Rav4 2.0 Turbo Diesel - Dmf Broken In Malawi !

[mbf001]

Hello All,

URGENT - Sick RAV4 in Malawi

I am writing from the UK on behalf of a young doctor friend who has recently gone to Malawi to assist in delivering medical care for people in remote regions.,,,gutsy girl. She purchased a used 2.0 Diesel RAV4 here and exported it for use in Malawi. Apparently it's one of the vehicles of choice but they're rare as hens' teeth tto purchase there.

PROBLEM

Dual Mass Flywheel (DMF) has failed and vehicle out of action so she can't deliver her medical assistance to the remoter areas. As can be imagined, the facilities for repair there are not exactly easy to obtain.

QUESTIONS

1. Should she replace the DMF with a Single Mass Flywheel - future reliability being the main issue?

2. Should she replace the clutch at the same time?

3. What is the most robust & reliable option, e.g. what brand/make/model is best for 1. & 2. above?

4. Is there a complete 'kit' with all new fixings etc. for the above?

5. What sort of price should be paid for good quality replacement parts?

6. Does anyone know of a reliable supplier who can and will export the parts and provide some good, old-fashioned, genuine after-sales customer care & follow up if required.

7. Do you have any other relevant useful advice?

She has a local 'mechanic' (quality unknown) but obtaining parts there is problematic.

For obvious reasons I am waiting for her to inform me of the precise RAV4 model details.

Many thanks in advance.

[Big Kev]

Hi mbf and welcome to the forum.......we have a superb parts guy hereon whose company may (or may not be able to.....nae pressure Kingo aka Parts King at Lindop....sorry to do this on open forum.....) be willing under the circumstances to help get these parts to you. Use the Personal Mail system and let me know how to get a wee contribution towards said bits to you or her.....good on ya girl !!!!!

Links between Glasgow and Malawi are very strong so besta luck.....YES DO CLUTCH AT SAME TIME......single mass flywheels are considerably cheaper and some members have had success with them, others not so positive.

Big Kev

[crofter]

Why, o why, does the bad luck always fall on the good peeps ???

[Big Kev]

Why, o why, does the bad luck always fall on the good peeps ???

Spot on Del min.....got some friends going to very same place shortly to do similar, so apologies for trying to get others to sponsor along with my now willing "double whammy" of interest.

Big Kev.....ALL ROUND good guy.....don't argue.....

[redlew]

If a DMF replacement including labour is (say) £2000 , how much extra is it to get the clutch done at the same time, please?

[avensisd4d786]

Hello All,

URGENT - Sick RAV4 in Malawi

I am writing from the UK on behalf of a young doctor friend who has recently gone to Malawi to assist in delivering medical care for people in remote regions.,,,gutsy girl. She purchased a used 2.0 Diesel RAV4 here and exported it for use in Malawi. Apparently it's one of the vehicles of choice but they're rare as hens' teeth tto purchase there.

PROBLEM

Dual Mass Flywheel (DMF) has failed and vehicle out of action so she can't deliver her medical assistance to the remoter areas. As can be imagined, the facilities for repair there are not exactly easy to obtain.

QUESTIONS

1. Should she replace the DMF with a Single Mass Flywheel - future reliability being the main issue?

2. Should she replace the clutch at the same time?

3. What is the most robust & reliable option, e.g. what brand/make/model is best for 1. & 2. above?

4. Is there a complete 'kit' with all new fixings etc. for the above?

5. What sort of price should be paid for good quality replacement parts?

6. Does anyone know of a reliable supplier who can and will export the parts and provide some good, old-fashioned, genuine after-sales customer care & follow up if required.

7. Do you have any other relevant useful advice?

She has a local 'mechanic' (quality unknown) but obtaining parts there is problematic.

For obvious reasons I am waiting for her to inform me of the precise RAV4 model details.

Many thanks in advance.

hello, the single flywheel option is a after-market conversion.

Toyota will advise not to do the conversion as its fitted with a dmf for a reason.

Im pretty sure the rav4 and avensis share the same engine. quote me if im wrong (1cd-ftv)

Like big kev has advised there are mixed views on the smf or dmf.

I asked the question before and this is the response I got.

'My advice - DON'T go down the solid flywheel route. I did it and regret it. The Avensis has a DMF for a reason as the springs in it dampen the clutch shudder. My nice smooth car has become a nightmare to drive in traffic and no matter how slow or fast you let the clutch out you can never get it right!!

Spend the extra hundred quid and get the DMF version - just my opinion of course.

Here is a another answer from Kingo(lindop toyota)

'DMF's are fitted for a reason, to reduce and dampen the effects of vibration throughout the lump of a diesel engine. Now it could be argued that it is not necessary, but manufacturers dont spend a chunk of money in R&D to go on and fit a DMF if its not needed. There have been a few people on here that have fitted solid flywheels, but the long term effects on the vehicle are an unknown quantity, so you pays yer money......................

Kingo '

if you put into google toyota single mass flywheel into google you will find plenty of results.

I would change the clutch the clutch at the same time aswell.

Try your local toyota dealer. you could always get the parts and post them your self.

try http://www.eurocarparts.com, they do international shipping, try giving their export number a ring for prices.

Rest of World

If you are outside of Europe or your country isn't listed above, please don't worry as we can still help you!

Please select your parts and check out normally selecting your country; we'll then weigh your parcel and email you with the additional delivery charge. We can then proceed with your order once you have confirmed the additional charges.

We endevour to despatch all international parcels using the most cost effective methods, we'll use a number of couriers to find you the best deal.

Alternatively you can call the export team on +44 (0) 870 150 6506, and they will be happy to help with your enquiry and quote to export outside of the UK.

or http://www.andrewpage.com/content/10/contact_us

its always handy if you get prices on trade.

bit more info:

http://www.honestjohn.co.uk/faq/dual-mass-flywheels/

I hope this helps.

[Big Kev]

Stonking input there.....

Big Kev

[mbf001]

Thanks Guys

It looks like most of you so far do NOT believe that the DMF should be converted to a solid one and that a DMF should be re renewed with a new clutch at the same time.

That leaves three of original questions unanswered:

3. What is the most robust & reliable option, e.g. what brand/make/model is best?

4. Is there a complete 'kit' with all new fixings etc. for the flywheel and clutch?

5. What sort of price should be paid for good quality replacement parts?

I am waiting for complete spec/model and year of the RAV4 in Malawi but there's a power failure in the village just now. Hopefully they'll fix it and I'll get an email tomorrow. If so, I'll post details here asap after I receive it.

Cheers,

mbf001

[Davrav]

3 - in this situation I would favour a genuine Toyota replacement if it can be obtained/sent/received

4 - pretty sure DMF is one kit and clutch is another

5 - you need to contact Kingo for a discounted price for comparison

[mbf001]

3 - in this situation I would favour a genuine Toyota replacement if it can be obtained/sent/received

4 - pretty sure DMF is one kit and clutch is another

5 - you need to contact Kingo for a discounted price for comparison

Hi Davrav,

Thx for your reply.

Re Item 3: As the original DMF was obviously a Toyota part and it broke so catasrophically it seems to me that their Quality Control might be not as good as it should be. On various other sites there are numerous reports of owners who have suffered (they say) from the same issue at low mileages.

As a non-specialist it's difficult to make a judgement though.

Ta

mbf001

[avensisd4d786]

Thanks Guys

It looks like most of you so far do NOT believe that the DMF should be converted to a solid one and that a DMF should be re renewed with a new clutch at the same time.

That leaves three of original questions unanswered:

3. What is the most robust & reliable option, e.g. what brand/make/model is best?

4. Is there a complete 'kit' with all new fixings etc. for the flywheel and clutch?

5. What sort of price should be paid for good quality replacement parts?

I am waiting for complete spec/model and year of the RAV4 in Malawi but there's a power failure in the village just now. Hopefully they'll fix it and I'll get an email tomorrow. If so, I'll post details here asap after I receive it.

Cheers,

mbf001

Stonking input there.....

Big Kev

thank you big kev, may help someone in the future.

all your questions were you answered all you had to do is click on the links. but will i make it more simplier for you.

1.make sure you dont get the chinese copys. i would go for OE quality. I'd go for one with the most years guarantee. LUK seems to be popular with the taxi drivers round here. im pretty sure avensis and corolla share the same engine.1cd-ftv as mention before if its 2003-2006 model.

2.they dont come with as a 'complete kit' but i see some people on eBay are offering it as a kit, I gave you a link for www.eurocarparts.com you can get prices of there.

please click on the link i have put the car as rav4 2.0 diesel.

http://www.eurocarparts.com/clutch-kit

ranging from 60-180 depending on make.

flywheel

http://www.eurocarparts.com/flywheel

400-600 again depending on make

I have spent alot of time trying to help you and all of it is advice only its upto you if you take it.

:D

[mbf001]

Details of RAV 4 in Malawi...at last:

Model: Rav4 XT-R D-4D

1995 cc

Manual Transmission.

VIN: JTEYG20V500035859

Big Kev,

Your pointers to eurocarparts and I think it was you who mention the LuK make, have been gratefully received. Checking back through what I previously wrote in this 'thread' I dunno if or how I have ruffled yer feathers.

One thing that is very difficult for me to judge is the differences in quality of DMFs made by different after-market manufacturers. It seems to me that the original Toyota part is a bit below par because of the number of people who have had problems with it. But then, some say it's just the way that DMFs are, i.e. they're all 'flakey'.

My intention was and still is to find out the experiences others have had with different suppliers of DMFs and if any brand of replacement should be favoured. I owe it to the Doc out there to get as much info as possible so that the best part and manufacturer can be chosen.

I do not hold you responsible for the generous advice you have provided. Thanks again. It is greatly appreciated, together with that from all other contributors.

[Big Kev]

Not my feathers me ol' mucker.....ye must mean the previous poster, avensis.....etc.....my name just appears as linked.....nae bother min.

Big Kev

[Parts-King]

The DMF and clutch is one very very hefty lump (in weight terms) and unless you have courier contacts, sending a DMF might cost as much as the ruddy parts!

My advice is to go DMF, NOT a single flywheel and a new clutch at the same time. you takes your choice on manufacturer, genuine or pattern. The whole DMF situation could be described as flakey but you have to consider the job these things do, we all want powerful diesels that are super smooth to drive, but a diesel (in general) is one big unrefined lump of a motor and the DMF is there to iron out the huge vibrations these engines cause

Kingo

[Davrav]

How many miles has this car done on what, I presume, is the original DMF? That would be a guide as to what could be expected from a direct replacement.

As has been said, the DMF is there for a reason and I'm guessing that the biggest proportion of those who have had success with an SMF conversion have not been driving around on the type of roads found in the hills of Malawi [or even the backstreets of Glasgae]

I imagine a broken crankshaft or a stripped gearbox would be terminal in the wilds of Malawi.........................

I guess a lot depends on how long the good Doc wants to be using the RAV

Just a thought

[Tech01]

If I can throw my two-pennyworth in...

2003 RAV4.2 D4D

Original DMF failed at around 50k miles. Replaced with "modified new-type" genuine Toyota replacement. This failed too after a further 20k miles. The DMF design, from whichever manufacturer, still seems to remain flawed, and is now regarded as a "consumable part"!

We fitted a Blueprint SMF kit (replacement standard one-piece flywheel, conventional sprung clutch plate, clutch cover + thrust bearing). Car drives really well, clutch control is perfect (which DMF never was - always difficult on very steep hill starts, or backing uphill), and no increase in vibration.

Not sure about Malawi, but our RAV is driven daily on rocky mountain and dirt tracks here in Spain, as well as normal tarmac and high-speed motorway runs, and through mud and river beds in winter.

No-one seems to have complained about the Blueprint 4-part kit (ADT-330206 for our vehicle), which is available worldwide (Google ADT-Blueprint).

Chris

[avensisd4d786]

according to the vin on http://www.toyodiy.com(just incase you needed more info)

keep that website in your favourites may come to use in the future regarding parts/numbers etc.

Market Europe,General

Year 08/2005

Make TOYOTA

Model RAV4

Frame CLA20

Vehicle characteristics

DESTINATION: EUR: EUROPE DRIVER'S POSITION: RHD: RIGHT-HAND DRIVE ENGINE: 1CDFTV: 2000CC DIESEL TURBO TRANSMISSION: MTM: MANUAL TRANSMISSION COLOR CODE: 1D4 TRIM CODE:

FA11

taken from eurocarparts.

Dual Mass Flywheel

Most vehicle manufacturers now use dual mass flywheels to help reduce engine vibration and eliminate the transmission of that vibration to the drive train. This has been done mainly for driver comfort but also helps with fuel economy and in some cases helps to protect certain parts of the transmission. Because of the moving parts in a Dual Mass Flywheel they are much more likely to fail than a Solid Flywheel.

ECP would always recommend the fitment of a new clutch at the same time as replacing a Dual Mass Flywheel and always to replace a Dual Mass Flywheel if the vehicle is fitted with one when replacing the a clutch.

Because of the type of product this is and where it fits it is important to take notice of engine codes and BHP when using the catalogue to look your vehicle up.???ÿ When you receive your Dual Mass Flywheel it is always advised that you check the crank sensor pick up points are the same as your old Flywheel before fitment

[igormus]

Hello All,

URGENT - Sick RAV4 in Malawi

I am writing from the UK on behalf of a young doctor friend who has recently gone to Malawi to assist in delivering medical care for people in remote regions.,,,gutsy girl. She purchased a used 2.0 Diesel RAV4 here and exported it for use in Malawi. Apparently it's one of the vehicles of choice but they're rare as hens' teeth tto purchase there.

PROBLEM

Dual Mass Flywheel (DMF) has failed and vehicle out of action so she can't deliver her medical assistance to the remoter areas. As can be imagined, the facilities for repair there are not exactly easy to obtain.

QUESTIONS

1. Should she replace the DMF with a Single Mass Flywheel - future reliability being the main issue?

2. Should she replace the clutch at the same time?

3. What is the most robust & reliable option, e.g. what brand/make/model is best for 1. & 2. above?

4. Is there a complete 'kit' with all new fixings etc. for the above?

5. What sort of price should be paid for good quality replacement parts?

6. Does anyone know of a reliable supplier who can and will export the parts and provide some good, old-fashioned, genuine after-sales customer care & follow up if required.

7. Do you have any other relevant useful advice?

She has a local 'mechanic' (quality unknown) but obtaining parts there is problematic.

For obvious reasons I am waiting for her to inform me of the precise RAV4 model details.

Many thanks in advance.

Hi Matey

PLease contact -- http://www.toyotamalawi.com/contacts.html

THey might to help when urgent assistance is required or even recommend scrap cars to take spares.

Tell us how you get on

Good luck

Igor

[mbf001]

All - Wow,

Plenty of great advice from all. Many thanks.

DavRav - From memory, I think the Malawi based RAV4 had done about 65K You'r right re Malawi tracks - big time wear & tear. Night-time breakdowns mean stay in the car until morning....unless you relish being something's snack.

Avensis 4d786.- Good point re the crank sensor pickup points

Tech01 - Your recommendations re the Blueprint SMF kit are appreciated.

Big Kev - Yours too. I'm glad I didny upset the laminar airflow o'er yur feathers.

Still, some say go the DMF route others recommend the SMF.

I know, I know - it's the Doc's choice so maybe she should digest this stuff, spin a coin and go ferrit. I sorta favour going the DMF because that's how the engine gearbox was designed to work. I could be wrong tho.

Streuth, I long for my old Landrover now. An 'ammer, a screwdriver, a shifter and some effort and just about anything could be hashed up as a 'get me home' fix. Only downside was cracked vertbrae.

Have a luke-warm pint of e-beer on me lads

[mbf001]

Parts-King

Apologies for missing you out in my last post.

It wasn't deliberate and somehow I know you won't cry about it.

Cheers matey