Volvo V70 Ph.2 D5 clutch

[valhalla]

I had a very sorry Volvo dropped-off this afternoon. Clutch is absolutely ragged, heavy on the pedal, dragging, and you can smell it from 1/4mile away.

Has anyone got any experience of doing the clutch on one of these? The engine is the 2.4 diesel, I believe the code is the basic D5244T (not D5244T5), and it's on a 2002-plate.

I'm reckoning that the clutch is a gonna, but hoping that (as this happened quite suddenly on the customer this afternoon) the flywheel is not too bad. All-in, the bits alone are the thick-end of £350 for the kit without the flywheel, plus VAT. What I cannot fathom is whether the subframe has to come out or not. The gearbox is the 5-speed unit (M56) not the 6-speed, and that might make the difference between dropping the subframe or not. I'm also unsure whether I'm going to definitely find a self-adjusting unit in there, or whether this one got a "standard" clutch pack.

The reason I don't want to drop the subframe, if I can help it, is that this is going to have to be done on on the 2-poster, and that's a bit precarious when the C of G is shifted. It also might mean that the ramps are totally blocked if the job gets bigger when the 'box is out.....

Thanks for any help!

[mayfly]

Don't know if this is much help but here goes. We did a clutch and flywheel in a 2007 s60 d5 with 6speed manual box ,it was a hell of a job ,subframe had to come down and there was a mountain of stripping as well, all in all nearly 2 days work. Then we did a ring gear in a 2002 v70 D5 auto, this time we took engine and box up in one piece, it was a lot less bother. I understand neither are exactly what your dealing with but maybe someone else can give a bit more info.

[valhalla]

Mayfly,
Thanks for your help. It had occurred to me that it would make sense to lift the whole lot upwards, and I'm sure that the manual M56 5-speed box cannot be that much bigger than the auto? If you managed to do it with less hassle, then I need to weigh that option up. Most of the information out there is for owners doing the job on their front drive, where lifting the whole powertrain might not be an option, but in a decent workshop, this could be the way to go.

I think book time is roughly 7 hours for the 5-speed box, but doing the whole lot on the drive (including making tools fit the new self-adjusting cover, which has to be set....) can be around 21 - 26hours. So your 2-days is not that far out! The problem I foresee is that the best way to lift a V70 on the 2-poster front pads is to use the subframe brackets as lifting points. Hmmn......

[mayfly]

Wouldn't like to have to do it on the drive, we had a 2 post lift and an engine hoist. These jobs are not for the faint hearted.

[valhalla]

Started this job today, decided to treat it as a "holiday" where I just do it in chunks, and do admin work on the workshop inbetween. There's going to be no profit in this one, as it needs a host of other things doing whilst I'm in there (front suspension is flopping around everywhere), and I wasn't going to do anything like this before Xmas now - I've got too many other jobs to clear before then, mostly wiring on Landrovers.

Looks like 15hours would be about right. I'm going to do it through the N/S wheelarch, but I've cleared more than necessary around the gearbox to make like as easy as possible when realigning the box to the engine. I need to make a tool to align the driven plate, and I'm hoping that one of my automatic clutch tools will do the job on the cover.

This would have been an easy job, but Volvo let themselves down by piling a load of ancilliary bits (like EGR cooler) over the top of the gearbox, meaning that there isn't a clean access to the bellhousing fixings.

I had to stop, as the high winds were shaking the workshop and making the car wobble a bit on the 2-poster.