Ford Galaxy / Ford S-MAX. Manual — part 498

flywheel.

Do not clean the gap between the primary and

secondary mass. Only clean the bolt connection
surface and the clutch surface.
NOTE: Discoloration is not a reason in itself to
replace the dual mass flywheel.

Remove the clutch disc and clutch pressure plate.

1

Can the secondary mass be turned freely by more than
15 teeth?
Yes

INSTALL A NEW dual mass flywheel.

No

GO to E17

.

E14: CHECK THE SPRING RESISTANCE

Twist the secondary mass in both directions.

1

Can spring resistance be felt in both directions?
Yes

GO to E17

.

No

GO to E15

.

E15: CENTER THE FRICTION CONTROL DISC

Secure the primary side with Special Tool 303-254.
Gradually turn the secondary side in one direction

against the resistance until spring resistance to the
force applied by hand is felt on both sides. If it is
not possible to reach the spring resistance on both
sides, gradually turn the secondary side in the
opposite direction in the way described above.

1

Is it possible to find a middle position with spring
resistance on either side?
Yes

CONTINUE

No

INSTALL A NEW dual mass flywheel.

E16: ROTATION OF THE DUAL-MASS FLYWHEEL

Secure the primary side. Twist the secondary side
in a clockwise direction until spring resistance is

felt and release. Mark the rest position on the
primary and secondary sides. Then twist the
secondary side in a counter-clockwise direction until
spring resistance is felt and release. Mark the new
rest position on the primary side. Count the number
of teeth between the marks for both directions on
the toothed ring.

1

Are more than 5 teeth counted?
Yes

INSTALL A NEW dual mass flywheel.

No

GO to E17

.

E17: CHECK THE DUAL-MASS FLYWHEEL

Perform a visual inspection of the dual mass
flywheel.

1

Is the dual mass flywheel free of damage?
Yes

GO to E18

.

No

INSTALL A NEW dual mass flywheel.

E18: CHECK THE TOOTHED RING OF THE DUAL-MASS FLYWHEEL

Perform a visual inspection of the toothed ring of
the dual mass flywheel.

1

Perform a visual inspection of the toothed ring of the
dual mass flywheel.
Yes

GO to E19

.

No

INSTALL A NEW dual mass flywheel.

E19: CHECK THE WELD SEAM OF THE DUAL-MASS FLYWHEEL

Visually inspect the weld seam of the dual mass
flywheel to check for loss of grease.

1

Is a clear loss of grease visible at the weld seam of the
dual mass flywheel?
Yes

INSTALL A NEW dual mass flywheel.

No

GO to E20

.

E20: GUIDE PINS OF THE DUAL-MASS FLYWHEEL

Check the installation of the guide pins of the dual-
mass flywheel.

1

Are the guide pins for the dual mass flywheel present,

and do they all have the same length?
Yes

GO to E21

.

No

INSTALL A NEW dual mass flywheel.

E21: DISCOLORATION OF THE DUAL MASS FLYWHEEL DUE TO OVERHEATING

Check the dual mass flywheel for discoloration due
to overheating.

1

Is any discoloration evident in the marked area?
Yes

INSTALL A NEW dual mass flywheel.

No

The dual mass flywheel is OK.

E22: ENGINE SELECTION – PETROL ENGINES

1

Does the vehicle have a 2.0L petrol engine or a 2.5L
petrol engine?
Yes

Vehicles with a 2.0L petrol engine

GO to E23

.

Vehicles with a 2.5L petrol engine

GO to E29

.

E23: CHECK THE ROTATION OF THE SECONDARY MASS OF THE DUAL MASS
FLYWHEEL

CAUTIONS:

Do not rework or machine the dual mass

flywheel if it is distorted.

Do not clean the dual mass flywheel with any

kind of liquid. Use only a dry cloth to clean the
flywheel.

Do not clean the gap between the primary and

secondary mass. Only clean the bolt connection
surface and the clutch surface.
NOTE: Discoloration is not a reason in itself to
replace the dual mass flywheel.

Remove the clutch disc and clutch pressure plate.

1

Can the secondary mass be turned freely by more than
15 teeth?
Yes

INSTALL A NEW dual mass flywheel.

No

GO to E25

.

E24: ROTATION OF THE DUAL-MASS FLYWHEEL

Secure the primary side. Twist the secondary side
in a clockwise direction until spring resistance is

felt and release. Mark the rest position on the
primary and secondary sides. Then twist the
secondary side in a counter-clockwise direction until
spring resistance is felt and release. Mark the new

1

rest position on the primary side. Count the number
of teeth between the marks for both directions on
the toothed ring.

Are between 1 and 3.5 teeth counted?
Yes

GO to E25

.

No

INSTALL A NEW dual mass flywheel.

E25: CHECK THE DUAL-MASS FLYWHEEL

Perform a visual inspection of the dual mass
flywheel.

1

Is the dual mass flywheel free of damage?
Yes

GO to E26

.

No

INSTALL A NEW dual mass flywheel.

E26: CHECK THE TOOTHED RING OF THE DUAL-MASS FLYWHEEL

Perform a visual inspection of the toothed ring of
the dual mass flywheel.

1

Perform a visual inspection of the toothed ring of the
dual mass flywheel.
Yes

GO to E27

.

No

INSTALL A NEW dual mass flywheel.

E27: CHECK DUAL MASS FLYWHEEL FOR GREASE LEAKAGE

Visually inspect the weld seam of the dual mass
flywheel to check for loss of grease.

1