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850 T5 clutch noise (creaking)

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Old Sep 18th, 2017, 21:04   #1
milgo86
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Default 850 T5 clutch noise (creaking)

I bought my 850 T5 less than 3 months ago and already it has thrown just about every common fault at me.

On my drive home with the car it overheated (stuck thermostat) and then blew the rear main seal, which killed the clutch.

I had an 850r clutch kit installed by my local main dealer with a re-machined flywheel. After around 3 weeks and 900 miles the clutch started to feel notchy when warm, which made smooth pull offs difficult. Initially I thought the dealer had neglected to fit the plastic pivot cup onto the release fork, causing it to grind on the pin. But after ordering a new pivot cup, fork and pivot pin I don't think this is the case.

I think the pressure plate has either been installed incorrectly or has failed prematurely. I just thought I would post this as reference for other people in case they have the same problem. The car is going to a Volvo specialist tomorrow so I will update this thread with the outcome. I've uploaded a video of me depressing the clutch when the car is warm.

https://www.youtube.com/watch?v=ZtfU...ature=youtu.be
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Old Nov 11th, 2017, 18:45   #2
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I thought I should follow this up. The specialist couldn't replicate the problem, but recommended a gearbox rebuild.

I got an inspection camera and sprayed PTFE lubricant (dry) onto the input shaft and problem solved.
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Old Sep 27th, 2018, 14:33   #3
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A year on and I still have this problem!

The dry lubricant appeared to work for a while, but the creaking came back and didn't improve with further applications. Perhaps it was just coincidence.

I've just had a Quaife ATB and TTV flywheel fitted. New 850R clutch again, new fork, new fork pivot and cup, new release bearing, new guide tube. The clutch was installed using the official tools.

Just like last time the first ~1000 miles have been lovely. Now the the clutch has bedded in, pedal firmed up and it's back to feeling notchy and makes an awful loud creaking/grinding sound once the car has warmed up.

The pedal box looks and feels fine. The noise is mostly in the engine bay. Clutch master cylinder is original as is the hydraulic line. As you can imagine I'm feeling quite desperate now as I've plowed loads of time into this car and I'm getting sick of driving it.

Any help very much appreciated!
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Old Oct 1st, 2018, 09:37   #4
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Well I guess no one else has a clue either.

Tried a different master cylinder yesterday and no change. It's definitely coming from the gearbox end.
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Old Oct 1st, 2018, 11:25   #5
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Wish I could help as it sounds like an annoyance, I had a similar small creak on my old Honda ATR some years back and I never managed to solve it... although there was some discussion that it could have been a spring or thrust bearing.

It never worsened or created any issues for me or the following owner.
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Old Oct 1st, 2018, 13:41   #6
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Can't help with a possible cause, but just to mention that a mechanic's stethoscope might be your friend here, they're really good and really cheap (just search for one online). This might help pinpoint exactly where the noise is coming from, and thus make diagnosis a lot easier.

Just a thought!
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Old Oct 1st, 2018, 13:42   #7
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kmb, I have seen quite a few videos of creaky Honda clutches. Seems like a common thing with them.

I would ignore it if there was only noise, but the pedal becomes so bad its hard to drive smoothly in traffic.

Does anyone know if assembly grease should be used on anything? It looks like a completely dry installation to me.
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Old Oct 1st, 2018, 13:45   #8
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Funny you should say that Luxobarge, I just ordered one at the weekend. Couldn't believe how cheap they are!
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Old Oct 1st, 2018, 16:39   #9
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I used some of that bicycle chain grease, the one that comes out as a liquid and turnes to a sticky grease. Sprayed it down where you sprayed the dry lub. using the attached thin tube. Been good now for several years.
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Old Oct 1st, 2018, 18:48   #10
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That's great to know, thanks huron.

I looked in my Haynes manual earlier and it states molybdenum disulphide grease should be used between the pivot and plastic cup. I suspect both times it has been assembled dry.

Going to give the transmission place a call tomorrow.
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