to bits when going up hills and around corners etc. Now it is silent, smooth as anything, MPG has greatly improved too and I am able to use 6th gear again on the country A roads 45 mph - 60mph without feeling rhe engine is being completely stressed out! Another improvement is the feeling of better response, more power and better acceleration from a stand still. As you can see in video the flywheel was definately the cause. Any other questions, let me know!

@pontesmocho3140 6 жыл бұрын

adamjosey.. Hi mate, thanks for your video. Can you please help me with my S Max 2007.. The sound is like your.. I think I have the same problem. DMF.. Thanks for your time.. kzfaq.info/get/bejne/e9pxaaiZldmYfo0.html

@adamjosey 6 жыл бұрын

Pontes Mocho , just watched your video of your car. Certainly sounds like its DMF failure, it looks very unbalance with the way it is throwing your gearbox about. I would look to get it resolved asap before it causes any damage to the gear box and/or crank. Glad my posted video is helping others!

@pontesmocho3140 6 жыл бұрын

adamjosey. Hi. Thanks for your reply.. I buy a kit, and I still waiting for arrive.. To take the gearbox out, I need take the subframe out? Or just put them down little bit? Thanks for the help.. And sorry for my bad English..

@adamjosey 6 жыл бұрын

Pontes Mocho you need to drop subframe completely, if you using winch straps to control the drop it is easy, you have to disconnect exhaust from rear of subframe / gearbox to enable it to drop. Watching the video through should given you a good idea to what is involved. Its not quick to do, so make sure you have plenty of time and patients! And somewhere dry to work!

@pontesmocho3140 6 жыл бұрын

Hi. Thanks for your video.. I finished work well. But now I have a new problem.. My hose pipe high pressure, from power steering pump to steering rack jump out after fix the subframe..

@arturmi100 6 жыл бұрын

Could this be Noisy Clutch Release Bearing ? Regards Artur

@adamjosey 6 жыл бұрын

No, definitely the DMF had failed! The spring was coming out of the side of the DMF!

@duratorque 6 жыл бұрын

Well done. How long did it take you?

@adamjosey 5 жыл бұрын

It is a fair job to commit to with out a lift ramp. At certain times you absolutely need a second person with you to help lower and lift parts out and into place. I was having to call in favours when I could get people down to help at those moments. So in total it took a weekend plus two evenings. In particular as after I found the marks to the block I stopped to complete some research. Looking back, if all went smoothly you could get it done in about 8 hours on your own with someone coming to help at the right times. Appreciate a garage could probably do it much quicker, but its money in my pocket in saving labour charges!

@SpannerAT34 5 жыл бұрын

@@adamjosey How many hours do you think a good mechanic would require to do this job?

@Landybandy1 4 жыл бұрын

ZbgZ just had all mine done parts & labour just under £600. My engine is the ford galaxy 6 speed 140 BHP. Considering over half of this cost is for the parts, it just was not worth a weekend of stress & cut knuckles. The garage has got all the right kit & job is done proper. Money well spent.

@twig3288 5 жыл бұрын

Do you know who makes these components for Ford? I think the engines themselves are by Peugeot; not sure about the transmissions, I think the automatics are mostly German.

@adamjosey 5 жыл бұрын

Twig the car was fitted originally with a LUK clutch and flywheel, these were the original parts and I can only assume were OEM as I have know the cars history since it was 6 months old / 10,000 miles. I believe the engine is a PSA (Peugeot / Citroen) engine as you say but this model of engine was co developed with Ford but physically made by PSA. However on this engine there are no PSA markings visible on the engine or plastics that I can see. Where a neighbour of mine has a 2.0 TDCI on a 2014 plate (mk 5) and the engine bay is covered in PSA logos (Peugeot / Citroen) everywhere. I remember being surprised when working on the fuel filter for him.

@liamgray958 5 жыл бұрын

The parts are 100% luk fomoco stamped opersite side usually I've done alot of ford clutches ,

@johnhunt2388 4 жыл бұрын

I hope I don't get that with an automatic as I'm going to have to put my 2012 Mondeo into the garage so that will cost me won't it.

@ajcool8202 4 жыл бұрын

If your car is an automatic it won't have a clutch like this. I don't know whether its cheaper or not to repair but your probably gonna be looking at a big labour charge from the garage either way.

@koukiben9841 5 жыл бұрын

Hi do u recommend putting a solid flyweel on 2007 ford galaxy 2.0 tdci I did it but still a bit noisy and making to much noise when staying to start don't realy know if it's the flyweel or the starter. Thank you

@safefix 5 жыл бұрын

Don't know about the Galaxy but my last car was a 130bhp PD tdi Passat that someone had done a solid flywheel conversion on before I had it and it was horribly rough when pulling hard at lower revs. Just about to have the DMF replaced on my Volvo S40 2.0D (same Ford engine and box) and will be replacing like with like.

@ianoconnell8678 6 жыл бұрын

I didnt think you would be in ireland for this job or did the car come to u

@adamjosey 6 жыл бұрын

Mercedeslhamiltonfan this is in Ireland, near Tullow county Wicklow side. I am from the UK but now live in Ireland. Still have some CRX’s and my accord back in the UK at my parents!