Clutch query

[Grimble]

XC60 D4 62 plate 118k miles. No towing.

Clutch has started playing up. To be more exact its the pedal. I start in the morning and the pedal needs depressing almost to the floor to engage gear.
Sometimes it doesn't return back up and I need to hook my foot under before it springs back.

In heavy use around town or motorway stop/start, it behaves normally, ie 'bites' in the usual place.

Next day, repeat.

I have monitored the fluid and there is no leak. My indy says it sounds like an issue with the slave cylinder and to access it is a big job and I may as well change the clutch plate/dual mass flywheel at the same time.
All fair enough, I can't moan too much at needing a new clutch at my mileage, but can anybody shed any light on what is happening?

[Tannaton]

Originally Posted by Grimble

XC60 D4 62 plate 118k miles. No towing.

Clutch has started playing up. To be more exact its the pedal. I start in the morning and the pedal needs depressing almost to the floor to engage gear.
Sometimes it doesn't return back up and I need to hook my foot under before it springs back.

In heavy use around town or motorway stop/start, it behaves normally, ie 'bites' in the usual place.

Next day, repeat.

I have monitored the fluid and there is no leak. My indy says it sounds like an issue with the slave cylinder and to access it is a big job and I may as well change the clutch plate/dual mass flywheel at the same time.
All fair enough, I can't moan too much at needing a new clutch at my mileage, but can anybody shed any light on what is happening?

I've just had this on my 17 MY D4 (FWD) at 47k miles (ish). Required a new slave cylinder which was done under warranty. Exact symptoms you describe - if not used for a while pedal biting point is lower, but with regular use it's fine. Mine got gradually worse until it stuck to the floor.

[Grimble]

Cheers for the reply, unfortunately to access the slave cylinder is apparently a big job, so the clutch/flywheel may as well be done at the same time.

I've been quoted around £1000 including the flywheel at £200 or so.

Anybody care to comment on these numbers?

Either way I've got no option, its got to be done.

[airbrass]

Same for me, 22k D4 2016, gearbox removal to replace slave cylinder.
Done under warranty.

[NigelDay]

Originally Posted by airbrass

Same for me, 22k D4 2016, gearbox removal to replace slave cylinder.
Done under warranty.

So this (and the recent D4 starter motor replacement posted elsewhere) makes me more inclined to go for an extended warranty when mine runs out. It's disappointing to see significant items going wrong at an early mileage.

[Grimble]

To be fair, mine has done 118k miles, but I do regard it as poor mechanical design practice to make an item that is subject to wear and containing seals so inaccessible.

[Grimble]

Got the clutch, slave cylinder and dual mass flywheel replaced. At not inconsiderable expense.

The following day after a night parked up, same problem appeared. Pedal feels ok, then pressed down to start, feels ok, then engage 1st, foot off pedal and pedal remains down, requiring my toes to hook underneath to bring it back up. After one or two more presses, its ok again all day.

Indy has never heard of a master cylinder failure.

Any suggestions?

[Tannaton]

Originally Posted by Grimble

Got the clutch, slave cylinder and dual mass flywheel replaced. At not inconsiderable expense.

The following day after a night parked up, same problem appeared. Pedal feels ok, then pressed down to start, feels ok, then engage 1st, foot off pedal and pedal remains down, requiring my toes to hook underneath to bring it back up. After one or two more presses, its ok again all day.

Indy has never heard of a master cylinder failure.

Any suggestions?

I would guess that they have forgotten to change the slave cylinder? My symptoms were exactly as you are describing and it was the slave cylinder. Hopefully they will collect and sort at no extra cost.

[Tannaton]

Originally Posted by NigelDay

So this (and the recent D4 starter motor replacement posted elsewhere) makes me more inclined to go for an extended warranty when mine runs out. It's disappointing to see significant items going wrong at an early mileage.

I know it is a little concerning - £1000 job to change a £30 part. And we can't even blame the remnants for Ford cost cutting as it's Volvo's own M66 gearbox (in AWD and FWD cars).

[S40D5]

Could Just Need Bleeding Up Properly