V40: !!! HELP!!! 960KG, GATOS.anyone with knowledge.. no clutch

[neanderthal]

Originally Posted by neanderthal

hi,took the plastic thing off and removed the rubber cover,and managed to get some molegrips on the rod,but ufortunately it was solid....but thanks for effort......gatos and 960kg...i tried tightening the rod itself...should i have put the molegrips on the end of the rod(picture1)....as i tried tightening the rod from the middle of it

volvo v40 2003 1.9 td sport estate

[neanderthal]

i would just like to say a big thank you to the following people for all the information,diagrams,pictures,hints,and time and effort in helping me to understand the fault with my volvo.....GATOS960KGBIOTOXICV40B ARTSIAMBLUEANDY D...i will let you all know in due course the outcome.i feel more confident that the volvo will be back on the road soon thanks to this info....much appreciated.regards neanderthal......keep up the great work

[inchley313]

Originally Posted by neanderthal

i would just like to say a big thank you to the following people for all the information,diagrams,pictures,hints,and time and effort in helping me to understand the fault with my volvo.....GATOS960KGBIOTOXICV40B ARTSIAMBLUEANDY D...i will let you all know in due course the outcome.i feel more confident that the volvo will be back on the road soon thanks to this info....much appreciated.regards neanderthal......keep up the great work

There are some very nice people on this site who's help is greatly appreciated and have also helped me with my recent problems (and there has been a few and likely to be a few more of)

So I'd like to second that with a thanks from myself!!!

[neanderthal]

hi,update.i managed to take everything apart myself ,except for dropping the gearbox(brotherly love) to get to the clutch slave cylinder.(picture 2 of 3)...volvo main dealers have quoted £111 including vat for the slave cylinder.will update more when i find the money as i need other parts....thanks.

[gatos]

Well done. I am sure it was a fun experience.... Keep us updated.

Check with Rufe for a good price and see if it is cheaper.

Maybe its worth emaling this guy and ask for the part number:
http://www.ebay.co.uk/itm/GENUINE-S4...item43aa386490

Also check here: http://www.volvoforums.org.uk/showthread.php?t=126676

DWM got one for £70

[andy_d]

Parts Monster, as per the link from Gatos/ebay, they Can and will advise by emal/phone if the part is correct going on reg number or vin number.

it Might be just seals in the slave cyl, parts monster also have repair kits for slave cyls
http://www.ebay.co.uk/itm/Volvo-S-V4...item415acc5fe8


there looks to be a fair bit of fluid "fling" around the bell housing and on the outside of the pressure plate. it would be worth removing that and checking the friction plate for contamination by fluid as well.

[neanderthal]

thanks gatos and andy d...i am afraid i dont feel confident enough to touch the clutch as i am assuming it would have to be re-alligned,i have never taken a clutch apart.also i think i would rather buy a new slave cylinder as again i dont feel confident or know how to take that apart either....i appreciate that you are trying to save me some money....i will get someone to have a look at the clutch,and go from there.by the way, should the gearbox have had a seal round it(gasket),as i only noticed remmenants of some black stuff...thanks...ps i will try parts monster and rufe..

[SIAMBLUE]

The clutch is only held on with 6 or 8 torx screws, then it will come apart.. it will have to be lined again for it to go back in...

Gary

[neanderthal]

thanks siamblue.thats what i was concerned about.would the garage have to re-align it.thanks

[andy_d]

its not too hard to re line the clutch up

http://www.youtube.com/watch?v=QpE-RbZKw1c

fairly ok vid showing what/how and a method where you dont need a special tool.

http://www.youtube.com/watch?v=tuJzK...eature=related
with the clutch alignment tool,

its "only" a matter of lining the friction plate with the pressure plate ,getting it central to that so the splined hole is exactly in the middle

worse that happens is
you find the gear box Wont line up/mate with the engine, you slip the box back out the way, undo the bolts and fiddle it central, then try again,as long as you dont hammer the box home you shouldnt be able to cause any extra damage.
cost > a bit more time to fiddle it to central,
garage will want a chunk to swap the clutch. and some will try and tell you "they need X y z special tools,,etc,,,", they dont.

lost count of the times i had to drop the box on my Tr7 always chucked it all together without any special tools,,and that was a RWD , with a huge heavy gbox, and a rather heavy pressure plate asm. did it all on axel stands with a trolly jack, 30-40 mins total from up in air,, strip, swap/fix, rebuild, wheels down.

if you look @ your 3rd picture, you can see the center splines that will pick up the shaft on the gearbox, And a nice "dimple" in the shiny bit behind it (crank) That is the clutch all aligned spot on,, and what you are aiming for when "done"