2000 Ducato 2.8L (v230) IdTD (IVECO Tranny)

I'm sitting in a garage in France. They just started the clutch replacement and noticed that the flywheel is quite burnt. So I said okay to a new flywheel.

Now they have told me that the 98452703 flywheel is extinct! I have looked all over the internet but found them to be right except for some used parts from Poland but with the number 7450498. I don't know that is the exact compatible part number but it sure 'looks' the same.

In any case, they propose to get me back on the road tomorrow by resurfacing my original flywheel. Sounds reasonable enough given the non-ability to find an OEM replacement and only used parts out there that will take a week to get to this garage. Bad timing as I am just traveling through France at the moment.

I am committed now, the flywheel just went to the machinist, but I just wanted to post this in hopes of some reassurances that I have done the best possible thing. (For the next time, and anyone that faces the same ordeal)

Hi

That sounds sensible..

In essence its akin to an overheated brake disc..
You can change the friction material.. but it would have a hard time with the 'abused' surface

How far has the van travelled.. ?

100..200..300k ??

Thank you for the encouragement! I feel better today as I have seen my re-machined flywheel and it looks like a new one. The disc surface is beautiful and it appears that they only removed a few microns!

I have 330,000 Kms from new on the engine. This is the 3rd clutch kit. I also replaced the right and left trans axles (with the CV's as one unit) in this repair service as I have never replaced the CV's in all of these kilometers and there was a bit of looseness.

Thanks again!

umanemo said:

Thank you for the encouragement! I feel better today as I have seen my re-machined flywheel and it looks like a new one. The disc surface is beautiful and it appears that they only removed a few microns!

I have 330,000 Kms from new on the engine. This is the 3rd clutch kit. I also replaced the right and left trans axles (with the CV's as one unit) in this repair service as I have never replaced the CV's in all of these kilometers and there was a bit of looseness.

Thanks again!

Click to expand...

Good for you .
It is becoming increasingly difficult to find machine shop in UK to resurface flywheel for a reasonable fee rather than a few approaching the cost of a new flywheel.
If you don't mind telling how much did the flywheel work cost?

An OEM FIAT part priced the 'new' flywheel at over £500 here in France. The garage had a machine shop 'renew' my part for £75. Due to the integrity of the garage and my time constraints I authorized the remanufactured flywheel even before I knew the cost. I was very satisfied.

That seems like a lot of clutches for the mileage. It equates to around one every 66,000 miles.

With the burnt flywheel face, the clutch has been slipping a lot before final failure.

Do you tend to rest your left foot on the pedal in normal driving? Even slight pressure can lead to clutch slip. Foot needs to be completely off the pedal unless moving away, stopping or changing gear.

umanemo said:

An OEM FIAT part priced the 'new' flywheel at over £500 here in France. The garage had a machine shop 'renew' my part for £75. Due to the integrity of the garage and my time constraints I authorized the remanufactured flywheel even before I knew the cost. I was very satisfied.

Click to expand...

£75 is not bad at all being done quickly so I would say it's a big win.

portland_bill said:

That seems like a lot of clutches for the mileage. It equates to around one every 66,000 miles.

With the burnt flywheel face, the clutch has been slipping a lot before final failure.

Do you tend to rest your left foot on the pedal in normal driving? Even slight pressure can lead to clutch slip. Foot needs to be completely off the pedal unless moving away, stopping or changing gear.

Click to expand...

Good advice for all to be sure, but it's just normal wear for a twenty year old Ducato that's climbed all of this continent's highest passes, Nemrut Dagi was 20Km's at 15%, and remember that these are very under-spect'd platforms. These chassis are held to the EU's limitations of their citizens driver's licenses. It is a shame but EU citizens have a 3.5 ton license cap. We, in America, have a liberal limit for a standard license, GVWR of 23,001 pounds (10,455Kg) or 'any' RV and our RV chassis have that built-in leeway. But in the EU that places the burden on the RV manufacturer's to maximize their product with little regard for their power to weight ratio's. Plain and simple, the little engine that could does work very hard as does the frequently overweight burdened clutch. A flywheel at over 200,000 miles would probably be pretty much spent on any chassis. But also as I am sure you are aware, all clutches slip, that's their job - right? It's just a more delicate escape that we are more comfortable with in our vehicle operation, that being due to the fact that we are moving around a house full of Waterford crystal and Burleigh chinaware. In our world, once the inertia is smoothly achieved, it is a guarantee that the left foot takes a rest, of course that's how we were all taught how to operate a manual transmission, weren't you? As for me, I used to race top-fuel but I retired my helmet, burn suit and my drag racing days 45 years ago.

It is recommended to machine the flywheel if you replace the clutch.
Specially if the visual inspections reveals issues with the flywheel.

IceVovo said:

It is recommended to machine the flywheel if you replace the clutch.
Specially if the visual inspections reveals issues with the flywheel.

Click to expand...

Never heard that one before. Seems a bit over the top for a normal clutch replacement. If done more than once, could cause issues with release as the clutch effectively moves away from the gearbox.

Only time I've ever seen a flywheel refaced was to sort damage, otherwise, clean and reuse.

On the upside, a lighter flywheel might make it rev faster.

It is generally recommended to replace the rear crankshaft seal whilst you have the clutch out also.

...which means removing the flywheel.

...but you don't have to do any of the recommendations.
They are general to all vehicles.

Note. My van has a flywheel and flexplate.