Major Reasons A Dual-mass Flywheel Fails Or Fails Prematurely

A Dual-mass flywheel, also referred to as DMF, is a unique kind of flywheel which has been used on various pickup trucks and passenger cars since the late 1980s. In this article, we are going to have an in-depth look at dual mass flywheels as well as discuss the signs and symptoms you need to look out for prior to complete failure of this important car component. Interestingly, your driving style also plays a part in the life span of this component, so read on to see what you should and shouldn’t be doing so you can extend the life of your car parts! 

Firstly, What Is A Dual-mass Flywheel?

A dual-mass flywheel is a component of your manual vehicle's transmission system. This two-piece assembly consists of two separate flywheels, a front primary flywheel and a rear secondary flywheel, that are attached by a series of coil springs which are mounted sideways between the two masses. 

The primary flywheel bolts directly to the crankshaft (the same as an ordinary solid flywheel) and the secondary flywheel is bolted to the clutch, providing the friction surface for the clutch to make contact with. So in the most basic terms, a dual mass flywheel is essentially two flywheels in one, attached together with springs.  

What Does A Dual-mass Flywheel Do?

It is quite normal for your car engine to vibrate whilst driving. The movement of pistons, rotation of the crankshaft, transmission gears, and other moving components inside the car engine will cause slight vibrations. A DMF is specifically designed to absorb and dampen engine vibrations, protect the drivetrain and chassis and prevent torque spikes from reaching the gearbox. 

Engine vibrations can cause damage to the vehicle’s engine over time and reduce its overall efficiency, so by absorbing these vibrations, dual-mass flywheels play an important role in the overall performance of your vehicle.

It is the springs between the two flywheels that provide the cushioning to dampen torsional engine vibrations and shock loading when the clutch is engaged. These springs compress and release, allowing just enough movement between the flywheels to absorb and dampen the engine vibrations, cushioning the vibrations through the drivetrain when the clutch is engaged, and smoothing clutch engagement in vehicles with high torque output engines.  

This makes for smoother gear changing, reduced drivetrain noise, and longer gear life, and altogether provides a smoother, quieter ride for the driver and passengers.

Dual Mass Flywheel Failure

When the dual mass flywheel fails, it can cause several complications and problems with your car, least of all a very uncomfortable ride. These are the most common symptoms that should  alert you to the start of dual-mass flywheel failure:

The Most Common Symptoms Of Dual-mass Flywheel Failure

• Hard Clutch Pedal

• Problems Shifting Gears

• Increasing Torsional Vibrations (especially through the clutch pedal)

• Rattling Sound (which disappears when the clutch is depressed)

• Slipping Clutch (flywheel is imbalanced, worn out, and delaminated)

• Clutch Surface wear (rough, grooved, cracks, warped or hard spots) is another reason for flywheel replacement. 

What Are The Major Reasons A Dual-mass Flywheel Fails Or Fails Prematurely?

There are several reasons a dual-mass flywheel can fail, but the most common causes are:

• Overheating due to friction and heat can cause the flywheel to crack or warp over time. 

• Spring Fatigue and Failure will cause the flywheel to rattle or make a clunking noise during clutch engagement.

• Free Play Between the two Masses as the springs become loose, the flywheels move independently from each other, damaging the flywheel and leading to failure

• Little or No Lubricant generates friction which will lead to damage and failure

• Normal Wear & Tear due to the constant friction and heat damage

• Worn Out Bearings or Bushings will cause damage to the flywheel

• Bad Driving Habits such as Riding the Clutch, Harsh or Quick Shifting of Gears can cause the flywheel to crack or break which leads to premature DMF failure 

• Stop-and-go driving

• Overloading the drivetrain by pulling more weight than the vehicle's maximum towing capacity

• Driving on Rough Road Conditions

• Using the Incorrect type of Motor Oil

• Irregular Maintenance

• Slipping Clutch 

• In Diesel applications,  basically anything that causes the engine to run roughly and vibrate excessively for example bad fuel injectors, loss of compression in cylinder etc

Should You Drive With Dual-mass Flywheel Problems?

No, it is not recommended you drive if you are experiencing problems with the dual-mass flywheel as it could be potentially hazardous. Furthermore, it will not only make driving uncomfortable, but it will cause damage to your vehicle and put too much stress on the clutch. We would recommend taking your vehicle to a mechanic as soon as possible.

What Vehicles Have Dual Mass Flywheels Fitted?

Dual-Mass Flywheels are fitted to vehicles and trucks with manual gearboxes. They are often used in high-performance engines, diesel and high-torque petrol engines. 

What Is The Average Lifespan Of Dual-mass Flywheels?

The average lifespan of a dual-mass flywheel is around 80,000 - 100 000 miles. However, this does vary - a lot depends on your driving style, the quality of the part itself and how well you take care of it. If you ride the clutch or shift gears too harshly, you may shorten the lifespan of your flywheel and some DMFs could go bad in as little as 20,000 miles.

Is It Necessary To Change The Clutch With The Dual Mass Flywheel?

If you are replacing your dual-mass flywheel, it is a good idea to replace it together with the clutch as both components are prone to wear out around the same time. Moreover, the clutch disc is designed to work with a specific type of flywheel so using a different clutch disc can potentially cause problems such as premature wear or poor performance. 

Dual-mass Flywheel Replacement Cost

The replacement cost for a dual-mass flywheel is dependent on the make and model of your vehicle, so it does vary. However, it is known to be a fairly expensive component to replace. One of the influencing factors in the high replacement cost of a dual-mass flywheel is that you will need to factor in the cost of a new clutch and clutch disk as well, in addition to labour charge as the replacement should be done by a mechanic. Taking all of this into account, you are looking at quite a sizable replacement bill.

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