Sealey VS019 - Manual (Page 2)

fig.1
4. oPeRation
4.1 Remove gearbox from the vehicle as per the manufacturer's instructions.
note: The dual mass flywheel is in two parts of which, one half is connected to the gearbox and thus will be removed
when the gearbox is removed from the vehicle, and the other is connected to the crankshaft. Testing is carried out on the
engine side.
4.2 TEST 1: TESTING THE ROTATIONAL ARC SPRINGS/DAMPER SPRINGS FREE PLAY (Refer to figs. 2 & 3)
4.2.1 Attach the slotted bar (1) across the flywheel using the adaptors (2) supplied so that the angular torque gauge (3) is in
the centre of the flywheel, see fig.2. If the flywheel has an odd amount of fixing screws, see fig.3, it is not possible to
mount centrally and a reading will have to be taken by counting the ring gear teeth movement then working out the
degrees of free play (see below).
4.2.2 Lock the flywheel using the Ring Gear Locking Tools (7) to stop the flywheel rotating under test. Spacers/washers may
be required to align the locking tool with the ring gear.
4.2.3 Lightly (using the palm of your hand) turn the Slotted Bar (1) in either direction by the handle to find (start to compress)
the Arc spring inside the flywheel. Then remove the pressure and allow the flywheel to return to the rest position. Zero
the angular torque gauge (3) and lightly rotate in the opposite direction to find the opposite spring, then allow the flywheel
to return to the rest position, then take a reading from the degree plate. When rotating, a thud may be heard which is
common and not a faulty flywheel.
note: The Arc springs are packed in grease, so a small amount of grease from the vent holes is normal but excessive
grease will mean that the flywheel needs replacing.
4.3 TEST 2: TESTING THE CENTRE BEARING/BUSH FOR WEAR- ROCK (REFER to fig.4)
4.3.1 Fit DTI gauge (4) using the bracket provided (5) to the engine and locate the DTI tip onto one of the adaptors (2) that is
holding the Slotted bar (1) onto the flywheel. Pre-load the DTI gauge, pull the slotted bar handle gently towards you and
set the DTI gauge to zero. Then gently (using finger and thumb) rock the slotted bar handle back and forth to check the
wear in the bush, taking the reading from the DTI. When checking for wear we are checking for rock not end float which
on some flywheels is normal.
4.3.2 Once the two measurements have been taken, it is important to check the tolerance to the specific vehicle being worked
on using the manufacturer's specifications. If the measurement exceeds the manufacturer's specifications the Dual Mass
Flywheel will need to be replaced.
Examples of readings are: Maximum Freeplay 15° and Maximum Rock 1.6mm, but tolerances will vary depending on the
vehicle being worked on.
Calculation for degrees rotation by counting the flywheel teeth (example)
If a flywheel has 112 teeth and freeplay is 4 teeth.
360degrees/112teeth = 3.214 X 4 = 12.85 degrees
VS019 ISSUE No:1 - 20/06/13
Original Language Version © Jack Sealey Limited