Santa Fe (CM - 2007-12) :: Loud Clatter From The Flywheel (dual Mass)

I know I am stating the obvious but a clutch job on a 2010 Santa Fe CM (diesel) takes a lot of time.

My brides Santa Fe has over 280,000 km (175000miles) and has had the loud clatter from the flywheel (dual mass) for quite some time and more recently the pedal started to remain on the floor and the 'fix' of bleeding and flushing new fluid through the system stopped being effective. When a leak from the slave developed I was forced to accept that I would have to either fix or sell the vehicle.

By far the biggest obstacle I found was the non availability of a workshop manual to guide the task as it would no doubt speed the process massively for a number of reasons, some of which are listed below:

* Having a structured step by step procedure to follow, showing hidden bolt placement, torque settings, specific tools required and little tricks.

* By allowing one to assess the extent of the task and determine if one has the time/skillset/tools to deal with it would be great.

* Taking the guesswork away and thereby preventing unneeded parts removal.

* Having actual parts numbers to confirm parts suppliers supply correct parts.

Finally, of note is the way in which vehicle manufacturers assemble cars on the production line by using subframe cradles etc places massive extra difficulty with a task such as this as the clearances for tools, hands, arms and body are very very tight indeed.

I don't intend to outline a step by step process as others are far more qualified to do so, however I will point out some tricky things I have learned during the experience which may assist others. I will list them in no apparent order and will add others when I think of them.

1. The flywheel bolts are Torx T60.
2. The flywheel bolt access aperture had blocked access to the head of two of the bolts that required the use of a die grinder to remove some flywheel material. Not sure as to why this occurred or how.
3. Initially, I intended to remove the gearbox from the bell housing and remove both separately to make it easier but after removing the available bolts and prying the two apart (unsuccessfully) I removed the unit as a whole. Once on the bench I saw there were 4 bolts going into the gearbox from within the bell housing. So this unnecessary attempt needed me to split the two on the bench, scrape and clean old gasket material away and rejoin them together with new gasket silastic.
4. I supported the gearbox and bell housing from the top with an engine hoist and lowered it to be wrestled out.
5. I only dropped one side of the cradle but would remove it entirely if doing it again.

Probably enough for now i guess