S40 (New) G/box : - Clunking Gear box? or not ?

danny r · May 25th, 2010, 21:02

When changing through the gears my 2007 S40 'clunks'.

It is apparent up through 1st to 2nd, 2nd to 3rd and 3rd to 4th gears. It clunks when the clutch is depressed to the floor and as the gears re-engage. It sounds as if the sound is under the centre of the car. Its a metalic sound.

I cannot hear it going through the other gears (fifth & sixth) and also it does not appear when going down through the gears, (thats not to say its not there!)
Firstly Volvo couldnt hear this problem but its clear when, in a built up area the sound reverberates off the houses / surrounding walls etc. So, its not a sound that at first grabs you but its there and is only when changing gear as mentioned.
Last month, on an extended warrenty, volvo changed the gear box FOC. Needlees to say, i was releived as it was just out of warranty. The car had a new clutch in warranty, at 43,500 odd miles due to the slipping gears at 19-2100 revs which is/was a manufacturing fault on this model/clutch etc.

So, we have a new clutch and gear box and....Last week the same clunking noise reppeared.
I have returned the car to the garage who are unsure where to go with this problem.

The outcome is that no-one at the dealership can (at present) identify the problem. Today I was told that the car has not been fixed but is ready for collection!
The dealership do not know the faulty part to remedy the problem and I am not a happy volvo driver .....

Can you please help with this as I would be very grateful for some advice.

Welton · May 27th, 2010, 08:59

My T5's gearbox/drivetrain does the same I think (it's a different box to the diesel though) but I sometimes get a kinda heavy machinery "ker-chink" when using the gears.

I have put this down to slightly poor driver timing of the clutch action during changes and most of all the gearbox oil is now much hotter than it was in the winter effectively 'loosening up' all the gearbox components.

If gears select ok with the engine on and off then I wouldn't worry. Similarly if there's no whining or difficult changes it should be ok. A good gearbox should feel kinda 'snickety' where the gear selection has some resistance at first and then snicks in nicely without crunching and it should feel like it's going to stay in gear (like you've pushed a lever over a crest if you like).

A naughty gearbox will feel difficult to engage and like it's going to pop out of gear again as if the level isn't quite reaching where it needs to.

Bigmunkynutz · Aug 9th, 2010, 13:57

I have this same issue/occurance on my 05 S40 2.0d SE Sport.

I'm guessing it's not a big problem...

Like you mentioned its only really there 2nd to 3rd and 3rd to 4th for me and although its a clunk its quite a 'soft' clunk similar to the kind of clunk you get when you reach full lock on steering. like somethng hitting a rubber stopper, really strange.

It does worry me slightly (usually when I have the stereo down low and can hear it)

I was going to ask about it when I took it for a service.

Bulgarianvolvo · Mar 27th, 2011, 05:56

I also have a slightly clunkly gearbox on my LHD 2.0D and a very heavy clutch. My wife has a 1.6D and the pedal pressure is lighter and much more pleasant. I have never experienced such a heavy clutch and cannot believe that it was designed to be like this..... It is a company car and thinking to take it in to the dealer for a checkup.

fenton_jd · Mar 27th, 2011, 12:53

I had the same on the 2.0d and T5.

zork · Sep 21st, 2018, 22:31

Hello!

Did anyone managed to fix this?

I have this clunk sound when:
1. changing gears... It doesnt happen only if I have a good timing for clutch pedal and acclerator...
2. Climbing a border
3. Shutting off the engine... But here is more than a single clunk... There are like 2-3 clunks... If I press the clutch pedal it's ok...

I replaced the engine mount on the drivers/battery side(left) ; I replaced the torque pad to no avail... Some say it could be the flywheel, but it seems that replacing the entire clutch didnt helped Danny...

Any ideeas?

Thank you!

Volvo S40 2.0D 2004

LizardOfBodom · Sep 24th, 2018, 15:12

Quote:

Originally Posted by zork

Hello!

Did anyone managed to fix this?

I have this clunk sound when:
1. changing gears... It doesnt happen only if I have a good timing for clutch pedal and acclerator...
2. Climbing a border
3. Shutting off the engine... But here is more than a single clunk... There are like 2-3 clunks... If I press the clutch pedal it's ok...

I replaced the engine mount on the drivers/battery side(left) ; I replaced the torque pad to no avail... Some say it could be the flywheel, but it seems that replacing the entire clutch didnt helped Danny...

Any ideeas?

Thank you!

Volvo S40 2.0D 2004

Mine did this ever since I got it 2 years ago, so did my previous S40 previous gen. Its not related to clutch/DMF , I can tell you that, as on brand new set it still does that so its still an "one of those things" issues

May 25th, 2010, 21:02	#1
danny r New Member Last Online: May 27th, 2010 09:36 Join Date: May 2010 Location: oxford	Clunking Gear box? or not ? When changing through the gears my 2007 S40 'clunks'. It is apparent up through 1st to 2nd, 2nd to 3rd and 3rd to 4th gears. It clunks when the clutch is depressed to the floor and as the gears re-engage. It sounds as if the sound is under the centre of the car. Its a metalic sound. I cannot hear it going through the other gears (fifth & sixth) and also it does not appear when going down through the gears, (thats not to say its not there!) Firstly Volvo couldnt hear this problem but its clear when, in a built up area the sound reverberates off the houses / surrounding walls etc. So, its not a sound that at first grabs you but its there and is only when changing gear as mentioned. Last month, on an extended warrenty, volvo changed the gear box FOC. Needlees to say, i was releived as it was just out of warranty. The car had a new clutch in warranty, at 43,500 odd miles due to the slipping gears at 19-2100 revs which is/was a manufacturing fault on this model/clutch etc. So, we have a new clutch and gear box and....Last week the same clunking noise reppeared. I have returned the car to the garage who are unsure where to go with this problem. The outcome is that no-one at the dealership can (at present) identify the problem. Today I was told that the car has not been fixed but is ready for collection! The dealership do not know the faulty part to remedy the problem and I am not a happy volvo driver ..... Can you please help with this as I would be very grateful for some advice.

May 27th, 2010, 08:59	#2
Welton Premier Member Last Online: Sep 14th, 2021 17:03 Join Date: Feb 2009 Location: Market Harborough	My T5's gearbox/drivetrain does the same I think (it's a different box to the diesel though) but I sometimes get a kinda heavy machinery "ker-chink" when using the gears. I have put this down to slightly poor driver timing of the clutch action during changes and most of all the gearbox oil is now much hotter than it was in the winter effectively 'loosening up' all the gearbox components. If gears select ok with the engine on and off then I wouldn't worry. Similarly if there's no whining or difficult changes it should be ok. A good gearbox should feel kinda 'snickety' where the gear selection has some resistance at first and then snicks in nicely without crunching and it should feel like it's going to stay in gear (like you've pushed a lever over a crest if you like). A naughty gearbox will feel difficult to engage and like it's going to pop out of gear again as if the level isn't quite reaching where it needs to. __________________ 2005 S40 T5 SE - Manual. Bilstein B4's. (For Sale) 2010 Citroen C4 1.6 HDi (bizarre Gearbox model). 2010 Renault Twingo (refreshingly simple) 2018 Infiniti Q30 1.6T Business Executive (what's this button do?)

Aug 9th, 2010, 13:57	#3
Bigmunkynutz S40 Owner Last Online: Jun 16th, 2013 22:33 Join Date: Jul 2010 Location: Warrington	I have this same issue/occurance on my 05 S40 2.0d SE Sport. I'm guessing it's not a big problem... Like you mentioned its only really there 2nd to 3rd and 3rd to 4th for me and although its a clunk its quite a 'soft' clunk similar to the kind of clunk you get when you reach full lock on steering. like somethng hitting a rubber stopper, really strange. It does worry me slightly (usually when I have the stereo down low and can hear it) I was going to ask about it when I took it for a service. Last edited by Bigmunkynutz; Aug 9th, 2010 at 14:02. Reason: more info

Mar 27th, 2011, 05:56	#4
Bulgarianvolvo New Member Last Online: Mar 27th, 2011 15:30 Join Date: Mar 2011 Location: Sofia	Heavy clutch I also have a slightly clunkly gearbox on my LHD 2.0D and a very heavy clutch. My wife has a 1.6D and the pedal pressure is lighter and much more pleasant. I have never experienced such a heavy clutch and cannot believe that it was designed to be like this..... It is a company car and thinking to take it in to the dealer for a checkup.

Sep 21st, 2018, 22:31	#6
zork Junior Member Last Online: Apr 20th, 2024 23:54 Join Date: Dec 2014 Location: Constanta	Hello! Did anyone managed to fix this? I have this clunk sound when: 1. changing gears... It doesnt happen only if I have a good timing for clutch pedal and acclerator... 2. Climbing a border 3. Shutting off the engine... But here is more than a single clunk... There are like 2-3 clunks... If I press the clutch pedal it's ok... I replaced the engine mount on the drivers/battery side(left) ; I replaced the torque pad to no avail... Some say it could be the flywheel, but it seems that replacing the entire clutch didnt helped Danny... Any ideeas? Thank you! Volvo S40 2.0D 2004 Last edited by zork; Sep 21st, 2018 at 22:34.

Mar 27th, 2011, 12:53	#5
fenton_jd turkeyspace.com Last Online: Nov 5th, 2016 16:41 Join Date: Apr 2009 Location: Gloucester	I had the same on the 2.0d and T5.

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