Isuzu Trooper Owners Club UK™

[Red Robbo]

Note Retaining ring in centre..Remove and driven half and bearing assembly slide off spigot in driving half.Bearing in mine was fine and is a replacable item.

Back face of driven half.Note drive "Spline" male bit

Drive Spider female bit.4 points engage on free end of springs fixed at there other ends to driving half.Also note where I have tried to drill out rivets holding 2 halves of driving section together.

Note raised sections with friction coating,acts as damper for the assembly



As you can see failure is the breakup of the drive spider,every chain has a weak link  

If this is the common failure mode of the DMF then I think it would be possible to fix driving/driven halves together,either by dowelling or countersunk allen screws without imbalence,but the driving half would need to be split to remove spider and spring assemblys.
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Khotso...........

[Google]

[bazza2541]

How do think it would work if you left the whole inners workings in place and filled the gaps with a liquid nails type adhesive resin before through bolting?

[richard wilkinson]

[bazza2541]

[Gribble]

Whatever you do with it it would have to be dynamically  balanced  after and the runout on the clutch plate friction face runout checked to see it was under ten thou or so .
Whilst the making it rigid and checking the runout might not be too dear the spinning /weight  bit might and its then onto getting a spring type friction plate ,I still think a new ones cheaper if LUK do it and will sell to the club .  
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2 New Troopers !

[bazza2541]

I found a company in Newry, Northern Ireland who specialise in making DMF into solid flywheels.
They quoted me £300 plus £30 carraige to do the flywheel in my 3.0 They also said that it could go straight back in with the standard clutch and that they had already done between 40 and 50 Troopers with no problems.

[Red Robbo]

Spoken to several people over the W/E and just come off the phone to LuK technical support.
The long and short of it is,The 3.0 Engine/Transmission setup NEEDS a DMF.If it breaks its not cheap I know.But if a solid flywheel system were fitted then long term Engine or Transmission damage could occur,both far more expensive options than replacing the DMF.
I'm afraid In my book,after talking to people and musing about it over the weekend,the solid flywheel idea is a non-runner.
1) You need to limit torque takeup & shock to the transmission.
2) The DMF is designed to be harmonious with the engine,remembering we have two balence shafts in there.

Looking at the system logically and what the DMF does within the system,it becomes very apparent it should not be replaced with a solid flywheel system.

Just my take on it,but logic dictates....
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Khotso...........

[Red Robbo]

[Red Robbo]

Final update....cannot find pattern replacement for DMF,however my local mech(Agri/Plant any truck without a 4JX1 Motor   ) has spoken to several motor factors,and some will supply an OE(Isuzu) DMF,cost to customer approx £250 + vat,Quite a significent saving if you're doing it yersen.
Hope this may help..
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Khotso...........

[docstrooper3.0]

i fitted a dmf to a pajero lately that was made solid by a crowd in newry, the original clutch also has springs in it. drove it to test it and to be honest no judder or vibration. now saying that if you took off without a bit of juice you would feel a bit of vibration but a hell of a lot cheaper and reliable as the pajero dmf can fail after 40k.  Now i have a question, i converted 2 troopers and used both dmf but now doing another one but he wants the 3.1 solid flywheel. will the 3litre gearbox fit the 3.1 flywheel spigot bearing?????

[jacksdad1963]

You can buy a solid flywheel conversion but it costs more than a standatd clutch and DMF...
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1999 3.0 TD Duty SWB
3" Body lift, 3" suspension lift, diff dropped, balljoints flipped, extended panhard, Tree sliders, Superwinch, +2" Pro Comps, 33" Mudders: Nearly finished!

[diytrooper]

[diytrooper]

Hi All,
     Just thought I'd add a possible cheaper solution to the failing dmf issue.
First off my trooper is a 3.0 converted to 3.1, but the flywheel and gearbox are the original 3.0 units.
My dmf was on the way out, so before it went completely I took the following action.

I removed the flywheel, removed the pressure plate and separated the driven plate from the dmf

I then drilled out the rivets holding the back of the dmf  together.



Next I drilled and tapped the Driven plate with an M10 Tap



Next using strong bolts I bolted the flywheel together.





I used 3.1 clutch disk which has the springs in it to relieve the pressure on the transmission.







I've done 2000 miles since, no problems, no rattles no vibrations, cost me 10 euro in bits and pieces.

Lets see how long it will last.

[diytrooper]

Apologies for the huge images, I need to find a way to resize those....

[bigb]

superb