Volvo S40 clutch/brake issue

kilkenny31

Hi Guys,



I really hope somebody can help me here. I have an issue with gear changes with 2006 Volvo S40 1.6 Petrol car. It is very difficult to change between gears. This would immediatly suggest its a clutch/gearbox issue but i dont think it is.

The same issue arose about six months ago and I brought it to the mechanic and he said it was the clutch or gearbox and just by chance when I was there he topped up the break fluid which he also said was also for the clutch.


I drove the car home and the issue was resolved. The gear change was perfect. I called him to tell him and he was surprised.

The issue has raised its head again over the weekend. I called a different mechanic and he said probably the clutch. But I just dont think thats the issue. This time however the break fluid is topped up and the problem is still occuring. I posted a thread a while back expaining how my handbrake is great sometimes and only takes a few clicks to hold the car othertimes its all the way up and feels loose and still doesnt hold the car. I think these issues are related and caused by some sort of problem with the Hyrdralic brake/clutch system. I know im not a mechanic but it just seems reasonable to me that these are related.
Also both times the gear changes became difficult I could not set the cruise control.

uncle-mofo

kilkenny31 wrote: »

Hi Guys,



I really hope somebody can help me here. I have an issue with gear changes with 2006 Volvo S40 1.6 Petrol car. It is very difficult to change between gears. This would immediatly suggest its a clutch/gearbox issue but i dont think it is.

The same issue arose about six months ago and I brought it to the mechanic and he said it was the clutch or gearbox and just by chance when I was there he topped up the break fluid which he also said was also for the clutch.


I drove the car home and the issue was resolved. The gear change was perfect. I called him to tell him and he was surprised.

The issue has raised its head again over the weekend. I called a different mechanic and he said probably the clutch. But I just dont think thats the issue. This time however the break fluid is topped up and the problem is still occuring. I posted a thread a while back expaining how my handbrake is great sometimes and only takes a few clicks to hold the car othertimes its all the way up and feels loose and still doesnt hold the car. I think these issues are related and caused by some sort of problem with the Hyrdralic brake/clutch system. I know im not a mechanic but it just seems reasonable to me that these are related.
Also both times the gear changes became difficult I could not set the cruise control.

Sounds like there is air in the system somewhere? A bleed might sort it out, worth a try before looking into a clutch.

gibbon75

Does the heavy gearchange happen as well when the gearbox is still cold?

kilkenny31

Thanks for the reply guys. I'd have to say yes that it is worse when its cold. Last night I noticed that the clutch was sitting in a little so i pulled it back out with my foot and now the gear change is smooth again.

mullingar

If you have to pull out the pedal you have either a leaking master brake cylinder or leaky slave cylinder.

If you had to top the fluid up, I'd say its your slave cylinder inside the gearbox is leaking.

Pulling up the pedal pulls on the master cylinder behind the pedal and this sucks in fresh fluid into the clutch system

Tabnabs

I had this issue with a 2005 1.8L S40. It's the slave cylinder and it's about to go bang on you. A known engineering problem with these engines and not particularly cheap to fix (a lot of labour involved). I would get it to a mechanic ASAP before you need to add a tow truck to the cost of repairs. Google it and you'll see it comes up with disappointing regularity.

gibbon75

Tabnabs wrote: »

I had this issue with a 2005 1.8L S40. It's the slave cylinder and it's about to go bang on you. A known engineering problem with these engines and not particularly cheap to fix (a lot of labour involved). I would get it to a mechanic ASAP before you need to add a tow truck to the cost of repairs. Google it and you'll see it comes up with disappointing regularity.

The OP has a 1.6 S40, which came with the IB5 gearbox, so his clutch and slave cylinder is different to the 1.8 and MTX75 combo. The 1.8 was indeed prone to hydraulic bearing issues, hence the release bearing and hydraulic lines were modified around 2007,as far as I remember.

gibbon75

kilkenny31 wrote: »

Thanks for the reply guys. I'd have to say yes that it is worse when its cold. Last night I noticed that the clutch was sitting in a little so i pulled it back out with my foot and now the gear change is smooth again.

There is clutch pedal return spring and those snap sometimes. We used the sell a few of those, but mostly for the diesel models for some reason.

http://www.skandix.de/en/spare-parts/body/interior-equipment/pedals/return-spring-pedal/1760/

kilkenny31

gibbon75 wrote: »

The OP has a 1.6 S40, which came with the IB5 gearbox, so his clutch and slave cylinder is different to the 1.8 and MTX75 combo. The 1.8 was indeed prone to hydraulic bearing issues, hence the release bearing and hydraulic lines were modified around 2007,as far as I remember.

So what am I looking at price wise to fix this. Is it a difficult job?