S40 2008 broken clutch pedal / pin

vwman · Apr 8th, 2021, 23:32

A friend of mine recently attempted to start his '08 S40D, and the clutch pedal went to the floor and stayed there. I had a look and it was clear the pedal is no longer connected to the clutch; there's no resistance there at all - it's just loose. We had a quick search online and found this is a well-known problem and in fact has been the subject of a Volvo recall for a new clutch master cylinder, documented elsewhere in this great forum. Input the chassis number and bingo! We're covered!

So we rang the local main dealer, who said yes the car was subject to this recall, but the recall had already been carried out. Gutted! They couldn't (wouldn't?) say when it was done, mileage, or where etc.

I haven't yet looked at the pedal assembly itself but it sounds to me as if the pin between the pedal and the master cylinder must have broken. Does anyone know any different please?

My key question is, do we really have to buy and replace the whole master cylinder just for the sake of one little pin? The MC isn't really that expensive, but the work to fit one looks quite involved and time-consuming. Is it possible just to replace the pin, either with a new one or an old one extracted from a second-hand MC?

Any help anyone can give would be really appreciated. TIA.

Willber G · Apr 9th, 2021, 01:56

Not sure about your car but the same thing happened to my Alfa as I was leaving my mechanic after an MOT. He fixed it using a nail, I think. Anyway, it did the trick and lasted years. In truth I meant to get the proper part but forget all about it.

vwman · Apr 13th, 2021, 22:26

Ok, so I've had a look at the pedal and to my surprise the pin is the metal one, and it's intact - so I'm a bit stumped!

Apart from the return spring the pedal has no resistance whatsoever, it's as if it isn't connected to anything. There's no fluid leaking anywhere in the car that I can see, at the pedal end or at the slave cylinder. The only thing that isn't perfect is the brake fluid level is at minimum.

Does anyone have any idea what could cause this / what has actually broken? The car had stood for a while; is it possible that the clutch itself was a bit sticky and required too much force to separate, causing something to give?

At this stage all I can do without spending money is to bleed the clutch so I'll try that next. Any suggestions would be gratefully received.

Many thanks.

Apr 8th, 2021, 23:32	#1
vwman New Member Last Online: Jun 16th, 2021 13:51 Join Date: Apr 2021 Location: Ipswich	S40 2008 broken clutch pedal / pin A friend of mine recently attempted to start his '08 S40D, and the clutch pedal went to the floor and stayed there. I had a look and it was clear the pedal is no longer connected to the clutch; there's no resistance there at all - it's just loose. We had a quick search online and found this is a well-known problem and in fact has been the subject of a Volvo recall for a new clutch master cylinder, documented elsewhere in this great forum. Input the chassis number and bingo! We're covered! So we rang the local main dealer, who said yes the car was subject to this recall, but the recall had already been carried out. Gutted! They couldn't (wouldn't?) say when it was done, mileage, or where etc. I haven't yet looked at the pedal assembly itself but it sounds to me as if the pin between the pedal and the master cylinder must have broken. Does anyone know any different please? My key question is, do we really have to buy and replace the whole master cylinder just for the sake of one little pin? The MC isn't really that expensive, but the work to fit one looks quite involved and time-consuming. Is it possible just to replace the pin, either with a new one or an old one extracted from a second-hand MC? Any help anyone can give would be really appreciated. TIA.

Apr 9th, 2021, 01:56	#2
Willber G Upstanding Member Last Online: Aug 26th, 2022 23:00 Join Date: Mar 2020 Location: Southampton	Not sure about your car but the same thing happened to my Alfa as I was leaving my mechanic after an MOT. He fixed it using a nail, I think. Anyway, it did the trick and lasted years. In truth I meant to get the proper part but forget all about it. __________________ . __56 C70 D5 SE Geartronic

Apr 13th, 2021, 22:26	#3
vwman New Member Last Online: Jun 16th, 2021 13:51 Join Date: Apr 2021 Location: Ipswich	S40 2008 broken clutch pedal / pin -update Ok, so I've had a look at the pedal and to my surprise the pin is the metal one, and it's intact - so I'm a bit stumped! Apart from the return spring the pedal has no resistance whatsoever, it's as if it isn't connected to anything. There's no fluid leaking anywhere in the car that I can see, at the pedal end or at the slave cylinder. The only thing that isn't perfect is the brake fluid level is at minimum. Does anyone have any idea what could cause this / what has actually broken? The car had stood for a while; is it possible that the clutch itself was a bit sticky and required too much force to separate, causing something to give? At this stage all I can do without spending money is to bleed the clutch so I'll try that next. Any suggestions would be gratefully received. Many thanks.

Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)