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Discussion Starter · #1 ·
It is good news and bad news. <p>The clutch asssembly (friction components) look good at 125K miles. The bad news is that I suspect few will ever get to that mileage before the clutch actuation system fails, i.e., the slave cylinder! Looking at the disc, I suspect it would have gone another 75K miles, for a total of 200K miles!<p>I don't baby my car, nor do I abuse it. A good portion of the time it is fully loaded as it is our touring vehicle. Last major road trip was up to Alaska and back for a 10K mile ride. Lots of trips to The City (San Franciso), an area not easy on clutches. Of course mileage is a very poor indicator of clutch wear since it really relates to the number of starts from a stop, and overall driving technique. <p>Clearly no one can expect a slave cylinder to last forever, none have on my other cars using hydraulic actuated clutches, however due to the Volvo design, time and money get multiplied by 10. It is strictly a hydraulic failure, as the actual throw out bearing was still in good shape. <p>Common sense is to replace it all while in there, but this design, coupled with those that may actually WEAR out a clutch, make it very likely you will be facing this at some point. <p>Come to think of it, has any one actually WORN OUT a clutch? I suspect some of the 1/4 mile gang may have, but from my reading it is virtually all slave cylinder failure. <p><IMG SRC="http://i620.photobucket.com/albums/tt290/justsam/IMG_8069_edited-1.jpg?t=1242228602" BORDER="0"><p><IMG SRC="http://i620.photobucket.com/albums/tt290/justsam/IMG_8070_edited-1.jpg?t=1242228677" BORDER="0"><p>
 

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Re: Clutch Wear at 125K miles (rogersampson)

rather excellent post <IMG NAME="icon" SRC="http://********************/smile/emthup.gif" BORDER="0"> <p>question: the people who installed spec clutches, did they throw their money away?<p>from what I understand, you use the better friction material, but have to still re-use the Volvo slave cyl, since no replacement has been found...correct?
 

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Awesome news. Hopefully my clutch is wearing in the same fashion!
 

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Re: (Chuck_V70R)

I suspect I may have this issue...my clutch has a clunk sound when shifting...dealer said it was the springs on the flywheel or the pressure plate (worn out/weak)...what do you think?<p>90k miles, no problems with the clutch itself, no slip, etc.<p>The dealer did say the 04s did not come with a clutch damper, which 05+ did.
 

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Re: (S60R1)

I'd be willing to bet that's probably driveline lash from a Volvo-quality tranny/collar gear/Angle gear fit tolerance. I have the same thing.
 

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Re: (JoeLvo)

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>JoeLvo</b> »</i></TD></TR><TR><TD CLASS="quote">I'd be willing to bet that's probably driveline lash from a Volvo-quality tranny/collar gear/Angle gear fit tolerance. I have the same thing. </TD></TR></TABLE><p>I test drove another R at the dealer when we checked it out and it did it too, just at a much lower volume. Mine's pretty loud. Definately coming from the tranny, not angle gear. I'll see if I can replace the clutch/flywheel next year, see how it looks in there..
 

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Re: Clutch Wear at 125K miles (rogersampson)

Have any pics of the slave leak?
 

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Discussion Starter · #9 ·
Re: Clutch Wear at 125K miles (FEO)

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>FEO</b> »</i></TD></TR><TR><TD CLASS="quote"> <br>question: the people who installed spec clutches, did they throw their money away?<p>from what I understand, you use the better friction material, but have to still re-use the Volvo slave cyl, since no replacement has been found...correct?</TD></TR></TABLE><p>I certainly would not say they are throwing money away, because I don't think that buyer is looking for longevity anyway. Friction material is not unlike that on brake pads, and some prefer one "feel" to another. <p>I am not sure if the SPEC pressure plates have a greater clamping force. If they do, than that typically translates to a more difficult life for the slave cylinder and throwout bearing. In terms of longevity, I would be concerned about that. If I am a drag racer replacing my clutch every season, or better, I really don't care. <p>I suspect that the SPEC pressure plate does not have the idle damping springs, and they would laugh at you for asking. The springs role is to prevent gear rattle at idle in neutral with the clutch out. Five cylinder engines are not that smooth, so these types of things are done, as well as others. Again not so important for racers. <p>Then there is cost, it is about $350 for the Volvo clutch set, and about double that for SPEC, depending which one you buy. Having said all the above, if they made a more robust slave cylinder, I would be first in line!<p>Pictures of anti gear rattle springs:<p>
 

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Re: Clutch Wear at 125K miles (rogersampson)

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>rogersampson</b> »</i></TD></TR><TR><TD CLASS="quote">Pictures of anti gear rattle springs:<p><IMG SRC="http://i620.photobucket.com/albums/tt290/justsam/IMG_1876_edited-1.jpg?t=1242246289" BORDER="0"><br><IMG SRC="http://i620.photobucket.com/albums/tt290/justsam/IMG_1877_edited-1.jpg?t=1242246382" BORDER="0"></TD></TR></TABLE><p>Replied to correct image, IOT be able to see it... <IMG NAME="icon" SRC="http://www.vwvortex.com/vwbb/tongue.gif" BORDER="0"><p>-Steve
 

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Discussion Starter · #11 ·
Re: (S60R1)

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>S60R1</b> »</i></TD></TR><TR><TD CLASS="quote">I suspect I may have this issue...my clutch has a clunk sound when shifting...dealer said it was the springs on the flywheelQUOTE] <p>Volvo uses a dual mass flywheel, (as do many others including Porsche) to reduce vibration. It is a possibility; do you get the clunk when you just put in the clutch, or when you just release it? Do other drivers get the same thing? Is it there during upshifts and downshifts?<p>
S60R1 said:
or the pressure plate (worn out/weak)...what do you think?QUOTE]<p>There is only one diaphragm type spring on the pressue plate, (ignoring the anti gear rattle spings) so I do not know where this would come from. A weak pressure plate would result in clutch slipping at higher gears, not a clunk. It is directly connected to the flywheel, no chance of clunk. It would have to be on the driven (disc) side. <p>
S60R1 said:
The dealer did say the 04s did not come with a clutch damper, which 05+ did.</TD></TR></TABLE><p>I suspect most would not want this. It acts as a dashpot preventing rapid clutch engagement. It is done hydraulically, and again would not cause a clunk. <p>
 

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Re: (rogersampson)

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>unknown</b> »</i></TD></TR><TR><TD CLASS="quote"><br>Volvo uses a dual mass flywheel, (as do many others including Porsche) to reduce vibration. It is a possibility; do you get the clunk when you just put in the clutch, or when you just release it? Do other drivers get the same thing? Is it there during upshifts and downshifts?<br></TD></TR></TABLE><p>I get the clunk when engaging and disengaging the clutch, upshifts and downshifts, most noticeably between 1st and reverse and vice-versa. It really doesn't matter what gear I'm engaging or disengaging, the only thing that reduces the clunk is a very smooth (as in ridiculously burn your clutch slow) engagement/disengagement of the clutch. Even when practicing good smooth shifts it clunks a bit. The other R in the dealer lot did it as well, and it was IIRC an 06, but as I said, much less than mine. I bet there's more out there with this, you just have to listen for it (radio off, windows down, 1st to reverse and vice-versa a couple of times, listen for a clunk sound from under the tranny).
 

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Discussion Starter · #13 ·
Re: Clutch Wear at 125K miles (adykes)

Here is a picture of the slave with the bearing removed. <p>The leak was at the piston seal itself, (it is the black material around the annular piston) which I have pulled up out of it's bore. Not too many places for it to leak. It either has to be at the piston itself, or at the fitting.<p>It is not unlike a caliper piston seal. <p><IMG SRC="http://i620.photobucket.com/albums/tt290/justsam/IMG_1878_edited-1.jpg?t=1242251432" BORDER="0">
 

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Discussion Starter · #14 ·
Re: (Chuck_V70R)

About 16mm. You can not go to zero of course, need room for the rivets! I think I could have gotten another 50 to 75K from it. There was no slipping.
 

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Re: (JoeLvo)

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>JoeLvo</b> »</i></TD></TR><TR><TD CLASS="quote">I'd be willing to bet that's probably driveline lash from a Volvo-quality tranny/collar gear/Angle gear fit tolerance. I have the same thing. </TD></TR></TABLE><p> <IMG NAME="icon" SRC="http://www.vwvortex.com/zeroforum_graphics/screwy.gif" BORDER="0"> <p>That guy is crazy!<p>I have the exact same symptoms as others, but I had convinced myself it was due to the lash takeup when matching road speed to a different output-shaft speed. That is supported by the "ridiculously slow shift" remedy *but* so is an outright clutch system issue.<p>Roger, did you do your clutch work yourself? If so, have any ideas about this clunking sloppyness? <IMG NAME="icon" SRC="http://www.vwvortex.com/vwbb/tongue.gif" BORDER="0"><p>
 

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Re: Clutch Wear at 125K miles (rogersampson)

Roger<br>I don't think those are anti rattle springs. In the VADIS manual they mention that a special tool is needed when removing the pressure plate. That tool is to position those 3 tabs in sync for the self adjusting pressure plate. I'm not sure how it works. When I talked to the tech guys at Spec Clutch they said the tool wasn't needed since their pressure plate comes preset. It did have the same self adjusting feature as the original one.<br>Here's a pic of my stock one that failed at 66k. Well, the slave cyl failed and since I saw this broken part I ended up replacing the clutch & press plate.<p><IMG SRC="http://www.metalmeet.com/photopost/data/3699/press_plate.jpg" BORDER="0"><p>J. Clear<br>04 S60R
 
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