New Sachs kits bring simplified sourcing
In response to customer demand, ZF Services UK Ltd is now supplying complete kits containing all of the parts required for a clutch and dual-mass flywheel (DMF) renewal on a variety of vehicles.
Manufactured by Sachs, each ‘ZMS Modul’ kit contains the clutch cover, clutch driven plate and DMF together with new fixing screws and assembly grease. Depending on the application, some kits also include the clutch release bearing or concentric slave cylinder (CSC).
This aftermarket development brings many benefits for the customer. There is a saving in both time and cost by purchasing a boxed kit rather than sourcing parts individually, and the buyer can be sure that all of the kit parts are designed to operate together flawlessly. This also makes the replacement process more straightforward, as correct fitment is assured. A further advantage is the pedigree of the Sachs brand. Sachs ZMS Modul kits contain Original Equipment (OE) parts that major vehicle manufacturers certify for use in their vehicles, meeting their exacting specifications for fit and performance. This is important not only for long-term reliability and maximum product life but also to ensure that the vehicle’s warranty is not compromised.
By contrast, the conversion kits available to retrofit a conventional clutch and flywheel into a vehicle that is designed to use a DMF are not certified for use by vehicle manufacturers, and for good reason. As this type of conversion does not contain the DMF’s efficient multi-spring damping system, it results in engine vibrations being transmitted to the rest of the vehicle, an increase in engine noise, greater stress on the remainder of the drivetrain, and a harsher drive. There are also many reports in the aftermarket of conversion kit components breaking apart after only a few hundreds or thousands of miles. For these reasons, vehicle manufacturers do not endorse the use of conversion kits in place of a genuine DMF.
Like any mechanical component a DMF may develop a fault in service, although contrary to popular belief it is no more susceptible to this than a conventional clutch. Typical examples include scoring from allowing the driven plate to wear down to the rivets or overheating due to excessive clutch slip. Excessive DMF oscillation may cause premature wear to the arc springs within, which typically occurs at very low engine speeds. Driving in too high a gear, allowing the engine to idle for excessively long periods (e.g. to run air conditioning when parked) or frequent engine stalling are common causes. Ensuring adequate maintenance and modifying the driving style are usually all that is needed to significantly extend DMF life.
Less often considered is that faults in other vehicle systems may cause the noise and vibration issues usually attributed to the DMF, some of which may go on to accelerate DMF wear if not corrected promptly. The answer is to follow a systematic approach to fault diagnosis rather than assume at the outset that the DMF is at fault. Motor factors can help here by reminding their customers at placement of order to carry out basic testing of the vehicle’s mechanical and electronics systems before simply replacing the DMF. ZF Services UK offers a training module covering DMF and Vehicle Systems for workshop owners and technicians requiring practical tuition in such diagnostics.
The ZMS Modul range of DMF and clutch kits currently comprises 40 lines covering more than 60 applications, ranging from superminis to four-tonne light commercial vehicles. Marques catered for include Audi, Citroën, Ford, Mercedes, Peugeot, Seat, Skoda and VW, and the range is expected to expand further as customer demand grows.