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S40 / V40 '96-'04 General Forum for the Volvo S40 and V40 (Classic) Series from 1995-2004. |
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D.I.Y clutch replacement V40Views : 13747 Replies : 16Users Viewing This Thread : |
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Jan 12th, 2012, 19:47 | #1 |
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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 |
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Jan 12th, 2012, 20:52 | #2 |
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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.
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Jan 13th, 2012, 00:24 | #3 |
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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?
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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 |
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Jan 13th, 2012, 01:14 | #4 |
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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
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Current car: 2002 S40 1.9D, 1992 240SE Nullius in Verba
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Jan 13th, 2012, 20:03 | #5 |
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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....
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Jan 13th, 2012, 20:42 | #6 |
Insane!!
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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.
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'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!! |
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Jan 13th, 2012, 21:00 | #7 |
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yeah its a external slave cylinder so no probs there...
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Jan 14th, 2012, 08:40 | #8 |
G-BOAF
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Did mine on the 1.9D, drove in at 10am, was all done for 4pm. That included a few coffee stops. We do have a full equipped workshop though, but not that bad a job.
Rob |
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Jan 14th, 2012, 12:08 | #9 |
Insane!!
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We had to replace the jc5 gearbox on mine. took about 4 and a half hours in total on the floor with a trolley jack.
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'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 14th, 2012, 19:12 | #10 |
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job done. release bearing had collapsed- friction plate had plenty of life left, pressure plate fingers quite gouged though, cars done 90k so if this one lasts as long as the last i will be happy. took 8 hours, on the drive, just me (but wife did put a bolt in when i lifted the box back in) would have been quicker but didnt know about rollpin in r/h driveshaft...took a while trying to get shaft out, untill i turned it 90 degrees and seen the little bar steward! and had to seperate l/h cv joint as it wouldent come out of hub and i couldent get it to swing down and out like in the link- different box i think? oh and that sneaky little rivet in the gear selector linkage..grrrrrr! but car drives nice again and whats more i enjoyed doing it, especially as i lined the cutch up by eye and the box went in first time, as always ;-) damn im good
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