95 850GLT NT. Stalling after Clutch Replacement

Tfortuna · Post by **Tfortuna** » 20 Aug 2014, 01:46

Hi, guys. First time poster. Looking for advise.

I have a 95 850GLT non turbo, 225k, with manual transmission. A tank of a car that I have had for 12 years. I just had the original clutch replaced in a shop. I immediately started having a stalling issue. It idles fine at 900rpm when starting but when stopping after being in gear it stalls out. Releasing the clutch drops the rpms to about 500 at which point the car can't recover and it stalls out. I've also had an issue for a few years where it is a bit hard to keep in reverse. It likes to pop out. However since the clutch replacement, it is really hard to get into reverse (grinding) and hard to keep in (pops out). The shop thinks its time for a new tranny but I have my doubts. Any ideas?

Post by **abscate** » 20 Aug 2014, 04:02

Welcome to MVS!

My guess is your Idle Air Control valve hoses got torn during the clutch replacement. Search here for a pic or inspect the hoses at the left end (to your right looking backwards) of the engine for rips tears and general funkiness.

It does sound like you need a new transmission or live without looking backwards ...not a bad life philosophy, sometimes.

Post by **rmmagow** » 20 Aug 2014, 08:40

How good was the shop Volvo-wise? I had a Honda that had same sort of reverse issues and it ended up the tranny mount was broken and the shift linkage got screwed up from that. New mount and fiddling with the linkage and it was fixed.

Post by **cn90** » 20 Aug 2014, 08:43

Likely Crank Sensor damage, common problem during Clutch job if the mechanic is not careful protecting the Crank Sensor.
Scan for error codes.

Post by **JimBee** » 20 Aug 2014, 10:28

I'd second the idea of checking the shift linkage. While it could be internal wear of a synchro, shifting fork or some such, it could be the linkage is not fully positioning the gears together. So that would be the first thing to check.

Also, is your clutch master cylinder okay, and clutch slave (mounted by the starter) fully operating the throwout bearing to disengage the clutch for changing gears? If either isn't working properly, shifting will be difficult.

I've just looked at two 850's that have manual trans and both had newish looking clutch slave cylinders.

Tfortuna · Post by **Tfortuna** » 20 Aug 2014, 18:54

Thank you all! Very helpful info. I will definitely check for codes and vacuum leak. I checked with the Volvo mechanic I bought the car from, who is a good friend of mine, and he thought the stalling is a vacuum issue too. Too bad he lives 1000 miles away! I appreciate your help!

Tfortuna · Post by **Tfortuna** » 22 Aug 2014, 17:01

Well, turned out that I did have a minor vacuum leak and one sensor malfunctioning. With those two things fixed it no longer is stalling and no more bucking at 1500 rpms. Still very hard to get into reverse. But two out of three ain't bad!

Post by **cn90** » 23 Aug 2014, 05:54

The reverse issue:
- Check MT fluid: is it good?
- Adjust the linkage.