Shogun 3.2 DID Dual Mass Flywheel - Help!!!
Discussion
I have a problem with my 2002 DID SWB Shogun. She has done 117k, but is much loved and has full every 9k Main dealer (ha for what its worth 
but thats another lengthy story!!
) service history. She did the usual (or so I understand as being usual) Clutch bust at 50-60k and this was 'replaced' (although this was done by a main dealer under used car warranty and Im not sure which parts or all were replaced).
We now have problems, on starting she lets out a lengthy 'grinding' noise (clutch in or out). She also - now forgive me for my highly technical description here - grinds comes makes a semi 'stall' noise when pulling of in either reverse or first. This also occurs in low box. It does seem to be bad, very bad, and earth shattering at times and varies between the three.
However there is no sign of the clutch slipping and she is smooth through the rest of the gears.
My other half is a mechanic and is stumped - as are various other consulted parties; options come up with so far,
Clutch - sounds simple enough - however it is another opinion that the 'Grinding' is too 'Violent' to be this. £300 is a bit much to splash out on a maybe!!
Engine Mounts - however there seems to be no play in these.
Ahem and finally....... FLYWHEEL -
Right was hoping it wasnt this but am now swaying towards it being the Dual Mass flywheel breaking up. Main dealer only part at £1500+
so not looking forward to it. This has got me thinking though, whats to stop me welding the inner of the DMF to the outer then having it balanced? Now this relies on both parts being steel, doubt they would be cast but nothing would surprise me.
I know this would not be ideal as not having the DMF being able to balance itself any longer may put more stress through the crank but i dont know if it would or by how much? Has anyone tried bodging one up before if so how did it go?
God knows why they decided that after 100 odd years they decide that flywheels needed changing ? progress my ass!!
Also anyone removed a gearbox - how hard?? Stories, Advice etc please!!
Many Thanks
Kim & Don
but thats another lengthy story!!) service history. She did the usual (or so I understand as being usual) Clutch bust at 50-60k and this was 'replaced' (although this was done by a main dealer under used car warranty and Im not sure which parts or all were replaced). We now have problems, on starting she lets out a lengthy 'grinding' noise (clutch in or out). She also - now forgive me for my highly technical description here - grinds comes makes a semi 'stall' noise when pulling of in either reverse or first. This also occurs in low box. It does seem to be bad, very bad, and earth shattering at times and varies between the three.
However there is no sign of the clutch slipping and she is smooth through the rest of the gears.
My other half is a mechanic and is stumped - as are various other consulted parties; options come up with so far,
Clutch - sounds simple enough - however it is another opinion that the 'Grinding' is too 'Violent' to be this. £300 is a bit much to splash out on a maybe!!
Engine Mounts - however there seems to be no play in these.
Ahem and finally....... FLYWHEEL -
Right was hoping it wasnt this but am now swaying towards it being the Dual Mass flywheel breaking up. Main dealer only part at £1500+
so not looking forward to it. This has got me thinking though, whats to stop me welding the inner of the DMF to the outer then having it balanced? Now this relies on both parts being steel, doubt they would be cast but nothing would surprise me. I know this would not be ideal as not having the DMF being able to balance itself any longer may put more stress through the crank but i dont know if it would or by how much? Has anyone tried bodging one up before if so how did it go?
God knows why they decided that after 100 odd years they decide that flywheels needed changing ? progress my ass!!
Also anyone removed a gearbox - how hard?? Stories, Advice etc please!!
Many Thanks
Kim & Don
my mini had a similar problem and it was found to be the duel mass flywheel the centre of the flywheel was just rotating about half way round inside. Apparently they are quite common, mine did clunk when driving if I put my foot down. Could be a broken spring on the flywheel... tbh you need to have a look see.
I have recently change to a solid flywheel and its fine but does rattle around when stationary out of gear.
I have recently change to a solid flywheel and its fine but does rattle around when stationary out of gear.
Edited by RKDE on Monday 30th March 08:43
DMF's are mainly there to damp out torsional vibration of the crank and typically shut things up a bit ( geabox input shaft rattle etc.
Now potentially if you're not damping these vibrations you may have something nasty happen like the nose of crank fall off.
It all depends on how optimised your engine is however on most stuff it'l just rattle a bit more
Now potentially if you're not damping these vibrations you may have something nasty happen like the nose of crank fall off.
It all depends on how optimised your engine is however on most stuff it'l just rattle a bit more
A common cause of failiure on this is the flywheel centre bearing,this can cause DMF failiure and also destroy the layshaft,I would not use it until you can check it ,it may only need a centre bearing,The Dmf and all the clutch parts are available on the aftermarket,if you need any more info give me a poke.Tempus 
Alright Winston,
I worked as a tech in a mitsubishi dealer for a few years and im quite familiar with this particular problem.
It certainly sounds like the flywheel is knackered or if not very nearly. We had a few customers that went off to get it welded and balanced etc, but a lot have commented on the difference in smooth drive take-up. i even remember one guy who even replaced it with the genuine item in the end.
With reference to the gearbox, the manuals are ok to get out, you just need four strong people to get it in and out.The top bell housing bolts can be a pig aswell. Also i cant remeber if its the diesel or petrol variant that has the horrible clip on the release bearing.
I worked as a tech in a mitsubishi dealer for a few years and im quite familiar with this particular problem.
It certainly sounds like the flywheel is knackered or if not very nearly. We had a few customers that went off to get it welded and balanced etc, but a lot have commented on the difference in smooth drive take-up. i even remember one guy who even replaced it with the genuine item in the end.
With reference to the gearbox, the manuals are ok to get out, you just need four strong people to get it in and out.The top bell housing bolts can be a pig aswell. Also i cant remeber if its the diesel or petrol variant that has the horrible clip on the release bearing.
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