2004 V70 flywheel material defect Loud Starter, Chipped & Mashed teeth on flywheel/flexplate Topic is solved

[- Pete -]

I completely agree.

If I start hearing this noise again (hopefully no sooner than 130k from now) I'll know it's an alignment issue between the starter & flywheel.

Explaining that though, well, let your mind wander.

Inferior ring gear casting is what I'm sticking with, especially since there's other documented cases of this phenomenon.

For now, starts are whisper quiet like they should be. I'll pull the starter again in 5k & take pictures.

[abscate]

Pete .,Is this on the 2004 V70?

Bookmarking title for ID on the defective part

It looks like we should Document this for folks looking at the model year In question.

[- Pete -]

Abscate,

That’s correct, 2004 V70 AWD.

Bought it with 128k last October and the starter noise quickly climbed from just perceptible to its crescendo at 130-131k-ish miles, which was when I pulled the trans.

Edit: hey, thank you to whoever edited the title!

[abscate]

Save that flywheel and I can have it tested for hardness. It would be fun to tell Volvo what we think

I can measure steel composition with a spare laser I have lying around, too

[- Pete -]

Oh, it’s sorta a mantle/conversation piece around here. Not sure I want to rid myself of its presence just yet! Have a few more spitballs to shoot at it ya know.

PM inbound. Shortly.

[- Pete -]

Save that flywheel and I can have it tested for hardness. It would be fun to tell Volvo what we think

I can measure steel composition with a spare laser I have lying around, too

Eh? Eh? Eh?



Whenever you get around to it I may pay you to ship it back to me so I can make it into a clock for the shop.


Update:
148k on the car now and everything is as it should be with the starter & flywheel.

[abscate]

I’ll get it tested and send it back. Send me your ship details , please

[JunkyardPirate]

Hello everyone,
I hope you and your cars are doing well and the car with the questionable flywheel discussed is doing great still. Unfortunately I have the same problem on my 2004 Volvo XC90 T6. For context, this is my second car, and I saved up a very long time to be able to afford a car in general. I needed a car to get me to work, haul some things for my small business, and help my mom who is bed bound and needs to use a wheelchair. I was working multiple jobs prior to the pandemic to stay afloat, got laid off from 2 due to pandemic, had to leave my remaining only sources of income to care for my mom as I'm the only family member who she has that is able to help, and basically my car went downhill at the worst possible time.

I bought the car about a year ago and the "chugging/struggling" noise you described was definitely present pretty soon after I bought it. I took it to several mechanics for other issues, (radiator replacement was a big one) to have oil changed, etc. and no one mentioned anything. During the oil change mechanic said "car started weird" and I asked my roommate who is a mechanic what he thought of the noise and he said not to worry about it but maybe it could be the timing belt.

Unfortunately I didn't have extra money at the time to investigate further and the flywheel was apparently getting ground down further and further until one day it started really rough a few times, doing the noise plus a grinding loud metallic noise, and then all of a sudden it refused to start and left me stranded. I mistakenly tried starting it too many times, grinding flywheel further probably, and killing the battery.

I got towed, had it assessed by my roommate, several mechanics, and decided to not pay for the repair as it's 1500-2500. I can find the flywheel at a local scrapyard as the original author of the post did, but I don't have a way to do the work or get it done by anyone for a reasonable price. I live in Los Angeles and the inflation is unreal. I put in a rebuilt starter with my roommate and by charging it up we got it to start a few times and now it's back to not starting and doing the horrible aforementioned noise.

If you were in my place what would you do? Nobody wants to buy a car that won't start except for taking the catalytic converter. Without selling my car I can't buy another though so I'm kind of screwed.

Repair labor cost is a ridiculous price for good reason. I wouldn't wish that job on my worst enemy.

I 100% agree the material is sub par. Only explanation. Many mechanics have said they've never seen such a thing. It's comforting in a strange way to know others have been through it. Any suggestions? I'd love to hear your thoughts. Thanks in advance!

[JunkyardPirate]

Also, congratulations on accomplishing that flywheel job. No small feat! Many mechanics with established shops actually turned me down for the job

[abscate]

You can do an engine drop with a 150 use harbor freight engine sling and some friends. A new or used flywheel will fix it. Turn your labor into cash in your car and get her back on the road.

You have to budget 15-20 cents per mile for repairs on an old car or about 5 cents with your own Labour. It’s brutal in LA and most other cities, shop rates are reaching $200 an hour