i30 Owners Club

GOT PROBLEMS OR ISSUES? => DIESEL => Topic started by: Jones95 on February 24, 2019, 14:57:22

Title: i30 2011 harsh vibration at 2000rpm
Post by: Jones95 on February 24, 2019, 14:57:22
Hi all,

Basically, the issue is this.. originally, when accelerating somewhat heavily in 3rd-6th, going onto a slip lane for example, between 1800rpm - 2000rpm there was a harsh vibration/ loud noise that would occur. This would stop as soon as you passed the 2000rpm mark.

Pressure plate was replaced in the clutch, thought the issue was fixed... but the vibration moved and started at 2000rpm - 2200rpm.

So far the garage has ran a diagnostics, changed a plate that’s between the clutch and engine (not sure what it is) checked the DPF, the entire exhaust system, the turbo, engine mounts etc and yet STILL cant pinpoint the issue. So now, they’re going to bring it to a main Hyundai dealer and see what they’ve got to say. The dealer I purchased the car from is telling me they reckon it’s something loose, rather than drivetrain related. But this doesn’t make sense as when the pressure plate was replaced it went from the 1800rpm mark to 2000rpm. This would indicate to me it’s mechanical..

I’m hoping this main dealer can source the issue but has anybody has this problem?!? I’m getting so frustrated. It doesn’t happen in idle, is not dependent on cold/ hot and is not dependent on speed, only the engine speed and 3rd-6th gear.

Thanks in advance.
Title: i30 2011 harsh vibration at 2000rpm
Post by: xiziz on February 24, 2019, 17:40:48
It might just be vibrations under full load, diesels get vibrations at certain conditions. Im thinking it starts vibrating as its transferring max torque through the clutch, new clutch takes more torque before strting to vibrate.

Mileage?
Title: i30 2011 harsh vibration at 2000rpm
Post by: Jones95 on February 24, 2019, 18:33:56
Thank you for getting back to me..

The car has 90k miles on the clock.

This vibration, followed by the noise it makes in my opinion wouldn’t be normal.. I wish I had the car now to record it but it’s in the garage.. when it vibrates, the whole car does too and it’s quite a loud, unpleasant noise that follows. I’ll try YouTube to see if I can find anything similar and post the link.

Thanks again :)
Title: i30 2011 harsh vibration at 2000rpm
Post by: Jones95 on February 24, 2019, 19:08:34
I know this isn’t the best and also doesn’t show the extent of the issue... and it’s a VW... but it’s the most similar I could find regarding the noise itself and the fact it’s happening to him whilst accelerating..

 :link: Vibration and Noise from VW Passat 2.0 TDI - YouTube (https://youtu.be/jHfTtLFJlK0)
Title: i30 2011 harsh vibration at 2000rpm
Post by: Soegaard on February 24, 2019, 22:42:14
Hi Jones.

The way you describe it, is sound a 100% like my cars problem.
If I apply light to medium throttle, the "rattle" at 1900 rpm is almost none existing. Over 1900 rpm or in neutral the "rattle" is not present. Under load, worst in third gear, the car rattles and moans like crazy at 1900 rpm.

The rattle very annoying, and the whole car rattles and shakes. My car also suffers from rattles and creaks, and I suspect the 1900 rpm problem is causing every panel and clip to shake loose.

I have done my own troubleshooting, and my car is in perfect mechanical condition.  Some people have replaced the fly wheel with success. Others have replaced the engine mounts. I really like my car, but the problem drives me mad. Is your car under used car warranty? Or are you paying for the troubleshooting yourself?
Title: i30 2011 harsh vibration at 2000rpm
Post by: Bogdan1986 on February 24, 2019, 22:55:54
Mine started doing it at around 105.000 kms. Someone gave me a ride in a similar car a few months ago, with 200.000 kms on the clock, it did the same thing. He said he couldn't remember when it started. Most likely culprit would be the clutch and/or flywheel.



Title: i30 2011 harsh vibration at 2000rpm
Post by: Jones95 on February 25, 2019, 20:43:11
Hi Bogdan,

Really?! Well from the responses I am at least relieved that it is more common than Google would have me believe!

So far as mentioned the garage has checked most of the car mechanically, turbo, engine, exhaust etc. they’ve replaced the pressure plate (which was desperately needed!!) but now I’m thinking as I’m reading replies that maybe it is the flywheel.

Do you think the main dealer should spot this if it is?! It’s driving me mad and I’m so so hopeful that once it’s brought to a main dealer that the mechanics there will source the issue.
Title: i30 2011 harsh vibration at 2000rpm
Post by: Bogdan1986 on February 25, 2019, 22:00:25
It is frustrating to feel that something is wrong with your car and at the same time have mechanics tell you that everything checks out.
From my experience with dealers, if the car is under warranty, they will do everything possible to avoid big repairs. On the other hand, if the car is out of warranty, they will try to do unnecessary work on it, since you're paying.

I got used to this issue in my car. The way I get around it is I change gears over 3000 rpm, so the next one will engage at around 2000 lol. It is not the end of the world and other people seem to have lived with it for a few years now, without their cars breaking down.
When the time to change the clutch will come, I will have the flywheel changed also and see if that fixes it. But this won't happen soon... Either way, I won't step foot into a dealership service department again.



Title: i30 2011 harsh vibration at 2000rpm
Post by: nzenigma on February 26, 2019, 03:32:46
@Jones95

Hi mate,
If you drill down in our search engine you will find vibration complaints. You are not alone.

One thread deals with it in this way;
A long term member who has the habit of claiming some issue is commonly occurring in i30s came up with vibration.
I think HIS 'consensus'  opinion was that the problem lay with the clutch and or flywheel.
I pulled up all reported cases and found no evidence that this was the case.
As you have found, the vibration changed after components were changed.

I argue that the vibration is possibly the exhaust system resonating.
Moving the engine while replacing a clutch may alter the resonate tuning of the exhaust.
Title: i30 2011 harsh vibration at 2000rpm
Post by: Jones95 on February 26, 2019, 21:46:25
@Jones95

Hi mate,
If you drill down in our search engine you will find vibration complaints. You are not alone.

One thread deals with it in this way;
A long term member who has the habit of claiming some issue is commonly occurring in i30s came up with vibration.
I think HIS 'consensus'  opinion was that the problem lay with the clutch and or flywheel.
I pulled up all reported cases and found no evidence that this was the case.
As you have found, the vibration changed after components were changed.

I argue that the vibration is possibly the exhaust system resonating.
Moving the engine while replacing a clutch may alter the resonate tuning of the exhaust.

I’m quite new here so still figuring everything out regarding looking at certain threads etc. Firstly though, I’m so happy to know more people are having this issue as it’s infuriating especially with a mechanic telling you otherwise.

I’m also very thankful that you took the time to look into it. I’m new to this forum but also new to Hyundai. I love the car, but this has been very annoying. The mechanics checked the DPF, turbo, engine, etc as mentioned originally. I’m sure they checked the flywheel too although they didn’t say..? I’m not sure.

I’m not massively mechanically minded outside of the basics, but if you wouldn’t mind elaborating on the exhaust issue you believe may be causing this? If it’s easier, you can PM me. I’d like to know more or if there’s a solution/ DIY fix to it?

Thanks again!



Title: i30 2011 harsh vibration at 2000rpm
Post by: nzenigma on February 27, 2019, 02:18:59

So far as mentioned the garage has checked most of the car mechanically, turbo, engine, exhaust etc. they’ve replaced the pressure plate (which was desperately needed!!) but now I’m thinking as I’m reading replies that maybe it is the flywheel.


Before I explain resonating , I have to say, guys spend some time in Search. Read the many related posts. Bogdan is unwittingly repeating the repeated.

You will both see that flywheels have been changed to no avail.  not surprising!!!!

A trombone resonates. If you blow at a certain rate, the resonate vibration is music. The pitch changes as the player changes the shape of the instrument.
If you have a speaker inside a thin wooden cabinet (old style TV set) and play music, the cabinet may vibrate at a certain frequency. That resonating vibration can be  loud enough to block out the music. Make a small change to the cabinet shape and the noise is cured.

I have a theory that the exhaust pipe acts in a similar manner. It physically changes with age and movement during maintenance.
Thats your vibration .
Title: i30 2011 harsh vibration at 2000rpm
Post by: Bogdan1986 on February 27, 2019, 07:49:42
Indeed mine was just an opinion. I am not a mechanic.

The threads I read relating to this issue did not seem to have a definite conclusion. Perhaps I didn't read the right ones.

The exhaust system resonation hypothesis is something that I didn't take into consideration.

The turbo is also part of the exhaust system and the vibration appears at the same rpm that the turbocharger in these cars kicks in.

I just think that if it was the exhaust resonating, the vibration would be present when you hit the 1800 rpm mark while in neutral, too. The fact that it only happens when gears are engaged leads me to think it is more likely a clutch/flywheel issue.



Title: i30 2011 harsh vibration at 2000rpm
Post by: nzenigma on February 27, 2019, 21:16:20

I just think that if it was the exhaust resonating, the vibration would be present when you hit the 1800 rpm mark while in neutral, too. The fact that it only happens when gears are engaged leads me to think it is more likely a clutch/flywheel issue.

How do the flywheel and clutch change from N to a gear? They are locked together.

As I indicated all this has been discussed at length before.
Please search here for any of those discussions and criticise them. If you have new evidence it will be most welcome.
Title: i30 2011 harsh vibration at 2000rpm
Post by: hoolydooly on March 19, 2019, 09:54:38
Have you managed to find any more info on this issue? I've had the clutch replaced, flywheel machined and one of the engine mounts replaced. None of which fixed the issue, but just made the issue happen between 1800 and 2400rpm. All under warranty which is wonderful, but id rather have this sorted properly.
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: nzenigma on March 19, 2019, 20:01:18
Have you managed to find any more info on this issue?

Where do I start?  :undecided:
How much of our stored info have you studied so far?
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: Jones95 on March 19, 2019, 20:13:00
Still no luck!!

I got an extended warranty and have the car now. My own mechanic is doing his own bit of research and should be back to me by tomorrow.

I’m thinking of taking a recording of the sound while driving just to be sure everybody on this/ other threads are experiencing the same thing.

It’s a pain and as said it’s been discussed before but this sound is unreal, apparently everything was checked by the dealership so I’m hoping my mechanic can find the issue. It’s definitely coming from the front of the car, somewhere between the passenger side and center of the car, then spreads throughout.
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: hoolydooly on March 20, 2019, 00:59:50
I've read a fair bit of info about it, with regards to engine mounts, clutch, flywheel, exhaust as mentioned above and turbo.

I'd be keen to see what happens when the turbo is replaced.
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: nzenigma on March 20, 2019, 01:40:54
Still no luck!!

I got an extended warranty and have the car now. My own mechanic is doing his own bit of research and should be back to me by tomorrow.


To assist him, write a list of the things tried and collated in our threads. All were repeats of clutch and flywheel etc, all had different outcomes, none identified the culprit.

The car needs to go on the hoist and run in gear through the vibration. An Irishman needs to been under it with a stethoscope of some kind.  :mrgreen:

So far eyes have glazed over at the notion of a part resonating ( I suspect the exhaust).

Try to get your head around my explanation, Ive worked in this area and found cures.

 It would be interesting to see what happens if a piece of steel ( for example) is clamped to the pipe. Is there a change.?
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: Jones95 on March 20, 2019, 19:09:26
I definitely am not doubting the advice you have shared with me. As I will happily admit, outside of normal maintenance I haven’t got a clue. I just wanted to give an update.

But in the meantime I have uploaded 3 short clips of the noise onto YouTube. But if it’s the exhaust can you explain this to me (I don’t mean to sound smart!!) but..

It doesn’t happen in 1st - 3rd. There’s a very slight rattle as if something is spinning or loose over by the passenger footwell. This rattle increases sometimes when turning and accelerating.

The vibration only kicks in in 4th, 5th and 6th. It does go away as soon as I’m out of that particular rev range or if I let my foot up off the accelerator.

Is this due to more vibration in the engine when in those gears etc? And the noise will only happen under load. Very very slightly if I’m just cruising. I’m sure you can tell how mechanically minded I am now.. 😂

Anyway, I’ve uploaded the vids. If this noise is what you’ve heard before please tell me! It seems to be coming from the front left/ center of the car, then spreading a vibration throughout.

Thank you. (The shortest video I moved it to the passenger side of the center console and it’s quite noticeable. Last link).

 :link: Hyundai i30, 2011, harsh vibration - YouTube (https://youtu.be/SdnyxOxGf2s)
 :link: Hyundai i30, 2011, harsh vibration - YouTube (https://youtu.be/A_-NSvDSFMs)
 :link: Hyundai i30, 2011, harsh vibration - YouTube (https://youtu.be/yDqmYlLi5QE)
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: nzenigma on March 20, 2019, 22:06:26
The early rattle could be something else thats not tied down, but certainly worth investigating.

The buzzing  / vibration in the 2nd video - I would stake the reputation of my Irish grandmother that it is some thing , part or area that is resonating.
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: Jones95 on March 20, 2019, 23:32:14
Well hopefully it’s nothing too serious/ expensive! I’m still unsure as to why it’d only be under load in the upper gears as I would have assumed if that was the case it’d be throughout them all.

But; I’ll take your word and get the mechanic to take a look and post an update once I hear more! :)
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: mickd on March 21, 2019, 00:30:46
G'day jones95,
I have a 2018 Santa Fe 2.2 diesel 6spd. In eco or normal at 60kmh in 5th, appro 1400 rpm it gives off that diesel rattle, drone, rumble when slightly accelerating or a cruising.  Same at 80kmh in 6th. Using sport it  moves the shift point up by 15kmh and noise doesn't excist.
You can also feel this through the car. Basically,  too low a speed for a  gear tends to make this happen.  I've had quite a few TDI work vehicles and they all have made a noise/vib when gear /rev ratio hits a certain spot. The diesel combustion process is more severe with almost double compression ratio than petrol, thus making that loveable torque and fuel economy.
Hang in there,  sometimes things take a little while to track down.
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: nzenigma on March 21, 2019, 05:11:59
 :brilliant: Thanks Mick spot on.

Well hopefully it’s nothing too serious/ expensive! I’m still unsure as to why it’d only be under load in the upper gears as I would have assumed if that was the case it’d be throughout them all.


Just reinforcing what Mick has said. The motor esp. when the turbo is giving you a boost is acting differently at other speeds and work loads.

Re cost thats why I advised you to bone up on what  we have posted in the past about remedies that have failed.
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: Markyc95 on March 23, 2019, 14:51:05
Hi I had the same problem for months. This was cause by a previous owner installing a 3rd party clutch. Swapping it for a genuine Hyundai clutch solved the problem
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: nzenigma on March 23, 2019, 21:36:11
Hi I had the same problem for months. This was cause by a previous owner installing a 3rd party clutch. Swapping it for a genuine Hyundai clutch solved the problem

As your research will have informed you, this has been tried many times in the past, with mixed results.

Question : was it the caused by this component, or did vibration disappear because the position of the power train has moved? 
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: mickd on March 23, 2019, 23:02:03
Hi I had the same problem for months. This was cause by a previous owner installing a 3rd party clutch. Swapping it for a genuine Hyundai clutch solved the problem
Was anything else changed?,  could you check or post itemised invoice if you still have it please.
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: nzenigma on March 23, 2019, 23:46:17

But; I’ll take your word and get the mechanic to take a look and post an update once I hear more! :)

Noooo! do some reading.  :crazy1:

 :link: VIBRATION: i30 Diesel FD _ Links to past comments. (https://www.i30ownersclub.com/forum/index.php?topic=54039.msg482033#msg482033)  :link:
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: Jones95 on April 01, 2019, 22:18:58
I did some reading and saw your latest post earlier in the week also! Whilst I appreciate you compiling all of the information and whilst I don’t doubt what you have said and it may be the case for some people but  it has been confirmed it is not being caused by exhaust resonating for my situation.

Which is actually a shame as now I have to dig deeper. I’m still under the impression it’s clutch/ gearbox related as the vibration changed rev range once a new pressure plate was installed.

Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: mickd on April 01, 2019, 22:31:22
No worries,  get as much detail as you can, what was replaced and if possible the brand and keep us posted. Goodluck.
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: nzenigma on April 01, 2019, 23:18:17
confirmed it is not being caused by exhaust resonating for my situation.
Which is actually a shame as now I have to dig deeper. I’m still under the impression it’s clutch/ gearbox related as the vibration changed rev range once a new pressure plate was installed.
No worries,  get as much detail as you can, what was replaced and if possible the brand and keep us posted. Goodluck.
:wss:
The exhaust is just a possible resonator, can be some other part or area.
Follow the link to past examples.
I would love to see this scientifically examined.
 Suddenly we have not only the original pressure plate, but various replacement brands all causing a vibration.
The pressure and driven plates are fixed in place to the flywheel and do not move while driving.
The weight of the flywheel is 'about' 10 times the weight of the clutch. So, how much influence can the clutch have in that area?
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: nzenigma on April 02, 2019, 21:50:25
Hi I had the same problem for months. This was cause by a previous owner installing a 3rd party clutch. Swapping it for a genuine Hyundai clutch solved the problem
Was anything else changed?,  could you check or post itemised invoice if you still have it please.

No reply Mick  :( :( as usual 2 posts.  little detail , seems he may have petrol or diesel 1.6,.

This is like hearing an endless tape that you get to hate .  :crazy1:

Millions of after market replacement clutches are fitted, but they seem to only affect the i30 and only the DIESEL. Comeon!!  :crazy1:
They are also fitted after the original HY clutch has been blamed for vibration, Comeon!!  :crazy1:

They do not seem to affect the petrol - manual box i30.  :Juggler:

@mickd @tw2005
Trying to think laterally , what is common to the problem?  :workitout:
All diesel, not auto, only FD model, so far. Not every FD crdi.

Gerard (tw) and I worked on a problem where front oil seals were being pushed out.
This happens to some i30 manual cars (only petrol reported) because of clutch operating pressure .

It causes wear to the crank thrust bearings and therefore lateral play in the crankshaft and obviously, the flywheel.

Luckily the OP had an old timer mechanic who could methodically work through the evidence.
Between us we solved a rare, but well published GLOBAL problem. :drinks:

 :link: High oil pressure blowing crank seal (https://www.i30ownersclub.com/forum/index.php?topic=50406.0) :link:

@Jones95 , mate read the above then get your mechanic to check for the crank free play.


Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: hoolydooly on April 03, 2019, 00:25:22
Ok so i noticed something new yesterday, my partner was driving and I noticed as we were going up a big hill, in 5th gear at around 100km/h, the vibration started just below 2000rpm as normal, but I was watching the speedo and it was jumping up and down by 10-20km/h, just like a tacho would if the clutch was slipping.

I did a quick search and found that in most cars the speed is measured off the drive shaft? is this the same for the 2011 i30 crdi? It could point to a problem there....
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: nzenigma on April 03, 2019, 01:59:27
Interesting!  :goodjob2:
Almost there,  :evil:  the speed sensor will be at the back of an old gearbox or more likely on the diff. The VSS on the i30 is on the transmission/gearbox given that it also functions as a differential. (top, far Left from memory)

No direct relationship to the vibration comes to mind. I would be looking for a poor a electrical connection that is being physically shaken by the vibes.

 The connector may have been left loose when the 'A team' were doing the usual clutch change.
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: Jones95 on April 04, 2019, 18:30:57
Thank you for getting back to me with that!

I’m sure I (and others) have your head melted with all of this and I just wish it was something simple. I’ll admit I have no technical knowledge regarding what you’ve said but I’ll show my mechanic and hopefully get this resolved once and for all.

Thanks to everybody trying to help!
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: tw2005 on April 04, 2019, 21:21:41
Devils Advocate, Left field comment;

Has anyone checked out the driveshafts on this in particular the inner joints. Most susceptible the longest shaft. There may be evidence of grease leaving the boot under the clamp.

These wear out and the tripod goes off centre then due to the excess clearance causing vibration. Depending on how bad it is they can be quite bad and will transmit through the chassis, generally only at certain combinations of RPM , gears , load and speed. I found it more on the taller gears. maybe 3 up

Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: nzenigma on April 04, 2019, 21:54:43

Has anyone checked out the driveshafts on this in particular the inner joints. Most susceptible the longest shaft. There may be evidence of grease leaving the boot under the clamp.


 :Shocked: :Shocked: :Shocked: Noooooo!
It has to be the clutch.
Its always the clutch.

  The Lord sayeth :TutTut: New thoughts are the Devil thinking.   :Ouch:
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: mickd on April 04, 2019, 23:24:42

Has anyone checked out the driveshafts on this in particular the inner joints. Most susceptible the longest shaft. There may be evidence of grease leaving the boot under the clamp.


 :Shocked: :Shocked: :Shocked: Noooooo!
It has to be the clutch.
Its always the clutch.

  The Lord sayeth :TutTut: New thoughts are the Devil thinking.   :Ouch:
:rofl:
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: tw2005 on April 05, 2019, 02:46:11
 :Yeah: :groan:

I knew there was a reason I ignored this thread.

...   :phone1: out
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: hoolydooly on May 01, 2019, 06:04:23
ITS FIXED!!!!

Another new clutch, and this time a new flywheel and the vibration is gone.
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: tw2005 on May 01, 2019, 08:13:43
ITS FIXED!!!!

Another new clutch, and this time a new flywheel and the vibration is gone.
well I guess we can say Holy Dooly it's fixed, glad it is and `~I had my doubts on the clutch but t, there you go  :oops:
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: nzenigma on May 01, 2019, 08:48:09
ITS FIXED!!!!

Another new clutch, and this time a new flywheel and the vibration is gone.
well I guess we can say Holy Dooly it's fixed, glad it is and `~I had my doubts on the clutch but t, there you go  :oops:

No oops mate. :disapp:
You are ignoring your research principle.
Clutch and flywheel were changed. Which one was at fault?

Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: tw2005 on May 01, 2019, 08:57:55
ITS FIXED!!!!

Another new clutch, and this time a new flywheel and the vibration is gone.
well I guess we can say Holy Dooly it's fixed, glad it is and `~I had my doubts on the clutch but t, there you go  :oops:

No oops mate. :disapp:
You are ignoring your research principle.
Clutch and flywheel were changed. Which one was at fault?
:winker: :cold:
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: Dazzler on May 01, 2019, 09:26:07
ITS FIXED!!!!

Another new clutch, and this time a new flywheel and the vibration is gone.

 :brilliant: :goodjob2: :goodjob:
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: nzenigma on May 01, 2019, 15:45:27
ITS FIXED!!!!

Another new clutch, and this time a new flywheel and the vibration is gone.

 :brilliant: :goodjob2: :goodjob:
in 5th gear at around 100km/h, the vibration started just below 2000rpm as normal, but I was watching the speedo and it was jumping up and down by 10-20km/h,.... 

As the Red Head says : please explain! :workitout:
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: Jones95 on May 24, 2019, 16:47:46
Well, an update!

I see the noise has been fixed for a member, I’m happy for you!

The reason I haven’t made an update is simply I haven’t had anything new until this point. Got the car back a couple weeks ago, it’s still making the noise but; I went to the garage, got the invoice and this is what has been fixed:

New Clutch Kit
New Gearbox
Wheel Bearing (FRHS)
Turbo checked
Tyre rotation
Discs/ Brakes replaced.
A/C Pipes were fixed (didn’t know there was an issue there!)
Full Service
Flywheel checked
Exhaust checked for vibration

So, all in all, I practically have a new car. The noise is still there. I am not happy about that, but I will live with it. The garage (remember it was a used car dealer) bought me a nationwide warranty which covers parts/ labor for 12 months, should something go wrong. They also gave me a full tank of diesel so 👍.

If something goes wrong, I shall definitely update. But aside from the noise, the car is driving better than ever and I am thoroughly enjoying ownership. Thank you all for the help.
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: Dazzler on May 24, 2019, 21:02:30
Thanks for the update. They have certainly gone above and beyond. Still frustrating though.  :crazy1:
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: mickd on May 25, 2019, 13:31:58
Whoa !, thats a lot of work.   :crazy1:
Sensation is still there,  try and find one at a car yard and take it for a spin.
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: Scootlid on October 16, 2019, 10:31:25
I'm currently having a similar issue,  240000kms on clock,  car is in shop now,  mechanic said it's the injectors are faulty.  We will find out in a few days when parts come in
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: Lorian on October 16, 2019, 20:18:29
I had this on my FD just before it's 5th birthday (5 years ago).  1800-2000rpm rattle/vibration only in 4th/5th/6th.

IIRC they replaced the flywheel and the noise remained.
They then replaced the clutch and all was good.
I seem to recall they believed it was an issue with springs in the clutch.

Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: nzenigma on October 16, 2019, 21:13:23
I had this on my FD just before it's 5th birthday (5 years ago).  1800-2000rpm rattle/vibration only in 4th/5th/6th.

IIRC they replaced the flywheel and the noise remained.
They then replaced the clutch and all was good.
I seem to recall they believed it was an issue with springs in the clutch.

I remain convinced it is ( resonance) elsewhere in the car. Mainly because an issue with clutch springs is irrelevant when the plate is clamped to the flywheel when in gear.
Possibly the movement of the engine, during replacement work, did the trick for you.
Mr Jones was directed to earlier discussions and research, but as I suspected, his mechanics did what they always do, again and again without any success.

Cheers G
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: Lorian on October 16, 2019, 21:34:47
Indeed, I don't know, just relaying the experience and what they said. I think they said broken spring(s), but I can't be sure - its a long time ago. And keep in mind they removed it twice before it went away.

The only other observation I can make is the very slightest pressure on the clutch pedal at the point of the vibration was happening would attenuate it.

Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: dereknunn on November 25, 2019, 05:14:32
2013 GD 1.6CRDi

I had a new clutch fitted under warranty at 90,000km after a vibration at 1500-2000rpm became noticeable at 60,000km

You can see my original post and a short video of the loose springs by searching 'clutch vibration coolant loss'

Anyway, identical symptoms developed at 150,000km so in my case it seems the springs are good for 60,000km

I ignored the vibration, the car has just passed 300,000km and the vibration has not worsened.  The clutch still works fine.

If it does become necessary to replace the clutch again I will be fitting an Excedy item as the Hyundai item is clearly defective.

Aside from clutch issues the car has been great. I have had the electric cooling fan and reverse light switch replaced (possibly a result of driving through water that came over the bonnet), one of the temperature actuators replaced for the climate control system, and all the lacquer has peeled off the plastic door handles and tailgate spoiler.

I've found the originally fitted Hankook Kinergy Eco tyres to give me around 75,000km per set, more (and quieter) than both the Toyo and Bridgestone options I tried.

Almost exclusive country highway driving sees an average fuel consumption of 5.5L/100 at an average speed around 85km/h.

Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: nzenigma on November 25, 2019, 07:18:42
sorry but I remain unconvinced.

1. The majority of complainants about the vibration have owned a manual FD CRDi and have replaced clutches without it resolving significant vibration.

2. You own a GD and had a lot of other work done and " During this time the car was serviced by Hyundai at least twice, and test driven by numerous Hyundai representatives without comment. Prior to removal the clutch did not slip, judder, or in any way suggest to anyone it was worn; the fault would seem to be only the loose springs vibrating."

3. I suggest that loose springs 'spring to mind' whenever an explanation is needed.  :crazy2: Yerp that sounds good to me, Bubba.  :spitty:

3. Basic physics: While driving, the clutch is clamped hard and immovable to the flywheel. The springs in a clutch plate would have a combined weight of only a few grams. How would they influence a flywheel weighing about 10-12 Kg?
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: Dazzler on November 25, 2019, 07:58:08
I don't know about causing the vibration, but if you put clutch springs into our search engine there are lots of references about them failing or getting worn or loose...  :undecided:
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: nzenigma on November 25, 2019, 20:35:50
I don't know about causing the vibration, but if you put clutch springs into our search engine there are lots of references about them failing or getting worn or loose...  :undecided:

This is a basic mechanic talking about the loose springs;
You will note that the springs are there to soften the action of the clutch engagement and the initial clamping of the clutch plate.
The rattle is heard at very low speed or when the vehicle is idling.

 :link: Clutch Plate Faults - When a rattle is clutch plate springs and not a gearbox fault. - YouTube (https://www.youtube.com/watch?v=y7DE4iPLOhE)

Not only are the springs light weight compared to the weight of the flywheel, centrifugal force pushes against them holding them down. Therefore no rattle,no vibration at higher revs.

The majority of our CRDi owners who had a clutch replacement reported little of no improvement to 'the vibe'.
It is relevant that petrol i30s have a much lighter flywheel, but these owners do not report 'the vibe', therefore the usual clutch spring discourse rarely arises.

Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: dereknunn on November 26, 2019, 03:08:35
I can only report the facts in an attempt to assist others. The seeming harmonic vibration / rattle at low rpm was totally eliminated (in my case) by replacing the clutch assembly, and the springs in the clutch pressure plate were found to be loose to the point they were rattling around (see video in original post).

Hyundai technicians initially struggled to diagnose the fault; opinions ranged from 'air noise associated with the turbo' to something loose in the exhaust system, the front section of which was even replaced in the quest to rectify the fault. I remained adamant the fault was somewhere in the transmission and eventually insisted the gearbox was removed at which point the loose springs were discovered.

Regardless of all the comments about flywheels, the springs in the clutch plate should not become loose after such a short period of use. The friction surfaces of the removed components showed only normal wear, and despite the replacement clutch developing identical symptoms after an identical mileage it otherwise continues to operate perfectly over 200,000km later.

I am not a mechanic, or a physicist, but I do understand how a clutch works and the purpose of the springs.

My style of driving, a majority of highway miles, the evidence of only normal wear to the removed components, and the replacement still operating more than 200,00km later are not indicative of abnormal use. The experts I have discussed the matter with are of the same opinion.

I previously owned an FD CRDi 6 Speed and confirm no such symptoms became apparent in well over 100,000km.







Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: mickd on November 26, 2019, 06:42:17
It would seem, that after much discussion on noise/vibration re diesel engines, that maybe there is actually 2 or 3 different sounds/feels excisting all being interpretated as "the same as mine".
1- certain gear/ engine rev,
2- clutch issues
3- exhaust harmonics.
 :faint: :faint:  :head_butt: :head_knock:
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: dereknunn on November 26, 2019, 08:44:27
I think that is a very likely and valid point mickd.

Whilst I'd struggle to explain the sound characteristics of my vibration / rattle / resonance I would say that I only 'feel' it when at its most severe. Usually I just hear a 'buzzing' noise as I pass through the noted rev range.

What I can do is accurately describe how and when it occurs as being exactly how and when a worn clutch slips.

The severeness of the vibration is directly proportional to the load under which acceleration is taking place.

It is most extreme at low speed in a low gear, but only apparent if accelerating under an extremely heavy load, for example pulling away up a very steep hill.

It becomes less severe as speed increases but can be induced more easily with the combination of a high gear / heavy throttle.

It reduces rapidly as the amount of throttle is reduced, ceasing immediately if the accelerator is lifted completely.

The need to negotiate steep hills at relatively low speeds aside, occurrences of the vibration are virtually eliminated by driving smoothly and avoiding hard acceleration.

In my case, I have no regrets about choosing to ignore the issue when it re-occurred after being eliminated for 60,000km by fitting a new clutch.

However, other posts report symptoms that are far more severe, occur under different circumstances, and have not been eliminated in the way my problem was, ultimately adding weight to mickd's opinion that there are indeed a number of different issues here.
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: nzenigma on November 26, 2019, 09:30:10
It would seem, that after much discussion on noise/vibration re diesel engines, that maybe there is actually 2 or 3 different sounds/feels existing all being interpreted as "the same as mine".
1- certain gear/ engine rev,
2- clutch issues
3- exhaust harmonics.
 :faint: :faint:  :head_butt: :head_knock:

I'm along with you on all 3 prospects.

The  "the same as mine" interpretation may be the same thing or way off base.  :goodjob2:

Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: mickd on November 26, 2019, 11:05:24
Would be great to hold a "diesel vibration experience" weekend.   
:crazy1:  :crazy2: :crazy1: :crazy2: I've lost the plot   :faint: :rofl:
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: nzenigma on November 27, 2019, 01:45:29
Would be great to hold a "diesel vibration experience" weekend.   
:crazy1:  :crazy2: :crazy1: :crazy2: I've lost the plot   :faint: :rofl:

They have reserved a room for you on the 2nd floor of the Asylum . Same as me!  :happydance:

Unfortunately, 3rd floor with the best views is full of nutters from Facebook; aka "the echo chamber".
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: nzenigma on November 27, 2019, 03:55:10
I had this on my FD just before it's 5th birthday (5 years ago).  1800-2000rpm rattle/vibration only in 4th/5th/6th.

IIRC they replaced the flywheel and the noise remained.
They then replaced the clutch and all was good.
I seem to recall they believed it was an issue with springs in the clutch.

I only quote you Lorian so that I can demonstrate why @mickd  and I are in wards 2/34 & 2/35.

 If there is any logic to springs causing vibration it escapes me.

Calculations:

 A 10 kilogram, 300mm  flywheel rotating at 2000 rpm  develops a centrifugal force of 6,711 kilograms.
10 clutch springs with a combined weight of about 100 grams rotating at 2000 rpm develop a centrifugal force of 27 kilograms.

Thats about 200% difference.

Furthermore, the springs travel at 1/3 the speed of the flywheel; however, even at a mere 12.5 metres/second, they are not capable of moving.

And we are asked to believe that this can cause the whole car to vibrate.  :phone1:  :Pout:
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: Dazzler on November 27, 2019, 07:05:07
@nzenigma With respect Gary, a tiny little lead weight can stop a wheel and tyre vibrating, so maybe your theory is crap. Just saying..  :snigger:
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: nzenigma on November 27, 2019, 08:34:39
@nzenigma With respect Gary, a tiny little lead weight can stop a wheel and tyre vibrating, so maybe your theory is crap. Just saying..  :snigger:

@Dazzler  with respect, the lead weight is spinning at the same rate as the wheel.

@Dazzler  with respect explain to YOUR members why the clutch replacement rarely  solves the vibration/harmonic issue.  :mrgreen:

@Dazzler  with respect explain why the 'spring vibration' is limited to the diesel motor, not manual petrol motors.  :mrgreen:
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: tw2005 on November 27, 2019, 08:45:43
Would be great to hold a "diesel vibration experience" weekend.   
:crazy1:  :crazy2: :crazy1: :crazy2: I've lost the plot   :faint: :rofl:

They have reserved a room for you on the 2nd floor of the Asylum . Same as me!  :happydance:

Unfortunately, 3rd floor with the best views is full of nutters from Facebook; aka "the echo chamber".
I 'm not finished with my room yet gents. You'll have to get in line :crazy2:
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: Dazzler on November 27, 2019, 08:54:29
 :evil: :snigger:
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: mickd on November 27, 2019, 10:01:16
Would be great to hold a "diesel vibration experience" weekend.   
:crazy1:  :crazy2: :crazy1: :crazy2: I've lost the plot   :faint: :rofl:

They have reserved a room for you on the 2nd floor of the Asylum . Same as me!  :happydance:

Unfortunately, 3rd floor with the best views is full of nutters from Facebook; aka "the echo chamber".
I 'm not finished with my room yet gents. You'll have to get in line :crazy2:
:victory:  :crazy1: :crazy2:
I'm, a, happy little fruitcake ,
as nutty as can be,
diesel vibrations are the end of me,
they've put me in a straight jacket
and  now I need to pee  !!

 :eek: :rofl:
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: nzenigma on November 27, 2019, 20:36:07
From my room you can hear :laughter: :clapthanks:  :listentomusic:  :laughter:

At my window I can see my reflection  :harhar: :harhar: :harhar:

When I'm quiet I calculate stuff :Juggler: :workitout:  :plus1: :Dunno:  :TopicClosed:

Sometimes we are allowed to watch the 3rd floor echo chamber  :2giggling:

All this pleasure because of  :happyjumper: SRINGS. It can be yours too!
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: nzenigma on November 27, 2019, 21:07:31

 I 'm not finished with my room yet gents. You'll have to get in line :crazy2:

Wow, imagine having the whole basement to yourself 

 :backYoohoo:
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: nzenigma on November 27, 2019, 21:22:54
@nzenigma With respect Gary, a tiny little lead weight can stop a wheel and tyre vibrating, so maybe your theory is crap. Just saying..  :snigger:

 Actually @Dazzler , old mate,  :mrgreen: during this clueless meander you touch upon an important point.  :faint:

The flywheel is similarly balanced during manufacture; not by adding weight, but by machining metal off it. Like an undamaged wheel, the flywheel's balance remains perfect.
Clutch springs also remain at  their original meager weight, irrespective of tension.

If you missed my edit above, my 'crap theory' is only discussed when talking about diesel not petrol ?????? :crazy2:
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: Lorian on November 27, 2019, 22:48:00
And we are asked to believe that this can cause the whole car to vibrate.  :phone1:  :Pout:

Ah well, thankfully I don't give a frig, I was just quoting my experience and what I recall the dealer saying over 5 years ago in the hope it might help someone.

Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: BrendanP on November 28, 2019, 01:23:32
Having read all this lot, doesn't this sound like a DMF problem? There's part of the flywheel driven by the crankshaft, and another part of the flywheel that drives the clutch plate. Between the two parts of the flywheel there is a flexible coupling, which I presume contains springs and dampening material. The whole point of the DMF is to reduce vibration from the engine being transmitted through to the gearbox. Like any system containing mass, dampening and elasticity, resonance will occur at particular frequencies. As the flywheel ages and the damping becomes less effective as rubber parts get harder or start to crack, and the springy parts get tired, the resonant frequency will change to the point where it coincides with engine vibration at a particular rev band. The resonance amplifies the vibration instead of dampening it.

The two parts of the flywheel don't just rotate together at crankshaft speed, they also rock back and forth relative to each other. When they get worn it's this slop between the two halves that leads to excessive vibration. Not a clutch issue.
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: dereknunn on November 28, 2019, 04:47:23
I was assured by the Hyundai dealership who replaced my clutch under warranty that my flywheel is solid and not a dual mass item, but I know there is much conjecture on this subject too. The dealership also assured me no machining of my flywheel took place.

However, the previous DMF post together with another post about changing from an aftermarket to a genuine Hyundai clutch stopping the vibration got me thinking that perhaps the Hyundai clutch plate is not flawed as I was believing, and that maybe the clutch springs becoming loose and rattling are actually caused by an underlying issue; that is to say they are a symptom and not the cause.

In my case a replacement clutch stopped the vibration / rattle completely, but only for 60,000km, exactly the same time it took the original occurrence of the problem to manifest.

So, is it possible that the springs in a new clutch plate, be it of Hyundai or aftermarket origin, mask the vibration, until such time as the underlying issue causes wear to the springs to the point that they become loose enough for the vibration to become apparent again?

As I have said before, I am neither a mechanic or a physicist, and I have no suggestions as to what this underlying issue could be, but perhaps it is relative that peak torque is generated in the noted rev range, and according to the specs, the torque output of the motor is de-rated by Hyundai when it is coupled to a manual transmission opposed to the twin-clutch variant (from GD model onward)
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: nzenigma on November 28, 2019, 08:15:42
Between the two parts of the flywheel there is a flexible coupling, which I presume contains springs and dampening material.

No!!!! The flywheel is one solid lump of steel.
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: tw2005 on November 28, 2019, 08:16:34

 I 'm not finished with my room yet gents. You'll have to get in line :crazy2:

Wow, imagine having the whole basement to yourself 

 :backYoohoo:
Actually , you're genius. I believe you have enough landscape to go underground, the next bat cave.

LINK (http://www.wavsource.com/snds_2018-06-03_5106726768923853/tv/batman/batmobile_x.wav)
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: dereknunn on November 29, 2019, 00:55:47
After a little further reading and googling I am now firmly of the opinion it is NOT my loose clutch springs themselves vibrating, but instead believe they are the cause other vibrations being noticeable.

For those genuinely interested, the following link explains the role of the clutch damper assembly, and how it eliminates vibrations passing from the engine to the drive-train when the clutch is engaged.

Clutch Damper Assembly Explained (https://www.youtube.com/watch?v=Td15fzkTfo4)

And this link includes a rather more scientific explanation for members so inclined.

MODELLING AND EXPERIMENTAL INVESTIGATION OF CLUTCH DAMPER SPRING STIFFNESS ON TRUCK DRIVING COMFORT (http://www.makalesistemi.com/panel/files/manuscript_files_publish/aa0cfcd5888ff2211e8791d25e8cffef/f331208b890d16dad06ba8622f3859f7/c5788226bfcfad0.pdf)

This now leaves me wondering whether the vibration in my car is a fault or just a characteristic.

I guess I stick to my plan of fitting an Excedy clutch when the current Hyundai one fails and see if the springs in it last longer than 60,000km.
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: nzenigma on November 29, 2019, 22:15:09
For those genuinely interested, the following link explains the role of the clutch damper assembly, and how it eliminates vibrations passing from the engine to the drive-train when the clutch is engaged.

  Being genuinely interested for several years  :whistler: I thank you for the vid and appreciate the fact that you now realise that in this case we are not talking about the dual mass flywheel (DMF)  :)

Given that most drivers have limited technical knowledge it is difficult to fully separate the many reported transmission and damper faults from the 2000 rpm range fault.

To reiterate several years of posts on this subject, many which are also linked to this thread:

The numerous reports of clutch changes provide no clarity as to this being an effective remedy. Many report mild or no improvement in the '2000 rpm range' vibration.

With the exception of one DMF, to my knowledge no clutch/flywheel rattle at idle has ever been reported.

The Excedy clutch is a top performing device that is attempting to replicate the action of the DMF.

 :link: Dual-mass flywheel - Wikipedia (https://en.wikipedia.org/wiki/Dual-mass_flywheel)

Incidentally, the more expensive DMF  has about a 5 year life span, depending on its work load. It comes with the Hyundai 7 speed DCT box.

Your video correctly gives several possible sources of vibration. One is the "loose" un-driven gears in the gear box. However, the reported i30 vibration is constant through 3rd, 4th and 5th gears, (these various loose gears are therefore being used). Using a heavier grade lubricant may resolve or simply illuminate this phenomenon.

After a little further reading and googling I am now firmly of the opinion it is NOT my loose clutch springs themselves vibrating, but instead believe they are the cause other vibrations being noticeable.

After years of further reading I have no firm opinion on the solution for the vibration .. I have a strong suspicion that it is a harmonic oscillation occurring somewhere  :crazy2: in the car.

Question, how do you know YOUR springs are loose?
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: Dazzler on November 30, 2019, 09:47:14
@nzenigma Excellent post thanks Gary. :goodjob:
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: BrendanP on December 01, 2019, 17:23:44
A dual-mass flywheel, by definition, consists of two masses. A flywheel which is made of one solid disc of steel is not a dual-mass flywheel, it's just a flywheel. Clutch plates also contain springs between the outer friction disc and inner splined hub which provide some torsional elasticity.
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: nzenigma on December 01, 2019, 20:03:26
A dual-mass flywheel, by definition, consists of two masses. A flywheel which is made of one solid disc of steel is not a dual-mass flywheel, it's just a flywheel. Clutch plates also contain springs between the outer friction disc and inner splined hub which provide some torsional elasticity.

The construction and operation of the Dual Mass Flywheel (DMF) is covered above and in other threads. It is not relevant to this thread because the FD and GD crdi, with 5 & 6 speed manual box, do not employ it . As I said, they have a solid (single mass) flywheel.
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: BrendanP on December 01, 2019, 23:17:05
I stand pleasantly corrected.
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: Dazzler on December 02, 2019, 00:35:51
I stand pleasantly corrected.

Thank goodness!  :sweating: That's how we like it.  :D
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: dereknunn on December 02, 2019, 04:19:49
@nzenigma

I never thought we were talking about a DMF, and I never believed my car was so equipped, as I stated in my post. It was simply the content of the post about how a DMF works that got me thinking about the elimination of vibration in the drive-train (by the clutch).

My vibration, whilst a more common occurrence in higher gears, is certainly far more severe when it does occur in lower gears.

My vibration is no longer apparent by 2000rpm, it only occurs in the 1600 - 1900rpm range.

I confirm I have never experienced any vibration at idle.

You may well be right about a harmonic oscillation, I certainly feel it through the floor of the car more than through the gear shifter and I can certainly understand why Hyundai elected to replace the front section of the exhaust system on my car in their earlier attempts to address the problem.

All I can report with absolute certainty is the vibration was not apparent AT ALL for the first 60,000km, or for exactly 60,000km after a new genuine Hyundai clutch was fitted.

The springs in my original clutch were loose. Very loose in fact. @Dazzler kindly posted the video of them rattling around in the post below, but unfortunately the link no longer works. I probably still have the video but wouldn't know how to post it myself I'm afraid.

Transmission Vibration (Clutch issue) & Coolant Loss (https://www.i30ownersclub.com/forum/index.php?topic=37622.0http://)

I can't of course be 100% sure the springs in the replacement clutch are loose, but an identical fault after an identical mileage makes it a fairly safe assumption in my book.

If I do need to replace my clutch again I will of course report on the condition of the springs, and in due course how the Excedy item fares in comparison to the genuine Hyundai item. Unfortunately, whether that transpires to be better or worse, it seems likely the springs will give out and the vibration will return long before the clutch otherwise reaches the end of its useful life.

Your comment about lubricant is duly noted and I will mention this next time I'm talking to the service manager at my local dealer who has taken on a bit of an interest in this case himself.
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: joel_t on December 02, 2019, 12:03:14
Thought I'd add 2c worth here. I've read plenty about the various theories and having removed my clutch over the weekend, I have another piece to add to the puzzle.

Mine is a 2013 GD diesel hatch which has always had the vibration/noise/resonance during the time I've owned it. I purchased it with about 150k on the clock and it recently clicked over 196.

There were a couple of instances in the lead up to removing the gearbox where I couldn't select a gear momentarily and on the second of those occurrences there was slippage in third. I didn't drive it again until moving it onto the hoist for repair, during which time it performed normally.

As I suspected, the clutch plate (friction plate) is what failed. The pressure plate is fine, it really could be used again (I'll replace it though) and the flywheel surface is also fine. The flywheel side of the the friction plate is not at all worn out, but the pressure plate side has totally failed (all the friction material gone) but there was a detached ring of material preventing pressure plate damage. Upon closer inspection, two of the friction plate springs contain hollow metal cylinders which are able to move freely backwards and forwards within the spring. The other two contain smaller springs and these don't appear to move.

I suspect that under certain rpm/load conditions, the metal cylinders are not in exactly the same position relevant to the other and this results in a harmonic vibration (which quite possibly is amplified by exhaust/whatever). This vibration is what caused the premature failure of the friction material one side of the friction plate only. The plate eventually shook itself to pieces. I should add that the springs themselves aren't loose really, the rattle comes from within the springs. When you rotate the plate backwards and forwards quickly, there is a noticeable change in momentum as the metal cylinders fly back and forth.

I'm really hoping that the replacement clutch doesn't contain these metal cylinders as I have no idea why they are present in the first place. I'd be interested to know how many of the replacement clutches fitted have these pieces present as this could explain why replacement clutches didn't fix the problem.

Anyway, it'll be interesting to see what happens when I put it back together over the next couple of days.

(https://i.ibb.co/yVtgq2s/IMG-20191201-132957.jpg) (https://ibb.co/R7fQc8H)

(https://i.ibb.co/1Zckz9h/IMG-20191201-132947.jpg) (https://ibb.co/kKZtmhk)

(https://i.ibb.co/dk39G3p/IMG-20191201-132942.jpg) (https://ibb.co/CVXdhX9)

(https://i.ibb.co/p33Ccsr/IMG-20191201-125446.jpg) (https://ibb.co/nDDh9V8)
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: tw2005 on December 02, 2019, 20:18:07
That clutch plate is mind blowing, never seen anything like that and te  mountain of dust in the background I assume came out of the bellhousing. It's as if it simply disintegrated
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: Dazzler on December 02, 2019, 20:29:55
Welcome @joel_t

Brilliant 1st post!  :goodjob:
Title: Re: i30 2011 harsh vibration at 2000rpm
Post by: nzenigma on December 02, 2019, 20:30:35
@joel_t

200,000 km is fairly reasonable  life from a clutch plate, you can get more or a lot less depending on the work you give it.

The wear you see on the DRIVEN PLATE is the normal end of life. I would change the pressure plate, probably ok, but for a few more bucks you get rid of one that may be tired and has contributed to some wear.

The springs are normal to any clutch plate, despite all the pontification,  there is usually movement and the steel ( or rubber???? ) inside them is usual ,  Im not sure of its role but presume it stops the spring from distorting and compressing too far when under load.

The i30 clutch seems to last a while. On 4x4s we use excedy or similar HD because the makers generally use cheap light duty clutches which burn out quickly and help to destroy the dual mass flywheel. Most owners swap to a cheaper , last for ever, solid flywheel.
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