Stiff gear change

Challo · Nov 21st, 2018, 22:22

Hi Folks,

Newbie here. Just picked up a 2003 S60 2.0T this week and the gear change is generally stiff, but can be a real struggle to select 1st and sometimes reverse.

If I’m stationary and try 1st it can be really tough and you have to really push it into gear, but if I’m changing down with the clutch already depressed it can be easier to select.

Could it be as simple as greasing the gear selector cables, or do you think the clutch is on its way out?

Anyway to easily test?

Thanks

Clan · Nov 21st, 2018, 22:36

Quote:

Originally Posted by Challo

Hi Folks,

Newbie here. Just picked up a 2003 S60 2.0T this week and the gear change is generally stiff, but can be a real struggle to select 1st and sometimes reverse.

If I’m stationary and try 1st it can be really tough and you have to really push it into gear, but if I’m changing down with the clutch already depressed it can be easier to select.

Could it be as simple as greasing the gear selector cables, or do you think the clutch is on its way out?

Anyway to easily test?

Thanks

It is called clutch drag , the clutch is still rubbing the flywheel slightly with the pedal right down , usually a sign the clutch is coming to the end or full of dust which drags the clutch plate round when it should be stationery .

Challo · Nov 22nd, 2018, 06:54

Quote:

Originally Posted by Clan

It is called clutch drag , the clutch is still rubbing the flywheel slightly with the pedal right down , usually a sign the clutch is coming to the end or full of dust which drags the clutch plate round when it should be stationery .

Thanks. Is there a way to check to confirm it’s the clutch? Would I need a DMF as well?

Anything else to check it could be? Slave cylinder? Cables?

oragex · Nov 22nd, 2018, 07:08

May want to return the car as this is a close to £1000 repair. This will also need a new flywheel. Usually the slave will leak underneath and the master cylinder will get low level.

Can replace with single clutch disk, google a bit for more info.

Challo · Nov 22nd, 2018, 07:27

It's a £900 car bought on on a private sale, so no chance of a return.

It's only a run around so might drag it out for the moment and decide if it's worth doing.

davebb · Nov 22nd, 2018, 09:09

Hi
Also have a good test of all of the engine mounts, the gear box torque mounts often need changing as the smaller rubber bush fails,
and there is also a mount from engine to subframe under the front pulley,
But Clan is the man with these cars,
Dave

Clan · Nov 22nd, 2018, 09:55

Quote:

Originally Posted by Challo

Thanks. Is there a way to check to confirm it’s the clutch? Would I need a DMF as well?

Anything else to check it could be? Slave cylinder? Cables?

when it is not going in , keep some pressure on the gear lever , turn the engine off and if it slips into gear as the engine stops it's clutch drag ..
Volvos dual mass flywheels are pretty good , if you have had no problems , no rattles etc and it passes volvos play test measurement then if you are on a tight budget re use it , If you do get the job done make sure you use the volvo clutch and slave cylinder and it will last another 20 + years ..

petey · Nov 22nd, 2018, 21:26

If the clutch is dragging, don’t fight it by banging it ever harder into 1st / reverse, it’ll only knacker the baulk rings on the dogs in the transmission.
It’ll be worse from a standstill so just knock it into third which will stop the clutch and then select 1st. When changing down to 1st matching revs helps also.

It’s a £900 car, it’ll have a few undocumented features....

benx · Nov 23rd, 2018, 12:25

I had the same problem on my manual V70/D5 - and often struggled to engage 1st or reverse (& especially when the engine was cold).

Took mine to a gearbox/clutch specialist. They didn't think the clutch was gone and they simply changed the gearbox oil to a different weight (& charged me £75). It completely transformed the car.

Could be worth a try.

Challo · Nov 23rd, 2018, 20:50

Cheers all for the comments. Over the week it's certainly eased up and gear changing is easier.

I'll try the test with turning the engine off and see how that works. Might give the cables a check as well.

There is a Volvo specialist near me in Camberley so might pop over there at some point and get them to take a look.

Nov 21st, 2018, 22:22	#1
Challo Senior Member Last Online: Mar 10th, 2024 20:33 Join Date: Nov 2018 Location: Reading	Stiff gear change Hi Folks, Newbie here. Just picked up a 2003 S60 2.0T this week and the gear change is generally stiff, but can be a real struggle to select 1st and sometimes reverse. If I’m stationary and try 1st it can be really tough and you have to really push it into gear, but if I’m changing down with the clutch already depressed it can be easier to select. Could it be as simple as greasing the gear selector cables, or do you think the clutch is on its way out? Anyway to easily test? Thanks

Nov 22nd, 2018, 07:08	#4
oragex Premier Member Last Online: Jul 26th, 2021 21:24 Join Date: Jun 2013 Location: Coldnada	May want to return the car as this is a close to £1000 repair. This will also need a new flywheel. Usually the slave will leak underneath and the master cylinder will get low level. Can replace with single clutch disk, google a bit for more info. __________________ Several Volvo Repair Videos https://www.youtube.com/playlist?lis...ECTts0FSVSOT_c

Nov 22nd, 2018, 07:27	#5
Challo Senior Member Last Online: Mar 10th, 2024 20:33 Join Date: Nov 2018 Location: Reading	It's a £900 car bought on on a private sale, so no chance of a return. It's only a run around so might drag it out for the moment and decide if it's worth doing.

Nov 22nd, 2018, 09:09	#6
davebb Premier Member Last Online: Apr 22nd, 2024 13:38 Join Date: Aug 2013 Location: Emsworth,hants	Hi Also have a good test of all of the engine mounts, the gear box torque mounts often need changing as the smaller rubber bush fails, and there is also a mount from engine to subframe under the front pulley, But Clan is the man with these cars, Dave

Nov 22nd, 2018, 21:26	#8
petey Master Member Last Online: Sep 11th, 2023 13:10 Join Date: May 2009 Location: Chippenham	If the clutch is dragging, don’t fight it by banging it ever harder into 1st / reverse, it’ll only knacker the baulk rings on the dogs in the transmission. It’ll be worse from a standstill so just knock it into third which will stop the clutch and then select 1st. When changing down to 1st matching revs helps also. It’s a £900 car, it’ll have a few undocumented features....

Nov 23rd, 2018, 12:25	#9
benx I've Been Banned Last Online: Sep 1st, 2022 10:50 Join Date: Oct 2018 Location: London	I had the same problem on my manual V70/D5 - and often struggled to engage 1st or reverse (& especially when the engine was cold). Took mine to a gearbox/clutch specialist. They didn't think the clutch was gone and they simply changed the gearbox oil to a different weight (& charged me £75). It completely transformed the car. Could be worth a try.

Nov 23rd, 2018, 20:50	#10
Challo Senior Member Last Online: Mar 10th, 2024 20:33 Join Date: Nov 2018 Location: Reading	Cheers all for the comments. Over the week it's certainly eased up and gear changing is easier. I'll try the test with turning the engine off and see how that works. Might give the cables a check as well. There is a Volvo specialist near me in Camberley so might pop over there at some point and get them to take a look.

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