S60 knocking/clunking noise fix?

[D5Russ]

Hi everyone, first post on the forum.

I begun my Volvo S60 D5 ownership last July and so far i've been really impressed but for the last few months i have a knocking/clunking noise that i can't seem to sort.

I've done a far bit of research on S60's and the usual knocking/clunking noise suspects. So far i've replaced the lower gearbox mount with polybushes, Upper engine mount with a polybush, lower drivers side engine mount, both front ARB droplinks and replaced the driveshaft bolts with XC90 ones. None of these parts have cured this knocking/clunking sound.

It'll make the noise when pulling off or coming to a stop, going over bumps at low speed and ocasionally when turning right. It sounds like its coming from the front drivers side and i swear i can feel it on the footwell when it clunks.

After more research i discovered that Volvo released a service bulletin due to a very similar fault to what i'm having. Volvo describe it as "A knocking noise that may occur when driving at low speeds on uneven road or at sharp turns, can be caused by one of the the rear subframe bushings moving in the sub-frame. The knocking can sometimes also be felt in the floorboard under the drivers feet."

Volvo say to install an O-ring between the sub-frame and the bodywork on the rear bushings on both left and right side as a service solution.

The part number for these subframe O-rings is 8638585. They can be ordered online from the USA but P+P charges seem to be £25+.

My plan is to order some of these O-rings and hopefully they'll cure the problem, although does anyone know where these O-rings can be purchased from in the UK? I'm guessing they can be ordered froma main dealer? Or does anyone on the forum sell them?

Thanks in advance

[The Edge]

Suspension Strut top mounts.

[D5Russ]

Originally Posted by The Edge

Suspension Strut top mounts.

How would one test if these need replacing?

I did the test on the strut top mount nuts, put a spanner on them and tried turning them round. They both moved about quarter of a turn and sprang back, passenger side performing better that the drivers side though.

[cheshired5]

No mention of testing or even visually inspecting the function of the vacuum engine mounts.
Also, is the gearbox a good 10-20mm clear of the subframe rubber stopper?

[D5Russ]

Originally Posted by cheshired5

No mention of testing or even visually inspecting the function of the vacuum engine mounts.
Also, is the gearbox a good 10-20mm clear of the subframe rubber stopper?

Just watched a video on how to check the vacuum mounts, so i'll check them tomorrow.

Where is the subframe rubber stopper located? I'm guessing in front of the gearbox near the torque mount?

[bkulcsar]

Originally Posted by D5Russ

Hi everyone, first post on the forum.
Volvo say to install an O-ring between the sub-frame and the bodywork on the rear bushings on both left and right side as a service solution.

The part number for these subframe O-rings is 8638585. They can be ordered online from the USA but P+P charges seem to be £25+.

My plan is to order some of these O-rings and hopefully they'll cure the problem, although does anyone know where these O-rings can be purchased from in the UK? I'm guessing they can be ordered froma main dealer? Or does anyone on the forum sell them?

Thanks in advance

I had been in the same boat, as you are right now. Spoken to a Volvo dealer about the O-rings the service bulletin mentions. He told me that the service bulletin refers to petrol engines ONLY. There are no D5 Volvos in the US.

I suggest you watch this video another forum member (oragex) posted on youtube:
https://www.youtube.com/watch?v=uy08iEdvEwg

[The Edge]

Originally Posted by D5Russ

How would one test if these need replacing?

I did the test on the strut top mount nuts, put a spanner on them and tried turning them round. They both moved about quarter of a turn and sprang back, passenger side performing better that the drivers side though.

Mine seemed fine, but replacement fixed the noise which I would have bet my house on being drop links.

I didn't test, I took advice from a very experienced Indi, who also did the work.

[D5Russ]

Originally Posted by bkulcsar

I had been in the same boat, as you are right now. Spoken to a Volvo dealer about the O-rings the service bulletin mentions. He told me that the service bulletin refers to petrol engines ONLY. There are no D5 Volvos in the US.

I suggest you watch this video another forum member (oragex) posted on youtube:
https://www.youtube.com/watch?v=uy08iEdvEwg

Thanks for the link, i'll check that too tomorrow.

What difference would fitting the subframe O-rings make on petrol and diesel models? Surely both models use the same subframes and that would mean that they could both have the same fault?

[bkulcsar]

Originally Posted by D5Russ

Thanks for the link, i'll check that too tomorrow.

What difference would fitting the subframe O-rings make on petrol and diesel models? Surely both models use the same subframes and that would mean that they could both have the same fault?

According to the dealer I spoke with, the O-rings are not recommended to diesel engines because that would amplify the vibration. I didn't quite understand his explanation.

[cheshired5]

Originally Posted by D5Russ

Where is the subframe rubber stopper located? I'm guessing in front of the gearbox near the torque mount?

It's located under the gearbox in the only place the gearbox could contact the subframe.
It'll be obvious when you look.