volvo v40 2003 1.9 td sport estate

i would just like to say a big thank you to the following people for all the information,diagrams,pictures,hints,and time and effort in helping me to understand the fault with my volvo.....GATOS:star:960KG:star:BIOTOXIC:star:V40B ART:star:SIAMBLUE:star:ANDY D:star:...i will let you all know in due course the outcome.i feel more confident that the volvo will be back on the road soon thanks to this info....much appreciated.regards neanderthal......keep up the great work:thumbs_up:

There are some very nice people on this site who's help is greatly appreciated and have also helped me with my recent problems (and there has been a few and likely to be a few more of)

So I'd like to second that with a thanks from myself!!! :thumbs_up:

hi,update.i managed to take everything apart myself ,except for dropping the gearbox(brotherly love) to get to the clutch slave cylinder.(picture 2 of 3)...volvo main dealers have quoted £111 including vat for the slave cylinder.will update more when i find the money as i need other parts....thanks.:thumbs_up:

Well done. I am sure it was a fun experience....:) Keep us updated.

Check with Rufe for a good price and see if it is cheaper.

Maybe its worth emaling this guy and ask for the part number:
http://www.ebay.co.uk/itm/GENUINE-S4...item43aa386490

Also check here: http://www.volvoforums.org.uk/showthread.php?t=126676

DWM got one for £70

Parts Monster, as per the link from Gatos/ebay, they Can and will advise by emal/phone if the part is correct going on reg number or vin number.

it Might be just seals in the slave cyl, parts monster also have repair kits for slave cyls
http://www.ebay.co.uk/itm/Volvo-S-V4...item415acc5fe8


there looks to be a fair bit of fluid "fling" around the bell housing and on the outside of the pressure plate. it would be worth removing that and checking the friction plate for contamination by fluid as well.

thanks gatos and andy d...i am afraid i dont feel confident enough to touch the clutch as i am assuming it would have to be re-alligned,i have never taken a clutch apart.also i think i would rather buy a new slave cylinder as again i dont feel confident or know how to take that apart either....i appreciate that you are trying to save me some money....i will get someone to have a look at the clutch,and go from there.by the way, should the gearbox have had a seal round it(gasket),as i only noticed remmenants of some black stuff...thanks...ps i will try parts monster and rufe..

The clutch is only held on with 6 or 8 torx screws, then it will come apart.. it will have to be lined again for it to go back in...

Gary

thanks siamblue.thats what i was concerned about.would the garage have to re-align it.thanks

its not too hard to re line the clutch up

http://www.youtube.com/watch?v=QpE-RbZKw1c

fairly ok vid showing what/how and a method where you dont need a special tool.

http://www.youtube.com/watch?v=tuJzK...eature=related
with the clutch alignment tool,

its "only" a matter of lining the friction plate with the pressure plate ,getting it central to that so the splined hole is exactly in the middle

worse that happens is
you find the gear box Wont line up/mate with the engine, you slip the box back out the way, undo the bolts and fiddle it central, then try again,as long as you dont hammer the box home you shouldnt be able to cause any extra damage.
cost > a bit more time to fiddle it to central,
garage will want a chunk to swap the clutch. and some will try and tell you "they need X y z special tools,,etc,,,", they dont.

lost count of the times i had to drop the box on my Tr7 always chucked it all together without any special tools,,and that was a RWD , with a huge heavy gbox, and a rather heavy pressure plate asm. did it all on axel stands with a trolly jack, 30-40 mins total from up in air,, strip, swap/fix, rebuild, wheels down.

if you look @ your 3rd picture, you can see the center splines that will pick up the shaft on the gearbox, And a nice "dimple" in the shiny bit behind it (crank) That is the clutch all aligned spot on,, and what you are aiming for when "done"

First of all this is only an opinion after reading of peoples experiences with "Scan-Tech" parts and the answer is don`t
these are cheap parts and depending on what they are usually need replacing again in 6 months our Volvo`s deserve better than that and in the end it will cost twice as much with also twice as much effort to replace the item

Regarding the clutch lining tool this is a "must have" as i have spent countless hours trying to line up gearboxes at midnight in the garage once i had the correct tool lining up was a doddle everytime
this is one tool that is not just sold to make a profit but has to be used because that is why it is manufactured
the clutch plate has to be exactly central for the box to line up if it doesn`t you cannot tell which way you have to move the plate so the tool is the easiest and best way, it has to be exact as the gearbox shaft not only lines up on the splines (the easy bit) but it has to then insert itself into the end bush on the engine crankshaft which is the difficult bit if not exactly central
you can buy one from 10 to 25quid even on ebay if you use Scan -Tech parts you will need it again anyway:lightning::lightning:

the reason DWM only paid £70 for his slave cylinder is because it depends which gearbox you have fitted and not the engine, his has the cylinder on top of the box with just the normal clutch release bearing, M5P box.

neanderthal has the clutch release bearing together with the cylinder inside the bell housing with nothing on top this is M56 box

When I did the clutch on my V50 I aligned it by eye, went in first time, no dramas. Shop around, my slave/bearing was £78 from Sachs.

There is a chance you could upgrade to self-adjusting clutch if your car already hasn't got one, ask the parts supplier.

Contrary to what garages tell you, special tools are not needed, they make life easier but are not a must have. Even a self adjusting clutch can be reset DIY and installed as normal by gradually tightening the bolts diagonally.

thanks for the links andy d....the clutch is easier than i was expecting,as i have never done one before.to be on the safe side as 960 kg has said i will buy a tool to line it up.cheers:thumbs_up:

960 raises a good point or 3
scantech,,yes i too have seen reports on here of "ah didnt last long" so perhaps parts from them arent that good an idea.
my bad for suggesting parts monster without checking Who's parts they supply.

in 50/50 on the clutch tool, never having used one but can see that they could make the job a lot easier for folk. But most of the cars ive replaced the clutch on were RWD , the only fwd being a older ford escort (the xr3 turbo thing).

thanks for all the info 960kg,i am definately going to buy a new slave cylinder and a locking tool..much appreciated...will let you all know the outcome...thanks

i couldn`t agree with you more andy, believe me i have had my stepmother at 10.30pm down the garage turning the back wheel of my tuned up 1650 Anglia in the early `70`s trying to line the splines up with me trying to get the engine back on the gearbox and i had even used the "tool" for lining up
of course tiredness has a lot to do with it as well, i remember it well, we had a sandwich and a cup of tea ,had another go at 11pm and it went on first go,the engine was hanging at the wrong angle for insertion and through being knackered did not notice it

yes, i have had them go on and lined them up by eye but it is usually just a fluke, ok if you can but if you can`t it is very,very frustrating and the weight of the things really does leave you open to fatigue, and you still have the rest of the assembly to go, it really is worth the £16 where i have just seen a universal clutch tool at Halfrauds

Or check this for £8.25 at fleabay

http://www.ebay.co.uk/itm/Toolzone-P...item1c1d9c7a23

just an update
 

just to update you all...will be getting some money on the 26-27 october to buy the parts i need to fix my volvo.if there is no rain then i will allow 2 days to repair it....thanks:clock:

Fingers crossed :)

Any updates? :thumbs_up:

a black v40 came into the scrapy today...im bagsying the rear calipers and the gearbox with the clutch assemblies once its depoluted...i will check to see if its a dirty weasel (diesel) for Alex's replacement hose on his S40 :)

- important question..are the gearboxes common across the range? i have an m56 box...with a failing second gear on it...new fluids did ought to help :/

HI Anadinolin could you bagsy me the aerial roof grommet? or give me the address of the scrappy? as mine keeps on letting in water everytime it rains, i am sure we can meet up at Gatos's place as some point in the future.

regards Gary.

Or we can come your end with Siamblue and go together to the scrappies... :)

Thanks for remembering me Anadinolin....

I still have the m56 gearbox hanging around. unless if you can take out the gear itself which would be cheaper

The scrapyard is "outens" in purfleet, just off the A13...i dont know exaxtly whats on the car still...maybe head up there next saturday for a closer look before i go see my new woman?

By "New woman" you mean one of the female human species or another Volvo?:hidesbehindsofa:lol

I guess you will be less active in the forum for the next few weeks then.......:):):)

If it is a P2 Diesel, then it is definitely worth a try. Do you now what their prices are like?

the prices are reasonable....put it this way a good engine with the gearbox @ mates rates for me was £200 last year, if i wanted my friend to take it out, an extra £50...

i have a volvo 460 in my aunts garage ;) and a new GF who works at millies cookies in lakeside lol :P

ps i might also be trying to change my front brakes next saturday too..if you can help, that would be fantastic :thumbs_up: i dunno whats happened, but the bolts would not budge when i tried to remove them today :S i gave up n put the wheels back on...lemme know if ur interested in going up there with me, ill be happy to take you from my place

I will have a word with Siamblue and we can take it from there. To be honest, I am only after the aircon hose. I am trying to get another car to break with Siamblue. With regards to your brake bolts, they may have seized and you may have to damage them to get them out. Maybe we can arrange a join meeting with Siamblue at my place, as I still have the V40 and **** loads of screws so we can replace yours

And congrats for new GF. I bet she is really sweet.....:):):)

almost there...but stuck?
 

!!!UPDATE!!!.....hi again....got the gearbox etc back in,but i cannot for the life of me get the left drive shaft back in,it just wont click into place...i have put the right shaft(drivers) in first, as it says in the instructions.....i am assuming the drivers side shaft just slots into place without clicking in place as it does not say this in the instructions.where as the left shaft does have to click into place according to the instructions......thanks

I have never put one back, so I am not so sure to be honest. WE just took apart the gearbox from the car I was breaking and never had to put it back again

any ideas anyone.thats the only thing as far as i can tell thats keeping my car off the road.....thanks

I had a problem with driveshafts a little while ago...im at work now so i cant find it to link, but if you search my posts going back about 3-4 months ago, it should be there...i bricked myself when ball bearings fell out of the end of the shaft...you put them back in with a hammer and resting the holder inside the shaft...ill show gatos how to for another amazing guide :)

We could do it on my spares car if you want...:)

update.... as i was trying again today to put the driveshaft back in,i pulled it back out and stuck my finger in the shaft....and...OH NO.....i could feel something loose.... half moon shape on the inside and smooth, with V shaped grooved teeth on the outside about the size of a fifty pence.....i wonder if that was,one part of where the drive shaft was to go into.....go on tell me the gearbox is coming back out....im'e bracing myself:broken_heart:......thanks

i am not 100% sure but i think you dismantled the shaft the incorrect way
you should of knocked out a 5mm roller pin on the inside joint first to seperate the inner joint from the inner splined shaft that goes in the box onto the sun gear

ok, so i understand that the whole thing can come straight out the box but i would assemble them as seperate items as the whole assembly is heavy and just to put the inner splined shaft in the box would be more delicate and easier

there is no clip so it won`t click in place as then when you replace the rest of the shaft the 5mm holes line up for the pin to be put back in

thanks for your reply 960kg,i just went by the instructions i was given on this forum,and it does not mention knocking out a roller pin...i have not actually been in the gearbox itself,as i only changed the concentric slave cylinder in the housing...i just removed the shaft out of the gearbox with a crowbar,as instructions...then to put the shaft back in it says.....install the drive shaft in the differential housing.press the drive shaft so that it is locked with its lock ring...thanks

neanderthal...have you read this thread, are you seeing something like this?

http://volvoforums.org.uk/showthread...=123853&page=3

hi,thanks for finding the thread anadinolin,yep the 2nd picture driveshaft with half a ring clip close to the end of the drive shaft.i am guesing the gearbox is coming out with the part been loose inside the gearbox....hope i can sort it as i have never touched gears before.or if something is broke inside,would i be better buying a second hand gearbox....

as you have seen in that thread i answered it does depend which combination of engine gearbox you have perhaps i read the wrong one last night but as least you seem on the right track now with the correct pictures!

that would be good :)

update
 

!!!update!!!....stripped the car again and removed the gearbox housing....i would appreceiate it yet again if anyone can tell me if as i remove the bolts to the gearbox if anything is going to jump out at me and i am not going to know what goes back where...its thanks to you people i have got this far....but i know nothing of gears and what position they should be in...i just want to look inside to see what is happening as i found something loose in the driveshaft bit of the gearbox and i'me dreading what i may find....if there is something broke.could i buy parts for it or do i have to get another gearbox....i believe i have an m56 gearbox....once i open the gearbox,will i have to buy gaskets...any pictures of inside the gearbox would be appreciated...and lastly should i tackle this myself...the truth is i am unemployed(so limited with many things):money:...thanks again everyone....:thumbs_up:

just noticed from page 3 of a drawing of the inside of the gearbox...thanks gatos.....