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New clutch doesn't fit input shaft m56hk C70 (rant)

Help, Advice and DIY Tutorials on Volvo's extremely popular car line -- Volvo's 1990s "bread and butter" cars -- powered by the ubiquitous and durable Volvo inline 5-cylinder engine.

1992 - 1997 850, 850 R, 850 T5-R, 850 T5, 850 GLT
1997 - 2000 S70, S70 AWD
1997 - 2000 V70, V70 AWD
1997 - 2000 V70-XC
1997 - 2004 C70

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Flystagg
Posts: 22
Joined: Fri Jul 24, 2015 2:23 pm
Year and Model: 2002 c70 coupe T5M
Location: California

New clutch doesn't fit input shaft m56hk C70 (rant)

Post by Flystagg »

Ok I know my car being a 2002 c70 is a strange love child between a p80 and a p2 volvo, but I never realized how big of a pain in the ass that was going to make my life.

I bought a clutch kit for my car over a year ago because my internal slave cylinder has always had issues and I knew it was on borrowed time (can't hold clutch disengaged longer than 60 seconds). The clutch kit is a valeo 52405401 every website I check says this clutch fits my car including amazon, IPD, and several others. The clutch looks identical to the sachs and luk clutches shown for my car on FCP.

Well today was finally the day I cracked my bell housing open to replace my clutch and was flabbergasted to find the input shaft on my m56hk gearbox is several millimeters too large like way too big to fit my new clutch disc. A little clicking around on the internet and comparing pictures and is very obvious that the correct clutch for my car is for a 2002 S60 T5. Which shouldn't be an issue except not a single website I checked matched my car with the correct clutch. How can this be? Is my car unique? vin # says it is a factory manual car. Was vovlo just slapping whatever parts they had laying around onto these cars without keeping track?

In all the forums I've read about, manual swaps, internal vs external slave cylinders, and single vs dual mass flywheels not once did I see it mentioned that M56 input shaft diameter changed in 2002. I was thinking about getting a single mass flywheel and R clutch, but that wouldn't have fit either.

Is it common knowedge that m56 shaft diameter changed, and I just missed it? How can it be this hard to buy the correct freaking part for a car. There was literally no way for me to have bought the correct clutch until I was physically holding my old one...wtf
Flystagg
Posts: 22
Joined: Fri Jul 24, 2015 2:23 pm
Year and Model: 2002 c70 coupe T5M
Location: California

Re: New clutch doesn't fit input shaft m56hk C70 (rant)

Post by Flystagg »

anyway ordered an s60 clutch kit (fortunately only $195 LUK), let me know if anyone is interested in a new in box clutch for a 99-2001 volvo s70, v70, c70
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abscate
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Re: New clutch doesn't fit input shaft m56hk C70 (rant)

Post by abscate »

Sometimes your car is just.....different, Mrs Gump.

I'll put some verbiage into the thread title to make searching easier
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A Captain in a Sea of Estrogen
1999-V70-T5M56 2005-V70-M56 1999-S70 VW T4 BMW
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tryingbe
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Re: New clutch doesn't fit input shaft m56hk C70 (rant)

Post by tryingbe »

I hope you order a new dual mass flywheel as well, those are not reusable.
85 GLH, 367 whp
00 Insight, 72 mpg
Flystagg
Posts: 22
Joined: Fri Jul 24, 2015 2:23 pm
Year and Model: 2002 c70 coupe T5M
Location: California

Re: New clutch doesn't fit input shaft m56hk C70 (rant)

Post by Flystagg »

do have a new dual mass flywheel, again stashed away for over a year, fortunately the correct part. Was there any trick to installing the new clutch with a dmf?
tryingbe
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Re: New clutch doesn't fit input shaft m56hk C70 (rant)

Post by tryingbe »

Follow whatever torque specs the manual calls for and use red threadlocker on flywheel bolts/pressure plate bolts if the bolts didn't come with some already on them.
85 GLH, 367 whp
00 Insight, 72 mpg
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