D.I.Y clutch replacement V40

rublehousen · Jan 12th, 2012, 19:47

Hi all, im doing the clutch on my 52 plate 1.6petrol v40 on saturday come rain or shine(or god forbid snow) im a very competent mechanic but not done any major work on volvos before, and would appreiciate some sound advice from any experienced volvo mechanics. stuff like: will i need extra long allen/torx keys? do driveshafts come out easy enough? hub nut off or split the cv joint? any special techniques required? any special tools that would be required? any special bolts that need specific torque? (my elbow clicks out at nip, tight and F.T) any trade secrets of what needs to be removed cos its in the way (but you wont realise untill your balancing the box in one hand and having gear oil running up to your armpit)that sort of thing.

any advice much appreciated

thanks. Rob

rublehousen · Jan 12th, 2012, 20:52

oh and does anyone know the book time volvo give for replacing the clutch? just to compare with how long it actually does take me. i like things like that.

Anadinolin · Jan 13th, 2012, 00:24

took me and a friend a day to remove the gearbox and approx 6 hours the next day to put it back, we only needed abut 5 different size sockets

we took out the airbox, battery and battery tray, gearbox mountings, the support bar underneath the car, driveshft on the passenger side (be careful as there are a set of bearings in this and they are easily pulled out of place) and took the gearbox out from underneath the car, while you are there, check your flywheel

you may want a breaker bar to seperate the gearbox from the engine to get at where the clutchplate sits....or am i thinking of the wrong thing here guys?

gatos · Jan 13th, 2012, 01:14

See my post 16 here: http://www.volvoforums.org.uk/showth...=135756&page=2

I have uploaded a pdf with instructions for the gearbox removal. Also that thread is an interesting read

rublehousen · Jan 13th, 2012, 20:03

thanks for that, its not the same gearbox as mine BUT it does show a different and possibly easier way of removing driveshafts than i was going to attempt, so hopefully save some time there. ive set my target time for 6 hours start to finish, we will see how that works out....

inchley313 · Jan 13th, 2012, 20:42

If you have the internal type clutch slave cylinder, it may be an idea to replace it while the gearbox is off the car. If it the M3B or JC5 renault box, these slaves are external and can be replaced without removing the box so I wouldn't worry about them until they need doing.

izzo · Jan 21st, 2015, 17:05

Quote:

Originally Posted by gatos

See my post 16 here: http://www.volvoforums.org.uk/showth...=135756&page=2

I have uploaded a pdf with instructions for the gearbox removal. Also that thread is an interesting read

Hi Gatos,

I'm trying to download the gearbox guide you uploaded here: http://www.volvoforums.org.uk/showth...=135756&page=2

But I guess is no longer available. Could you please be so kind to send it to me? Sorry to bother you.

Best regards,
izzo

kieran40 · Jan 21st, 2015, 20:51

Sooner you than me op lol not on a driveway on youre back which would be my case lol, matt is worth talking too he knows all about it. He rebuilt a entire car.

santoli3 · Jun 12th, 2015, 23:11

Me too!

Quote:

Originally Posted by izzo

Hi Gatos,

I'm trying to download the gearbox guide you uploaded here: http://www.volvoforums.org.uk/showth...=135756&page=2

But I guess is no longer available. Could you please be so kind to send it to me? Sorry to bother you.

Best regards,
izzo

brodak · Aug 3rd, 2016, 12:14

Hi gatos,
please, can you send me gearbox guide?

Thank you very much

Mail: brodak@centrum.cz

Quote:

Originally Posted by izzo

Hi Gatos,

I'm trying to download the gearbox guide you uploaded here: http://www.volvoforums.org.uk/showth...=135756&page=2

But I guess is no longer available. Could you please be so kind to send it to me? Sorry to bother you.

Best regards,
izzo

Jan 12th, 2012, 19:47	#1
rublehousen Senior Member Last Online: Nov 6th, 2018 10:16 Join Date: Feb 2010 Location: stockton	D.I.Y clutch replacement V40 Hi all, im doing the clutch on my 52 plate 1.6petrol v40 on saturday come rain or shine(or god forbid snow) im a very competent mechanic but not done any major work on volvos before, and would appreiciate some sound advice from any experienced volvo mechanics. stuff like: will i need extra long allen/torx keys? do driveshafts come out easy enough? hub nut off or split the cv joint? any special techniques required? any special tools that would be required? any special bolts that need specific torque? (my elbow clicks out at nip, tight and F.T) any trade secrets of what needs to be removed cos its in the way (but you wont realise untill your balancing the box in one hand and having gear oil running up to your armpit)that sort of thing. any advice much appreciated thanks. Rob

Jan 13th, 2012, 00:24	#3
Anadinolin VOC Member Last Online: Jun 20th, 2022 14:32 Join Date: Oct 2009 Location: Upminster View Photos By: Anadinolin	took me and a friend a day to remove the gearbox and approx 6 hours the next day to put it back, we only needed abut 5 different size sockets we took out the airbox, battery and battery tray, gearbox mountings, the support bar underneath the car, driveshft on the passenger side (be careful as there are a set of bearings in this and they are easily pulled out of place) and took the gearbox out from underneath the car, while you are there, check your flywheel you may want a breaker bar to seperate the gearbox from the engine to get at where the clutchplate sits....or am i thinking of the wrong thing here guys? __________________ what good music deserves is full deep bass to give it warmth. the stock volvo sub works....just at high volumes Drum n Bass and dubstep Last edited by Anadinolin; Jan 13th, 2012 at 00:39. Reason: i am tired, my spelling sux

Jan 13th, 2012, 01:14	#4
gatos Premier Member Last Online: Nov 15th, 2022 21:34 Join Date: Apr 2010 Location: London / Essex	See my post 16 here: http://www.volvoforums.org.uk/showth...=135756&page=2 I have uploaded a pdf with instructions for the gearbox removal. Also that thread is an interesting read __________________ Current car: 2002 S40 1.9D, 1992 240SE Nullius in Verba

Jan 13th, 2012, 20:42	#6
inchley313 Insane!! Last Online: Oct 19th, 2015 08:58 Join Date: Jul 2011 Location: Ramsey, Isle of Man	If you have the internal type clutch slave cylinder, it may be an idea to replace it while the gearbox is off the car. If it the M3B or JC5 renault box, these slaves are external and can be replaced without removing the box so I wouldn't worry about them until they need doing. __________________ '01 V40 2.0 Ph2 141,000mi (lower than the last one) '98 Honda CR-V 2.0 Auto (as this is the car I'm teaching SWMBO to drive in) Previous: '97 V40 2.0CD with 173,000mi on the clock and now sold!!

Jan 12th, 2012, 20:52	#2
rublehousen Senior Member Last Online: Nov 6th, 2018 10:16 Join Date: Feb 2010 Location: stockton	oh and does anyone know the book time volvo give for replacing the clutch? just to compare with how long it actually does take me. i like things like that.

Jan 13th, 2012, 20:03	#5
rublehousen Senior Member Last Online: Nov 6th, 2018 10:16 Join Date: Feb 2010 Location: stockton	thanks for that, its not the same gearbox as mine BUT it does show a different and possibly easier way of removing driveshafts than i was going to attempt, so hopefully save some time there. ive set my target time for 6 hours start to finish, we will see how that works out....

Jan 21st, 2015, 20:51	#8
kieran40 I've Been Banned Last Online: Mar 4th, 2023 12:36 Join Date: Aug 2013 Location: paignton	Sooner you than me op lol not on a driveway on youre back which would be my case lol, matt is worth talking too he knows all about it. He rebuilt a entire car.

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