Changing my clutch saga (again)

[Dangerous Dave]

So it begins.............

A year ago this month I decided to replace my clutch, and boy did I have an awful time, with my car being the awd things were so much more difficult to remove. It took me two days solid to sort it.

So you can imagine my joy when last week my clutch gave up (not just slipping, no drive at all!). Yep, 1 year and needing a new one!!

So I decided to take the engine out this time as I thought it would be easier to replace the clutch this way (which it was). I ordered my clutch from PFV, as the last one I had was from gsfcarparts and cost me a lot more than the one from PFV! But I had to wait for delivery (not really a problem as I've been using my dads old 940 all week), so I took bits off the car day by day (i'm so glad I replaced some of the front suspension as it was easy to crack).

So yesterday I took the engine out (which was bloody hard work as I had to lift the car - see pic)
http://i150.photobucket.com/albums/s101/bomb192uk/DSC00434.jpg

Only kidding, it helps having a 7.5 ton jack handy LOL
http://i150.photobucket.com/albums/s101/bomb192uk/DSC00433.jpg

But then of course, our summer being British, it rained so I decided to borrow the gazebo from work
http://i150.photobucket.com/albums/s101/bomb192uk/DSC00440-1.jpg

Some close ups of the engine and car (note the angle gear unit bolted to the gearbox, covering the oil return hose too!)
http://i150.photobucket.com/albums/s101/bomb192uk/18082008046.jpg
http://i150.photobucket.com/albums/s101/bomb192uk/DSC00435.jpg
http://i150.photobucket.com/albums/s101/bomb192uk/18082008049.jpg
http://i150.photobucket.com/albums/s101/bomb192uk/18082008048.jpg


Anyway, all is back together now, and no left over nuts or bolts!!

The driveplate had completely worn down to the rivets!

Took it for a test drive, and found out I forgot to tighten the wheelnuts :o. (Hmmmm, my name is Dave, and my wheels were Wobbly...... damn that nickname has already been taken)

Only problem is when turning the steering wheel there's a ghostly whine (its driving me crazy already!) that sounds like its against a rubber boot/grommet somewhere. I think its where the steering goes through the bulkhead/floor.

One other thing, my flywheel was in two parts, is this standard on the volvo 850/v70 engines?

[Tomcat]

Well done that man, that's one hell of a project to take on. I'm going to have to do my clutch and RMS soon, was it really easier to take the whole lot out rather than just the box?..

[Dangerous Dave]

It was for me as I have to remove the awd angle gear to get to anything. Should be easier to do on a non awd volvo.

[Niles]

top job

[snoop69]

top job

Told ya :nut:

[cameron]

Well done that man!

[CONDYBOY]

well done! I did my v40's clutch and it was a sinch compared to your epic journey!
You could change your name to torque 'em, then youll never again forget to tighten your wheels on, or poss' lucille!:D:D:D:D

[Dangerous Dave]

LOL condyboy, not sure how lucille would go down (oooh err). I'm known at work as Dangerous Dave so I might just stick to that.

As regards taking the engine out instead of changing the clutch in the car, most of the parts you have to remove (i.e. wiring loom, IC pipes, fan & shroud, subframe bolts, steering knuckle, etc) are the same as the parts to take the engine out of the car, but with a couple extra like unbolting the AC pump, and the fuel rail (no need to get covered in petrol then, just tape it to the strut brace LOL). I made a frame to move the engine out of 4 bits of 3"x3" wood and some large castor wheels I got from work. It worked a treat!

Once the engine was out, it took me literally 45 minutes to change the clutch, and thats including the time it took me to clean the flywheel and bellhousing of all the burnt out clutch dust, and bolt it all back to the engine.

I'm hoping that my clutch will last longer this time. I don't know whether it was my driving (I don't think I've driven it that hard over the last year though), or they ordered the wrong clutch last time (the driveplate does look a lot different to the one I took off, but the pressure plate is the same). I suppose its a number of factors, my driving plus the age of the system (12 years now) old parts are going to put more strain on the system I guess.

[Dangerous Dave]

top jobTold ya :nut:

Eh?

[ShadeTek]

You need balls of steel to do that job. Stay away from strong magnets mate. Well done.:jaw:

[Dangerous Dave]

The saga continues.................

So I drove over to Cannock to visit my cousin. A mile away from his house the oil light comes on on my dash. I knew immediately what it was, I pulled over (fortunately at a petrol station) and lifted the bonnet to confirm my suspicions. I was right, the bottom pipe on the oil cooler had come off and sprayed oil everywhere.

So I went into the shop, bought a jubilee clip, and a tub of oil, and repaired it there and then (I had a newspaper in the boot, they're useful for lying on!) In the end I used 5 litres of oil to refill her!

All done now, just got to get some new oil hose clips as the one that had broken was rusted.