They did the dial gauge as you suggested and one of the teeth is off on the flywheel by more than a few MM. Is that enough for the car to not start and give a CKPS error?
The flywheel is part of the CNS package I bought awhile back. They seem pretty easy to deal with but I can't speak to them until after the holiday.
damnz dude! How can a garage make such a mistake?
A garage that has make such a mistake, it is a reason for me to never visit.
but on the other hand I think its very clever that the dealer can install a wrong flywheel, a flywheel in the e39 m5 is only 1 way, because otherwise the bolt flywheel can fix!
Not an easy solution, but put the original flywheel/clutch back in and skip the driveshaft and exhaust and see if the car starts.
This will either rule the new flywheel in or out and confirm the crank sensor, wiring and that something else is not wrong like a pinched or broken wire due to the first clutch change.
Again, not an easy solution, but if the trans is out now and the car is on a lift, maybe 30 minutes if you skip the shifter, driveshaft & exhaust. All you want is to see if the engine fires off or if you still get the crank sensor error.
I spoke to Mark at CNS today. They are going to have my shop show that the flywheel is indeed bent and then they will replace it.
The cool part? I bought my clutch at the end of 2010 due to a sale they had going on, knowing I would need it someday. CNS is still standing behind their product!!
Thanks to Mark and the people here who helped. I'm sold on CNS!
I spoke to Mark at CNS today. They are going to have my shop show that the flywheel is indeed bent and then they will replace it.
The cool part? I bought my clutch at the end of 2010 due to a sale they had going on, and knowing I would need it someday. CNS is still standing behind their product!!
Thanks to Mark and the people here who helped. I'm sold on CNS!
I bought a dual mass setup from CNS and didn't install it for a while. When we got around to installing, it had a bent piece (I believe shift fork, going from memory). Apparently, there was a run of these on the early kits. After my mech confirmed to Mark he knew what he was doing, Mark overnighted a replacement, which went right in.
Hopefully, that will solve your problem and you will be back on the road shortly.
Yeah i have nothing but good things to say about Mark at CNS as well. I used their dual mass kit for 10,000 miles and loved every minute of it, but unfortunately my rear main oil seal went i stupidly didnt change it when the clutch was done, and it ruined the kit as it leaked over the disk etc and caused the whole thing to keep slipping, but mark was very helpful and gave lots of good advice, and in the end i purchased their new single mass kit, got about 100 miles on it and it feels really good, another 400 to go until i can give it some
New plan. It looks like the damage can be fixed. My shop is going to ship to CNS and they are going to make sure everything is in top shape and send back. CNS is doing all that for free even though my clutch was bought in late 2010.
Lets hope that when it gets back it fires and runs like a champ. I've been without my car for way too long.
New plan. It looks like the damage can be fixed. My shop is going to ship to CNS and they are going to make sure everything is in top shape and send back. CNS is doing all that for free even though my clutch was bought in late 2010.
Lets hope that when it gets back it fires and runs like a champ. I've been without my car for way too long.
I know how you feel mine was off the road for 3 weeks and that was bad enough, do you have any pics of the damage? Was it the teeth damaged?
I am guessing that because the clutch friction area is larger the tooth strength/material is thinner and more susceptible to damage/bending during shipping and handling??
I have not seen a OEM flywheel for a while, however, I recall the teeth being much more robust?
From what I understand CNS takes a stock flywheel and machines down the weight to increase acceleration times. The weight loss is substantial but the teeth are not affected. Looking at his flywheel and a stock flywheel I saw 0 difference in the teeth, and I'm certain that any change would affect CKPS sensor readings and durability.
As for durability CNS tells me that it would have to take quite a fall in shipping for the tooth to bend. CNS ships these in good packaging. When I received the box from UPS there was damage but I did not open the box at that time. A year and a half later when I went to have it installed we opened the box and noticed that the clutch alignment tool was shattered. I should of taken a look at it then but my first indy felt that everything was OK.
Luckily for me CNS is taking good care of me. Mark has been there since step one, and even though I can't go after UPS this late in the game they are making sure my flywheel is right. I cannot say enough good things about CNS and their customer service.
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A year and a half later when I went to have it installed we opened the box and noticed that the clutch alignment tool was shattered. I should of taken a look at it then but my first indy felt that everything was OK. 
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