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2005 volvo s60R clutch replacement

Help, Advice, Owners' Discussion and DIY Tutorials on Volvo's stylish, distinctive P2 platform cars sold as model years 2001-2007 (North American market year designations).

2001 - 2007 V70
2001 - 2004 V70 XC (Cross Country)
2004 - 2007 XC70 (Cross Country)
2001 - 2009 S60
2003 - 2007 S60 R
2004 - 2007 V70 R

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volvorecycle1
Posts: 1
Joined: 11 December 2013
Year and Model: 1995 850
Location: Ontario

2005 volvo s60R clutch replacement

Post by volvorecycle1 »

Customer came in with a bad clutch, over 400,000 km. I replaced it with a sachs clutch kit. new duel mass flywheel and slave cylinder.
I bled the clutch as good as i could ( vacuum bleed, helper pumping the pedal and reverse bleeding. I felt that the pedal was a bit soft, but I was able to shift the gears no problem with the car running.
Anyways at over 3000 rpm, the clutch slips.
So, I ordered another clutch kit, this time it was LUK, put it all together and the same thing, same pedal feel.
I have a clutch kit ordered from volvo for the morning, but these kits are volvo OEM. I do not understand what is going on. I made sure there was nothing behind the slave cylinder pushing it away from the tranny causing it to push against the pressure plate. Also the self adjusting clutch springs were compressed. From what i read that means it is pre-loaded and ready to go.
I ordered the duel mass flywheel from autocamping by the engine number. there were two available. The new one looked like the orginal, maybe there is a thickness difference between the two.
Any suggestions?

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regent
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Year and Model: 2015 XC60 T5
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Post by regent »

I have attached the replacement procedure from VIDA that applies to your arrangement.

As far as I know, there should be a certain amount of adjustable free play at the beginning of the pedal's travel (like an inch or less, not sure what the exact value is) before it even starts moving the hydraulics and release mechanism.

From your description of the problem, it appears that the pedal is pre-tensioned and the first thing that comes to my mind is to check that play; the pedal should not be pre-tensioned; if it is, it needs to be adjusted.
Attachments
M66 Clutch.pdf
(676.91 KiB) Downloaded 1366 times
Example of Precision: Measure with a Micrometer, mark it with Chalk, and then cut it with an Axe.
Disclaimer: We (very) seldom do that

2015 BMW 335i
2015 XC60 T5 Premier Plus
2002 S60 2.4 n/a - retired :(
1987 340 DL - retired :(

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