Ford Focus Estate 2008 1.6tdci 109ps to 133ps - Converting from DMF to RIGID flywheel - 3uga

Hi!

In the future i will need a new flywheel for my car because the dmf has wear but still working , with no noise. As a user that had 3 DMF fail untill now, I can feel when the DMF is at its last.
I found a Valeo conversion kit wich from what i've hear, it has no auto ajustable presure plate, springs on clutch disk.I think that means clutch pedal wont feel the same though the life span of the cluth disk as it wears out, and that realy doesent mater to me.

I want to know what could be the pros and cons of using this type of clutch asembley on long term use. I mean will it stress out the gearbox, does it have a impact on fuel consumption and will I lose torque or power (DMF working somehow as a torque converter as it offers a constant flux of energy to the gearbox)
Car was recently remaped to 133ps

Thank you !

Edited by 3uga on 06/05/2017 at 16:53

Ford Focus Estate 2008 1.6tdci 109ps to 133ps - Converting from DMF to RIGID flywheel - RobJP

Right.

Diesel engines produce lots of torque. That's why most people like the feel of them - that 'wall' of torque that you have from lowdown right through the rev range.

The DMF is there to act as a shock absorber for that torque - especially in low gears - otherwise that torque would be sent straight to the gearbox.

Remove the DMF, and you WILL end up tearing the gearbox apart. If you're the type of driver who has managed to go through 3 DMFs so far (I've been driving diesels almost exclusively, doing 30k+ a year for the last 15 years, and not managed to wreck one yet), then I'd expect the gearbox life expectancy to be a couple of years at most. Possibly just a few months, especially with the remap.

Rebuilding a gearbox is a lot more expensive than replacing a DMF.

Ford Focus Estate 2008 1.6tdci 109ps to 133ps - Converting from DMF to RIGID flywheel - 3uga

Thanks

Ford Focus Estate 2008 1.6tdci 109ps to 133ps - Converting from DMF to RIGID flywheel - RichardW

If you've re-mapped a Ford/PSA 1.6 16v diesel to 133 BHP you won't have to worry about the DMF for too long, as the engine will probably eat itself!!

The DMF doesn't reduce torque to the gear box, rather it smooths out the torque peaks as each cylinder fires. Removing it can lead to an increase in noise, vibration nd harshness (NVH). Many people that changed to a conventional solid flywheel found that the crank shaft snapped soon after! However, by the sound of it you are talking about a Valeo Kit 4P or equivalent. This is more than just a solid replacement - the clutch plate has singificant rotational flex built into it to take up the former role of the DMF - it is however less than the DMF, so you may find an increase in NVH. Best to treat the DMF with kid gloves, and it should keep going - don't allow the clutch to heat up, so no holding it on hills, and don't let it slip too much as you take up the drive. Don't sit with your foot on the clutch either, as modern release bearings are built down to a (cheap!) price. Note also that changing the clutch on one of these is a PITA as the DMF / Cat has to come out to get access to one of the bell housing bolts, and that often means draining the cooling system and removing the rad.....

Ford Focus Estate 2008 1.6tdci 109ps to 133ps - Converting from DMF to RIGID flywheel - 3uga

I'm hoping that the car will last me more than what was up untill now.
I re-mapped the car specialy to get rid of post injection wich was blowing my turbos, 3 of them in the last year. The added horsepower was something that came at resonable price while getting rid of post injection.
I'm not using the full power of the car all the time, but ocasionaly i floor it, so I'm hoping that engine wont suffer.

Ford Focus Estate 2008 1.6tdci 109ps to 133ps - Converting from DMF to RIGID flywheel - gordonbennet

Post injection?, a new one on me, what on earth is that?

Not unusual for this engine to eat turbos, but it's for other reasons and this site and the whole motoring world on the internet is overflowing with threads on this engine and its appetite for turbos.

Ford Focus Estate 2008 1.6tdci 109ps to 133ps - Converting from DMF to RIGID flywheel - 3uga

Post injection for burning acumulated soot in dpf.

It is the reason that this car is eating that many turbos. The last one wasnt loosing oil. The VNT vanes melted and were thrown out in the CAT. the turbo was deformed and looked like and old, dried up rose. The vanes that have not melted off were deformed touards the ground.

Edited by 3uga on 06/05/2017 at 23:55

Ford Focus Estate 2008 1.6tdci 109ps to 133ps - Converting from DMF to RIGID flywheel - gordonbennet

Thanks for that, never realised that regens could cause such damage, is the model known for this particular reason for turbo destruction or is yours unusual?

Edited by gordonbennet on 07/05/2017 at 00:24

Ford Focus Estate 2008 1.6tdci 109ps to 133ps - Converting from DMF to RIGID flywheel - 3uga

This is the main reason.
Also, got to eliminate the metalic filter form banjo bolt located on oil feed pipe(engine side). To get banjo bolt off, you got to remove DPF.

Ford Focus Estate 2008 1.6tdci 109ps to 133ps - Converting from DMF to RIGID flywheel - gordonbennet

Thanks, another black mark for this engine in my book.

Ford Focus Estate 2008 1.6tdci 109ps to 133ps - Converting from DMF to RIGID flywheel - 3uga

Heard their quite good if you lose the regen.

From what i've heard euro5 does not have the eolys sistem and engines do not have that high rate of turbo fails. It has something to do with a more agressive regen on euro 4 wich should be shorter by using the additive. The problem apears when regen is unsuccesfull and ecu continues to do it.


Know someone who has an Audi A6 3.0 TDi. Ended up getting a new engine after the old one got 2 melted pistons and stuck open injectors form regen. I know, other engine, other manufacturer, other regen sistem. The ideea is that a blocked DPF is unhealthy for an engine and the regen is what kills your engine.

Thank you for the time!

Edited by 3uga on 07/05/2017 at 00:53

Ford Focus Estate 2008 1.6tdci 109ps to 133ps - Converting from DMF to RIGID flywheel - Big John

Know someone who has an Audi A6 3.0 TDi. Ended up getting a new engine after the old one got 2 melted pistons and stuck open injectors form regen. I know, other engine, other manufacturer, other regen sistem. The ideea is that a blocked DPF is unhealthy for an engine and the regen is what kills your engine.

Thank you for the time!

The other bit of a regen that starts killing your engine is injected diesel falling past the piston rings when an engine has a bit of wear - diluting engine oil with diesel (not a great lubricant). If this becomes really bad and the engine oil level substantially raises with diesel all sorts of problems ensue including potential engine runnaway when engine starts running on it's own sump oil - commonly know as bang!

This was a serious problem on some early DPF installations but fortunately later designs have exhaust manifold close coupled DPF's that are much more likely to achieve passive regen (without injecting diesel!) and where if active regen is required this is much more efficient/quicker.

Edited by Big John on 07/05/2017 at 22:41

Ford Focus Estate 2008 1.6tdci 109ps to 133ps - Converting from DMF to RIGID flywheel - bathtub tom
diluting engine oil with diesel (not a great lubricant).

It used to do a reasonable job of lubricating old fashioned, mechanical injection pumps.

 

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