Dying flywheel? (video)
 

https://www.youtube.com/watch?v=YAI-J1PdjRA

I get this clunking noise sometimes at idle, and I feel clutch pedal vibrating a bit. When clutch pedal is pressed, clunking stops. Also sometimes, when car is stopped and I want to engage in 1st or reverse, pedal gets stuck and I have to bring it back up with my foot. When I accelerate, RPM revs but speed seems to be a little late. Apart from all that, switching gears while accelerating is totally fine and biting point too.

Is it the sign of a dying flywheel? How many miles can I drive before changing the whole clutch and flywheel?

Sounds like the flywheel to me, and reasonably well advanced too. It might last 1500 miles it might last 25,000, but if it were mine I'd be getting it sorted sooner rather than later.

that noise
 

Ild agree re the clutch/dmf but theres not much you can inspect without taking the gearbox off (big task)

Check if your brake fluid reservoir is low on fluid (or needs topping up regularly) or you can see any fluid leaking out of the bell housing (this would indicate a leaking clutch slave cylinder) which is common on the D5 but will at least give you a clue.

No brake fluid leak. I'll have a look at the bell.
Anyway if I replace clutch I might as well replace dmf. Now I don't know if it's worth it. That would cost me at least £1300 and that's how much I paid for the car a few months ago, and I already spent 1,5k servicing it in only 2 months.

It has 186k miles, don't know much about its history I just know it's been serviced at Volvo until 160k. Now I got that clutch problem and soon injectors are going to fail, they're ticking a lot. Idk if I dump it or fix it...

worth fixing
 

Hi,

the D5 engines are good for high mileages, but if its had a lack of basics like oil change then that could play its hand, the actual clutch is made by LUK if you want to get an idea of parts cost, the dmf's seem to be a bit less expensive as time goes by so its really time being the major cost to fix it, book hours is 8 for the clutch if you can find a good independant garage, i have some info on whats involved if your interested.

I'm going to change the whole clutch with master and slave cylinders + dmf, anything I should know? I'm handing that job over to my mechanic friend

stuff to know
 

Hi nb,

Well apart from use genuine volvo parts (certainly for the clutch slave cyl), and you probably wont need to change the master cylinder .. as the gearbox and subframe has to come out, swapping wishbone bushes (if needed im sure you dont want a massive bill) but Labour wise that kinda thing makes sense while its all in pieces.. things like the bolts (six or 8 i recall) should also be replaced when the clutch plate is replaced, similarly drive shaft bolts are a one off use fastener ..i have all the volvo & LUK part nos if you want somewhere, let me know..

Hi thassos

Thank you for that. Already recently changed the whole front suspension parts but that's good to know. About the bolts, are they included with the clutch kit and flywheel? Or do I need to buy them separately?

Here are the ref I found : LUK dmf 415 0220 10 and LUK clutch kit 624 3145 33.

I have a 3000 miles trip at the end of the month, and I won't be able to change the clutch before that trip. I hope it will hold on!

info 4 u
 

Hi NB,

3000 mile trip (lets hope its all motorways ..) certainly have the right car for that with a volvo ..

I found some info i had put together, this is for a 2006 D5-185 2006 D5244T4 engine..

The bolts for the cover plate are no (7) in the list

Also attached the info i had at the time, which at least gives an idea of whats involved.

A pic of the slave cyl (CSC) also attached (this is on the 'inside' of the bellhousing) mine had started to leak at 80=90k, i guess they must have improved the part as mines still going strong at 143K - the clutch is a self adjusting variety so you dont really notice any wear until its on its last legs.

If you ring LUK's uk helpline they are very helpful (unlink most 'help' lines these days) +44 (0)1432-264264 not sure of your location, incase not UK..

https://www.schaeffler.co.uk

the LUK clutch part nos (for mine anyway) were
624 325 619 (2pc) or 637 669 860 (3pc)

DMF is p/no 415031510 you can even get on amazon these days it seems..

Keep us posted & good luck with your trip, youll notice a massive improvement when fixed I suspect :)

Thanks a lot for your advice. Your parts are indeed for D5244T4, mine is the first D5244T so they're not the same. But the bolts are the same, I'll get them on skandix when I'll change the clutch.

One more question, should I at least change transmission oil to make my worn clutch last a bit longer before my trip, or should I not touch anything and keep the current oil? And can I use basic transmission oil as long as it's 75W80 GL-4 or do I really need to use Volvo's? :)

I'll definitely keep you updated after my trip! Just hope I won't blow up my clutch on some Italian hill :tounge_smile: