Transmission/Driveshaft concerns

[JamesT5]

I'm starting to get quite concerned with my driveshaft and transmission and as of yet, I've not had the opportunity to take the car to a specialist for a proper evaluation, something I intend to do as soon as possible after pay day next week!

At the moment, 2nd, 3rd and 4th gears are really noisey, especially when accelerating making a gargling/grinding sound. There's also a whistle or whine as I declutch at times in those middle gears and a constant 'humming' at lower revs and if I free wheel the car with the clutch down or the car in neutral. This humming also takes place in 5th gear where there is hardly any 'grinding' noise at all. 1st gear is also not too bad although I'm starting to hear some noise there too.

But what's most concerning is I'm getting a 'squeak' in both directions when I'm turning the car in a car park or manoeuvring for example. The best way I can describe it is that its like someone is wearing leather trousers on a leather seat and their trousers squeal against the seat.

My theory is the noise from the transmission is being caused by a worn driveshaft bearing, because this humming when the car is free wheeling means the weight of the car is causing load on the driveshaft and this is why there is noise in neutral.

Additionally, if you think about the logic of it, the gargling/grinding takes place unde acceleration because the transmission is transferring power to the driveshaft during this time and this is causing the bearings to grind together. The squeaking when I'm turning around etc, is either caused by the driveshaft sitting out of position and therefore making this sound or something has 'dried out', it may also account for why the car seems to want to stray off towards the left despite a 4 wheel alignment on a calibrated laser alignment system recently.

Something isn't right here somehow! :nono: :confused:

Regards

James

[graemewelch]

gearbox is shafted mate. nowt to do with shafts. new box and you might aswell get dmf and clutch as ive no doubt your dmf will be hammered to

[JamesT5]

gearbox is shafted mate. nowt to do with shafts. new box and you might aswell get dmf and clutch as ive no doubt your dmf will be hammered to

Thanks for the input, I know either way this will be another large bill, I'll let you know what the gearbox specialist comes up with. :B_thumb:

[Fubar1977]

That car is really testing you mate.
I admire your perseverance.

Good luck, I hope for the sake of your wallet that Graeme`s wrong!!!

Mines in for MOT tomorrow so hopefully it won`t be a ruinously expensive day.

[JamesT5]

Off to see a Gearbox specialist tomorrow afternoon, they'll be able to listen to it and let me know what they think the problem is. A soecialist is what's needed here because every other 'standard' fitter/mechanic has just said "it's transmission noise". A specialist will be able to give a better diagnosis so I'll post on here with the answer they give me.

Regards

James

[JamesT5]

I've noticed the rattle on the drivers side that was there even before I had my suspension changed is getting worse, I wonder if this is coming from the DMF or Clutch as it's worse when the clutch pedal is down. I've listened to DMF sounds on Youtube and there is no rattle when the car is at idle (a common sign of a worn DMF as far as I can tell), only mainly on uneven/rough road surfaces and at lower speeds. My bet is that this mystery sound which has been bugging me for months is on someway related to this gearbox issue.

Perhaps I should do a video of it for people to have a listen to.......

[claymore]

FFS James, I really feel for you, but please don't chuck any more big money at this car.

[JamesT5]

FFS James, I really feel for you, but please don't chuck any more big money at this car.

I won't let this car beat me! I'm sure there are people here who have spent alot more than me but just haven't felt the need to share the experiences with everyone else. Personally I see this as a useful learning experience although somewhat frustrating, when you don't have a lump sum to go out and buy a much newer car you have to replace the bad bits in stages.

I appreciate your input and wisdom, however the car owes me too much time and money now so in my view it's an all or nothing scenario.

I wonder how many users and guests will ultimately find this 'bread trail' of mine useful, I hope to think a great many over time. :)

Regards

James

[claymore]

I appreciate where your coming from, I suppose I'm in the lucky position that if one of my dailys develops a big fault I just weigh it in and pick something else up. I never pay more than about £800 for a car.

[JamesT5]

I appreciate where your coming from, I suppose I'm in the lucky position that if one of my dailys develops a big fault I just weigh it in and pick something else up. I never pay more than about £800 for a car.

Sometimes, as I've said before on the forum, it's not about the money but about the goal at the end of it............

I see lots of very good home mechanics posting projects about their cars on here, some even take complete none runners and fix them and turn them in to quality cars. Are they 'chucking big money' at their vehicles and wasting their time, or are they trying to achieve something at the end of it! I've noticed one in particular, Merc85 has done a brilliant job of getting 'Blacky' back from the dead, perhaps I'm just simply inspired by projects and perseverance of this nature.

The only difference with me is a lack of experience mechanically and a lack of facilities to fix my own car alot of the time. That said, I've tackled jobs I would never have even thought about doing a year ago, thanks in part to a lot of the regular members on this site. They have literally saved me thousands! :B_thumb:

[claymore]

How much have you spent on the car in the past 12 months?

[JamesT5]

How much have you spent on the car in the past 12 months?

As an estimate, somewhere between £2500 and £3000. :D

[claymore]

As an estimate, somewhere between £2500 and £3000. :D

I would not put a smile on the end of that sentence, you have spent around 3 times the value of the car in a year, your car is not a hobby car, it's just a daily driver, you can't compare your situation to the likes of Merc or myself who spend our money as a hobby to tune and modify our cars. But at the end of the day, it's your money, I really and truly hope it's not bad news tomorrow, but if the estimate is anything over £400 I would think about saving your money and putting it into another car, and take yours to your most local auction.

[graemewelch]

couldnt agree more. for what youve spent your almost close to spending what id want fo rmy car, never misses a beat ever £4500

[claymore]

couldnt agree more. for what youve spent your almost close to spending what id want fo rmy car, never misses a beat ever £4500

I thought I was on my own there for a while.

[merc85]

to be fair since Having got into t5's if i counted what i spent including buying the car and mods, which ive continually transfered from one car to another, The black car i know have as cost somewhere in the region of £4,000! lol but this does not take into account that breaking my 1st Auto 850 to which i paid £500 in the 1st for made me £1,100 including weighing it in.

The Manual red one which ive recently broke i paid £700 for this recently returned me £1,400 inc weigh in, which helped me buy blacky for £495. and i have a vast amount of spares to help me afford to run her.

You certainly have dedication bud. And if you love the car that much, keep on and eventually you should end up with a extremly good car that you know inside out.

It all boils down to how much you love the vehicle at the end of the day. :Handshake

[JamesT5]

but if the estimate is anything over £400 I would think about saving your money and putting it into another car, and take yours to your most local auction.

I'd get peanuts for it, and for the money I'd be buying another car of similar mileage and condition. With that will come along another big bag of bills and problems.

There's a saying I use, "Better the devil you know than the one you don't". The other one is, "The Grass isn't always greener on the other side". Both of these are my guiding principle here!

[JamesT5]

to be fair since Having got into t5's if i counted what i spent including buying the car and mods, which ive continually transfered from one car to another, The black car i know have as cost somewhere in the region of £4,000! lol but this does not take into account that breaking my 1st Auto 850 to which i paid £500 in the 1st for made me £1,100 including weighing it in.

The Manual red one which ive recently broke i paid £700 for this recently returned me £1,400 inc weigh in, which helped me buy blacky for £495. and i have a vast amount of spares to help me afford to run her.

I certainly have dedication bud. And if you love the car that much, keep on and eventually you should end up with a extremly good car that you know inside out.

It all boils down to how much you love the vehicle at the end of the day. :Handshake

Thanks Gav, I am rather connected with the car. :D

[merc85]

Editited, YOU have dedication mate, i cant believe how hard i found it breaking the Manual red 850 i had, but it saved another car in the process and it was nice seeing some very nice panels going to nealevo and other's

The Heart of the 1st 850 t5 i had (the auto) 4 years ago is still beating in the black car along with the Ported Head. Me and that 1st car have that connection you have with your car. ;)

[JamesT5]

For those interested, here's a video I made this evening of some of the gearbox noise during a short road test. The purpose of the video is mainly for the ears so forgive the boring view of the glovebox and dashboard.

The noise can be louder than this when the box warms up a bit but at lower speeds you'll hear the sounds better. In 5th gear cruising, the sound is more like a high 'humming' sound............


https://www.youtube.com/watch?v=SoIITGui4rI&list=UUIfFr5yOuHEjjFvdqvU6TXA&index=1

[merc85]

Certainly sounds like the bearings in the box buddy, Mind you the car sounds nice when you give her some :)

[JamesT5]

Mind you the car sounds nice when you give her some :)

Thanks! I don't often drive the car that hard and no I wasn't showing off, I wanted to give it some welly to highlight the sounds for the video (it's not the best mic on the camera to be fair).

Interestingly, a second hand box on ebay the other day was going for under £200 delivered. The cost will be labour to fit it though which is why it may be more cost effective in the long run to get my current box refurbed, then I'll have another 200,000 miles of trouble free motoring! :B_thumb:

[merc85]

Thanks! I don't often drive the car that hard and no I wasn't showing off, I wanted to give it some welly to highlight the sounds for the video (it's not the best mic on the camera to be fair).

Interestingly, a second hand box on ebay the other day was going for under £200 delivered. The cost will be labour to fit it though which is why it may be more cost effective in the long run to get my current box refurbed, then I'll have another 200,000 miles of trouble free motoring! :B_thumb:

Either way bud, refurbing your box or buying another, still results in the same, Engine and Gearbox down on the subframe, thats the easiest way i find on a 850 anyway.

[JamesT5]

Either way bud, refurbing your box or buying another, still results in the same, Engine and Gearbox down on the subframe, thats the easiest way i find on a 850 anyway.

Subframe down... mmmm..... Maybe I should get them to polybush my ARB whilst they're at it! ;)

[JamesT5]

The other purpose of the road test was to blow all the water out from the seals as I'd just washed the car. Then I get it back home and go over it with the damp drying cloth again and mop up the runs. It also dries the tyres off so I can put the Meguires Endurance Tyre Gloss on there. :beer:

[graemewelch]

your looking at 500 quid for a used box fitted and thats befor they touch the clutch. i cant help but think one day your going to realise that youve p#ssed a lot of money up the wall. as much as i love my car. if it was costing me half what youve spent it would be gone. part x it mate. what your spending will getbyou sumit reliable. what next. wheel bearing big ends dmf turbo the list gose ones.

[JamesT5]

your looking at 500 quid for a used box fitted and thats befor they touch the clutch. i cant help but think one day your going to realise that youve p#ssed a lot of money up the wall. as much as i love my car. if it was costing me half what youve spent it would be gone. part x it mate. what your spending will getbyou sumit reliable. what next. wheel bearing big ends dmf turbo the list gose ones.

I'm expecting a bill for at least £1500.

[merc85]

your looking at 500 quid for a used box fitted and thats befor they touch the clutch. i cant help but think one day your going to realise that youve p#ssed a lot of money up the wall. as much as i love my car. if it was costing me half what youve spent it would be gone. part x it mate. what your spending will getbyou sumit reliable. what next. wheel bearing big ends dmf turbo the list gose ones.

tbf i reckon there is peeps on here that would change a box for less, But you are correct with the DMF that would certainly be advisable to change if it was at all suspect tbh.

[JamesT5]

tbf i reckon there is peeps on here that would change a box for less, But you are correct with the DMF that would certainly be advisable to change if it was at all suspect tbh.

DMF, Clutch, they're both wear and tear items and you're right in that it's better to change them whilst everything is off the car because it's cheaper in the long run.

Yes they're expensive but so is a set of premuim tyres and we don't got scrapping our cars everytime the tyres are worn out.

[volvokid]

I would enquire about aa cover they might cover 500 towards a gearbox james

[Fubar1977]

James, your story reads almost identically to mine.
Since buying my 02 S60 I have ploughed just over £3k into it in the last 12 months. On top of the price of the car.
Obviously well over what a bog standard S60 D5 is worth and total insanity really when it's added no real resale value to it, it's worth peanuts to anyone else.
To me it's a 5 grand motor!

During that time it's tested my patience but I've developed a strong affection for it despite its constant attempts to bankrupt me.
I've learned a huge amount and am starting to become vey familiar with these cars.
I've discovered forums filled with helpful, friendly people who have literally saved me hundreds of pounds.
Much like you I have a lot of enthusiasm but I lack the equipment and specific knowledge or skills to attempt some of
the things I'd like to do myself.
I totally take on board others comments and it makes no rational sense wen you look at it but I am in far too deep to get my money back and basically refuse to sell a car with pretty much all the usual issues rectified for a pittance.
It started out as a nice daily driver and is now, as my wife calls it, my expensive hobby.
Within reason I am happy to take this 150000 mile car to 250000 and I am learning new skills and doing jobs I would always have paid a garage for in the past.

It would be interesting to compare notes and if nothing else at least there's someone else ploughing insane money into a daily driver.
And Martin obviously :-)
Do I regret it? Not really, the money §§§§es me off a bit but nearly everything that's been done to the car has made it better than when I got it and it becomes a bit of an obsession getting these things back to being "spot on".
I've not done spending yet as I know I need to look at wishbones and probably front suspension in the near future but I still want to upgrade the interior, refurb or replace the wheels and a few other bits I'd actually like to do to it.

Actually, one regret, should have bought a T5!

[JamesT5]

I would enquire about aa cover they might cover 500 towards a gearbox james

I've just joined the AA but I didn't opt for Garage cover as it looks a bit of a con.... it doesn't cover you against "wear and tear" only mechanical failure in a breakdown scenario. As most breakdowns are due to wear and tear of some description it does make the Garage cover a bit of a con does it not? You know what they're like, they'll find some reason or excuse why the breakdown isn't eligible for the Garage Cover repair despite the extra £50 a year.

Good suggestion though!

[JamesT5]

James, your story reads almost identically to mine.
Since buying my 02 S60 I have ploughed just over £3k into it in the last 12 months. On top of the price of the car.
Obviously well over what a bog standard S60 D5 is worth and total insanity really when it's added no real resale value to it, it's worth peanuts to anyone else.
To me it's a 5 grand motor!

During that time it's tested my patience but I've developed a strong affection for it despite its constant attempts to bankrupt me.
I've learned a huge amount and am starting to become vey familiar with these cars.
I've discovered forums filled with helpful, friendly people who have literally saved me hundreds of pounds.
Much like you I have a lot of enthusiasm but I lack the equipment and specific knowledge or skills to attempt some of
the things I'd like to do myself.
I totally take on board others comments and it makes no rational sense wen you look at it but I am in far too deep to get my money back and basically refuse to sell a car with pretty much all the usual issues rectified for a pittance.
It started out as a nice daily driver and is now, as my wife calls it, my expensive hobby.
Within reason I am happy to take this 150000 mile car to 250000 and I am learning new skills and doing jobs I would always have paid a garage for in the past.

It would be interesting to compare notes and if nothing else at least there's someone else ploughing insane money into a daily driver.
And Martin obviously :-)
Do I regret it? Not really, the money §§§§es me off a bit but nearly everything that's been done to the car has made it better than when I got it and it becomes a bit of an obsession getting these things back to being "spot on".
I've not done spending yet as I know I need to look at wishbones and probably front suspension in the near future but I still want to upgrade the interior, refurb or replace the wheels and a few other bits I'd actually like to do to it.

Actually, one regret, should have bought a T5!

You know you're so right, the resale value of the car is so poor compared to what has been spent on it that you think "I might as well keep this and finish what I started". I brought the car in March 2012 with 12 months MOT and a full Volvo service history so why would I expect loads of issues I thought to myself. Everytime a new issue arises, you don't then expect loads and loads of issues to follow especially as a lot of these just crop up with little or no warning, they just suddenly appear.

At some point, you've gone around the whole car changing bits and then you'll be left with something that is better than a car with half the mileage on it. As you said, you learn things about the car all the time and that helps for the future and one example is with me changing my Alternator, a job I never thought I would be able to do but I did it and saved 3 figures on garage labour.

It's what the car's worth to the individual rather than its actual physical value, that's what counts I think. :B_thumb:

[volvokid]

I've just joined the AA but I didn't opt for Garage cover as it looks a bit of a con.... it doesn't cover you against "wear and tear" only mechanical failure in a breakdown scenario. As most breakdowns are due to wear and tear of some description it does make the Garage cover a bit of a con does it not? You know what they're like, they'll find some reason or excuse why the breakdown isn't eligible for the Garage Cover repair despite the extra £50 a year.

Good suggestion though!

I could have claimed 1000 back but messed up so only managed 500 so its certainly not a waste. Lee uses it too.

[JamesT5]

I could have claimed 1000 back but messed up so only managed 500 so its certainly not a waste. Lee uses it too.

So you think I should upgrade and then make a claim? Thing is, I'm sure the Garage cover only applies if you've broken down but I'll have to read the small print.

[volvokid]

My maf and angle gear would both have been covered when they failed.. even brake calipers are covered.

[volvokid]

So you think I should upgrade and then make a claim? Thing is, I'm sure the Garage cover only applies if you've broken down but I'll have to read the small print.

You need to call them out even if its to your house first. Due to my circumstances I didn't call them out for my angle gear failure so I couldn't claim for it. The aa doesn't have to diagnose the issue accurately your garage does that part.

[JamesT5]

My maf and angle gear would both have been covered when they failed.. even brake calipers are covered.

It's reports like this that make me think......

http://www.consumeractiongroup.co.uk/forum/showthread.php?327945-AA-Breakdown-cover-didn-t-cover-me

[volvokid]

It's reports like this that make me think......

http://www.consumeractiongroup.co.uk/forum/showthread.php?327945-AA-Breakdown-cover-didn-t-cover-me

You have to stick to there rules James. I wasnt best pleased when they declined me trust me. But it was my fault. I cant guarantee your box is covered, but if it is you will save alot of money btw you dont have to go to an aa approved dealer. If you go to your normal one and get the garage to follow there part of the procedure, then you pay it and then send your bill to the aa then they send you a cheque minus your claim excess.

[Fubar1977]

Hope it's good news tomorrow James, you're due a bit now I think.

The MoneyPit got through the MOT today with only an advisory for slight deterioration of wishbone bushes.
(breathes sigh of relief) Tax due next month though, and then front tyres...and on and on...

It's an expensive hobby building a brand new Volvo piece by piece, especially when the end results only worth beans come resale time.
Oddly satisfying though...

[JamesT5]

You have to stick to there rules James. I wasnt best pleased when they declined me trust me. But it was my fault. I cant guarantee your box is covered, but if it is you will save alot of money btw you dont have to go to an aa approved dealer. If you go to your normal one and get the garage to follow there part of the procedure, then you pay it and then send your bill to the aa then they send you a cheque minus your claim excess.

But if the car still runs it's not a breakdown situation and they won't cover me surely?

[JamesT5]

Hope it's good news tomorrow James, you're due a bit now I think.

The MoneyPit got through the MOT today with only an advisory for slight deterioration of wishbone bushes.
(breathes sigh of relief) Tax due next month though, and then front tyres...and on and on...

It's an expensive hobby building a brand new Volvo piece by piece, especially when the end results only worth beans come resale time.
Oddly satisfying though...

If you want some pre-polybushed wishbones (front polybushes), I'll be getting mine up for sale soon once I've pressed the new bushes in. The only other thing left to do with them is to cut an old ball joint off the one that won't come off but I can probably pay a garage a small fee to carefully cut the ball joint off for me.

[volvokid]

But if the car still runs it's not a breakdown situation and they won't cover me surely?

Yeah they do I got them out to me, explained my running issue. Then drove all the way to the bottom of England lol.

[JamesT5]

but if the estimate is anything over £400 I would think about saving your money and putting it into another car, and take yours to your most local auction.

I'll put a reserve on it of £5000. Any takers? :hilarious

[Fubar1977]

If you want some pre-polybushed wishbones (front polybushes), I'll be getting mine up for sale soon once I've pressed the new bushes in. The only other thing left to do with them is to cut an old ball joint off the one that won't come off but I can probably pay a garage a small fee to carefully cut the ball joint off for me.

Could well be interested. Are they are straight fit onto my 02 D5?
I would have to get my garage to fit them, consider me low on the learning curve :-)
Presumably they will "tighten" the front end up a bit, not researched the poly bush thing much to be honest.

[jbconno]

Its reading threads like this that I thank my lucky stars that I have a company car that gets replaced every 4 years.

[graemewelch]

Could well be interested. Are they are straight fit onto my 02 D5?
I would have to get my garage to fit them, consider me low on the learning curve :-)
Presumably they will "tighten" the front end up a bit, not researched the poly bush thing much to be honest.


theyll fit but iwouldnt advise fitting without sorting rear bush.

[JamesT5]

Could well be interested. Are they are straight fit onto my 02 D5?
I would have to get my garage to fit them, consider me low on the learning curve :-)
Presumably they will "tighten" the front end up a bit, not researched the poly bush thing much to be honest.

Yes, they're genuine Volvo wishbones that will fit the 02 D5, and yes, they will tighten the front end up. They're my old wishbones, I've removed the old front bush and I've got to press in the new Polybushes and then get the old ball joint off the one before they're ready to go. I've also given them a scrub up with a wire brush the best I can to freshen then up slightly (nothing too drastic).

The back bushes are the originals but they're not cracked and look in good condition. I'd send you photos first before you made a final decision and I'm not going to be greedy on the price either (they'll be cheaper than new ones).

I'd advise you to get good garage to fit them for you!

[JamesT5]

theyll fit but iwouldnt advise fitting without sorting rear bush.

You have a vested interest in the rear bush though don't you? :D I still have a PM from you with the quotation on it you sent me, I might Poly the rear too and then sell it on but this will obviously attract a higher selling price I guess.

[Fubar1977]

Thanks James.
Give me a shout when they're done and I may well have them off you.

Assuming the cars left me with any money by then lol.

Are you still getting a diagnosis on the g/box today?

[JamesT5]

Ok, I've been to see a Gearbox specialist in Cwmbran today and they've taken the car for a test drive (with me in it), and quoted me for fixing the problem....

The chap I spoke to stated that the noise sounds like a worn pinion, he used the words "Lower Pinion" which does sound like 'Low Opinion' to me but never mind. Some of mechanical whizkids on here will probably know where he's coming from better than I do. He said it has some sort of sealed something or rather (can't remember his words on that bit though).

He said that the worst case scenario is that if the bearing fails the 2 front wheels will lock up and to quote his words, "the car will go up on its end". This could damage other parts on the car so I think really this should be a priority job.

The repair option (if it can be repaired) will be £400 +VAT but a reconditioned box is £795+VAT fully fitted. He said the DMF seems ok with no sign of a problem and he also said that he's never seen a DMF go on a petrol car (so bad luck MRP!) :D A new clutch will be around £150 but no fitting charge, they'd fit it as part of doing the gear box.

Total approximate cost for the job including clutch and VAT, and eye popping £1100 :eye-poppi

Right, time to nag the boss for some more overtime...... :B_thumb:

[V70 Graham]

£1100 for a gearbox AND clutch, seems like a good price, clutches (albeit with DMF's) can easily top a grand.
Any idea yet which option your thinking of going with ?

[Tomcat]

Its at this point I'd be seen sprinting across the carpark with a can of petrol and a box of matches,lol.. Feck me....£1100?....it's probably a good price but I'd still be crying over me keyboard..

[M-R-P]

I spent 1100 quid on a new clutch and DMF fitted. The guy is talking balls if he says a petrol DMF doesn't fail! I pulled mine apart with a screwdriver when I got it home. All the springs had failed and wandered-off somewhere and the 2 plates had separated so much you could get your fingers between them.

But the offer of a new box and clutch for that money is a steal mate. go for it ;)

[JamesT5]

£1100 for a gearbox AND clutch, seems like a good price, clutches (albeit with DMF's) can easily top a grand.
Any idea yet which option your thinking of going with ?

At the moment it's all money dependent and to be honest, I've still got a back log of bills to pay off owing to my constant battle with this car. If I had my first choice it's a new (recon) box and clutch but I'll see what I can pick up myself to save a few quid.

My second option is a second hand box and they said they's charge £300 including VAT to fit it.

Decisions, decisions........ :D

[JamesT5]

By the way, they had a Citreon C8 (or C4 Picasso) not sure whuch, in the workshop on a 57 plate with just 40,000 miles on the clock. The gearbox had gone on it. Then the guy gets in mine whilst I watch his eyeballs drop out the sockets as he reads my Odometer! ;) :B_thumb:

[M-R-P]

£60 for a gearbox from my local scrappy :)

[JamesT5]

£60 for a gearbox from my local scrappy :)

What mileage is on it and is it definatley from a 2001 or compatible P2 2.3 T5?

[Fubar1977]

Bad luck James, sorry to hear its yet more money :-(
Doesn't seem a bad price though tbh.
I spent £1162 on my clutch/slave and DMF last year...

I feel your pain mate I really do.

[M-R-P]

What mileage is on it and is it definatley from a 2001 or compatible P2 2.3 T5?

None in at the moment but when they have one, an bare in mind I (or somebody) will have to remove it from the car, it'll be right as all the info will be available on the website. You should get away with any p2 petrol gearbox with M56 on it.

[JamesT5]

None in at the moment but when they have one, an bare in mind I (or somebody) will have to remove it from the car, it'll be right as all the info will be available on the website. You should get away with any p2 petrol gearbox with M56 on it.

Thanks, I've been on to fleabay and discovered this one from a 2003 model for £100 plus £40 postage. There's a Best Offer option on it so I may see if they'll take a bit less for it but first I want them to tell me how many miles the car had done that it came off of.......

http://www.ebay.co.uk/itm/370793082427?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649

[graemewelch]

theres one in my local scrappy to. can get a price if need be. offers there if you want me to find out

[JamesT5]

theres one in my local scrappy to. can get a price if need be. offers there if you want me to find out

Thanks Graeme, please make enquiries if you're passing by at some point. Thank you!

I'm still considering my options at the moment, my preference will always be a new or recon unit and clutch but with budgets stretched I have to keep my options open.

[claymore]

Thanks, I've been on to fleabay and discovered this one from a 2003 model for £100 plus £40 postage. There's a Best Offer option on it so I may see if they'll take a bit less for it but first I want them to tell me how many miles the car had done that it came off of.......

http://www.ebay.co.uk/itm/370793082427?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649

Seems a bit steep, I've just sold my old one for £25, these gearboxes are usually bullet proof and will easily do 250k miles without an issue. I just think you've got a badly abused car.

[claymore]

thanks graeme, please make enquiries if you're passing by at some point. Thank you!

I'm still considering my options at the moment, my preference will always be a new or recon unit and clutch but with budgets stretched i have to keep my options open.

your car is 12 years old, stop throwing money at it.

[JamesT5]

Seems a bit steep, I've just sold my old one for £25, these gearboxes are usually bullet proof and will easily do 250k miles without an issue. I just think you've got a badly abused car.

My car has done 240,000 miles remember. I don't think the gearbox has been abused at all, I certainly don't abuse it and the original owner used it alot on motorways crusing to Scotland from Stoke-on-Trent on a regular basis. Somehow, I doubt he got the opportunity to abuse it either, unless he spent the whole journey trying to force it in to reverse!

[JamesT5]

your car is 12 years old, stop throwing money at it.

I refer you to comments made earlier in the thread.

[Fubar1977]

My car has done 240,000 miles remember. I don't think the gearbox has been abused at all, I certainly don't abuse it and the original owner used it alot on motorways crusing to Scotland from Stoke-on-Trent on a regular basis. Somehow, I doubt he got the opportunity to abuse it either, unless he spent the whole journey trying to force it in to reverse!

I think mine had 2 careful, conscientious owners for the first 98000 miles and 1 suicidally wreckless one who didn't do enough maintainence for the next 44000. Spent another 200 in the last 2 days but that's mostly annual servicing stuff, MOT and a couple of other bits.

[JamesT5]

I've placed an offer on the gearbox on fleabay. I do wonder though, if I buy it and it gets delivered how on earth I'm going to lift it in to the back of the car to get it to the Gearbox Centre.

Anyone know what the weight of these boxes are and is it going to be possible to lift it in to the back of the car single handed, for transport?

[claymore]

You can lift it easily

[JamesT5]

You can lift it easily

Thanks mate, at least I know I'll be able to move it around without having to hire a body builder. :D :B_thumb:

[JamesT5]

Brought the second hand gearbox on ebay, got it for a reasonable £80 plus £40 shipping. Let's hope it's a good one and not on the blink itself but I paid through Paypal so I've got buyer protection if the worst happens.

Ok, now I must save for the fitting, oh, and a new clutch (might as well whilst it's on the ramp)! Here we go again........ :D

[JamesT5]

My replacement gearbox turned up yesterday. Once I've unwprapped it and scrubbed the oil off it I'll post a picture for you all. Looks like the engine mount bushing is knackered on it though so I'll be buying a polybushed lower mount to go with it! :D

[JamesT5]

I gave my replacement gearbox a good scrub today as it came delivered in a thick layer of oil, I assume some of this may have been transmission oil but it was all around the big open area where the clutch goes (I think). Anyway, it's come up pretty well although it took 2 spray cans of Wynns Engine Degreaser (couldn't buy Gunk around here), half a litre of Fairy Liquid and 14 wire wool pads to get it as clean as I have. There's still some areas of grease on it but all things considered it's not too bad. I'm so tempted to get some silver paint and give it a once over or am I being too fussy now? :D

http://i1306.photobucket.com/albums/s562/_JamesT5/P1010885_zpsab9624fd.jpg (http://s1306.photobucket.com/user/_JamesT5/media/P1010885_zpsab9624fd.jpg.html)

http://i1306.photobucket.com/albums/s562/_JamesT5/P1010886_zpsa9431f1e.jpg (http://s1306.photobucket.com/user/_JamesT5/media/P1010886_zpsa9431f1e.jpg.html)

Oh, and correct me if I'm wrong, but looking at it I think this part........

http://i1306.photobucket.com/albums/s562/_JamesT5/P1010889_zps28855b9b.jpg (http://s1306.photobucket.com/user/_JamesT5/media/P1010889_zps28855b9b.jpg.html)

.... is actually part of this part......

http://i1306.photobucket.com/albums/s562/_JamesT5/9141042_zps63f41f77.jpg (http://s1306.photobucket.com/user/_JamesT5/media/9141042_zps63f41f77.jpg.html)

The bushing is totally knackered on the replacement box so I'll be getting a whole new lower engine mount (which is what it is I believe), and getting that fitted at the same time. I have seen pre-polybushed ones for sale so I may see if I can get one of those.

Just got to get a new clutch now and then book it in a day or 2 before payday which is 2 days before the Haynes day in Somerset. I don't fancy driving there with a dodgy transmission if I'm honest, so I'm looking to get it fixed before then.

:B_thumb:

[JamesT5]

You can lift it easily

By the way Colin, how strong are you because although I could lift it, I'd say it was far from easy. It's like lifting a small adult and getting up 2 flights of stairs took ages.

[graemewelch]

its even harder when your on your back and your trying to get the input shaft through the clutch.

[JamesT5]

its even harder when your on your back and your trying to get the input shaft through the clutch.

Thankfully the hard work will be done by a Gearbox specialist for £300 including VAT. The hardest thing for me will be loading it in to the car boot! :D

[claymore]

Why can't you use your old bottom mount?

[JamesT5]

Why can't you use your old bottom mount?

I can but it makes sense to get a new one as the bushes are probably past their best.

[JamesT5]

Slapped this video together this afternoon showing the gearbox noises as they are now.....

http://www.youtube.com/watch?v=oEUNI2PMPqM&feature=youtu.be

[graemewelch]

that dosnt sound good. were they hitch hickers on the round about about 3 mins in. if so you could of offered them a lift. sounds like its on it last legs to me. is it not worth looking into a 6 speed conversion. it should be all bolt on. no major dramas

[JamesT5]

that dosnt sound good. were they hitch hickers on the round about about 3 mins in. if so you could of offered them a lift. sounds like its on it last legs to me. is it not worth looking into a 6 speed conversion. it should be all bolt on. no major dramas

Nice idea about a 6 speed but I've got a 5 speed right here waiting to go on, just need a compatible DMF (preferably a new one).

[claymore]

Waw, your car doesn't half crash and bang on any small bump in the road, Mine is nowhere near as bad as that on the road, and I do that run quite often when I go to Swansea.

[JamesT5]

Waw, your car doesn't half crash and bang on any small bump in the road, Mine is nowhere near as bad as that on the road, and I do that run quite often when I go to Swansea.

It's the lowering kit and all the new suspension parts. And here's me wanting to tighten it up even more by getting the front wishbone 'Black Series' Powerflexed, fitting a strut brace and getting my ARB bushes changed over for the Powerflex bushes as well. Oh, and then I'm going to get those subframe bush inserts! Nothing else to fit to stiffen the ride up I don't think.

Anyway, first things first - this damn gearbox!

[claymore]

I couldn't live with that as a daily driver, my track only car is nowhere near as bad as that.
At 1:48 the car sounds like its going to fall apart, have you fitted lowering springs without shorter dampers?

[JamesT5]

I couldn't live with that as a daily driver, my track only car is nowhere near as bad as that.
At 1:48 the car sounds like its going to fall apart, have you fitted lowering springs without shorter dampers?

I brought the whole damper and coil kit as 'a kit' from Parts For Volvos. :B_thumb:

[JamesT5]

I do like the harder ride but it's all ruined by an output shaft bearing at the moment. Oh, and yes, it can be a very hard ride, especially over the bumps. :D

[M-R-P]

The camera made the ride look worse than it was from what I can tell. If you watch the videos in my car, it's much the same. I couldn't live with the extra noise and vibration from the black series bushes tho, that's a bit too much.

The lowering kit you used is probably not helping tho, I can't see the springs and shocks, at that price, being comparable to the bigger named stuff. Mine crashes a bit ober the bigger bumps at low speed but when moving, it takes fast bumps better than the OE suspension. A good example is cattle-grids. with the current setup, you hardly notice them. Possibly due to the bound/rebound rate of the apex springs - a cattlegrid has roughly the same spacing as corner rumble strips on race tracks.

On to the gearbox and transmission noises - I'd be scared to drive it mate, that's the sound of impending doom! Drive carefully till you get it fixed or risk leaving an embarrasing mess on the road :yikes:

Look on the bright side, you can get the transmission fixed and confidently go in search of the next niggle...

[graemewelch]

i used to have koni fsd and eibach set up. over 600 quids worth of suspension. handled like a gokart but if wanted a rough ride and great handeling i would of bought a scooby. bought a volvo for comfort and power. and good handeling. its a good all rounder. the fsd shocks didnt stay with me for long. back on standard shocks. after driving the c5 i find the s60 ride harsh untill i get used to it again

[M-R-P]

Mine's pretty harsh at low speeds to be honest but like you say, handles brilliantly. Motorways and fast roads are a different matter - it's more like a 747 for comfort and ride quality, just sucks it all up, the faster the better.

[graemewelch]

couldnt agree more. with fsd shocks it was like forklift truck on a bumpy road.

[JamesT5]

The camera made the ride look worse than it was from what I can tell. If you watch the videos in my car, it's much the same. I couldn't live with the extra noise and vibration from the black series bushes tho, that's a bit too much.

The lowering kit you used is probably not helping tho, I can't see the springs and shocks, at that price, being comparable to the bigger named stuff. Mine crashes a bit ober the bigger bumps at low speed but when moving, it takes fast bumps better than the OE suspension. A good example is cattle-grids. with the current setup, you hardly notice them. Possibly due to the bound/rebound rate of the apex springs - a cattlegrid has roughly the same spacing as corner rumble strips on race tracks.

On to the gearbox and transmission noises - I'd be scared to drive it mate, that's the sound of impending doom! Drive carefully till you get it fixed or risk leaving an embarrasing mess on the road :yikes:

Look on the bright side, you can get the transmission fixed and confidently go in search of the next niggle...

You should hear the box first thing on a cold morning - it's twice as bad as that and there are extra noises too. :scared:

[V70 Graham]

Any idea when you'll be having it looked at ?

[JamesT5]

Any idea when you'll be having it looked at ?

I'm going to phone a couple of Volvo specialists of my choice tomorrow (Thursday) to discuss the options and the costs. I may have to take a gamble and buy a second hand flywheel just because the alternatives are more sinister.

Bottom line is, it all boils down to money!

[V70 Graham]

.....I may have to take a gamble and buy a second hand flywheel.....

Bottom line is, it all boils down to money!

I know it's down to money mate, but if the cars a keeper, may be worth doing it once....but properly.

[JamesT5]

I know it's down to money mate, but if the cars a keeper, may be worth doing it once....but properly.

Yes I know, however if I don't do something drastic and soon the car may not be a keeper at all because the gearbox really is in a bad way. Tonight, I was cruising at around 50 mph and hear something 'slapping' the underneath of the car, when I looked back there was nothing on the road that I could see and the sounds were about 2 seconds apart. I'm thinking that could haver been part of the bearing breaking off in the gearbox, but who knows!

[V70 Graham]

Yes I know, however if I don't do something drastic and soon the car may not be a keeper at all because the gearbox really is in a bad way. Tonight, I was cruising at around 50 mph and hear something 'slapping' the underneath of the car, when I looked back there was nothing on the road that I could see and the sounds were about 2 seconds apart. I'm thinking that could haver been part of the bearing breaking off in the gearbox, but who knows!

C'mon mate I hardly do 50 mph in my car that's all sorted :redface:

I really don't want to be reading that summats gone drastically wrong and you end up in a ditch somewhere, luck don't last forever :saint:

[JamesT5]

I've just phoned a Independent Volvo Specialist about 40 miles from me and spoke to a chap who was really helpful and honest.

As far as he's aware, the DMF's are the same for both gearbox input shaft types and he's quoted me £240 + VAT and fluids for a straight swap over of the whole lot. He said it's about a 1 days work but would like it for two just to make sure there's time for anything unexpected (the bill will stay the same). The lady who I initially spoke to there said that about 50% of the time the DMF does need changing but the chap who I spoke to in the workshop said there is a solid flywheel conversion available for these cars to replace the DMF, and it's a lot less money too - something I need to look in to!

I'm going to book the car in for August (after pay day of course) and go from there. I'll keep you all posted and hopefully this time, the car will actually get fixed (I can't wait). I just hope the pinion shaft bearing holds out until then!

I'll keep you posted! :B_thumb:

[JamesT5]

I've booked the car in for the 8th August. :B_thumb:

[M-R-P]

I've just phoned a Independent Volvo Specialist about 40 miles from me and spoke to a chap who was really helpful and honest.

As far as he's aware, the DMF's are the same for both gearbox input shaft types and he's quoted me £240 + VAT and fluids for a straight swap over of the whole lot. He said it's about a 1 days work but would like it for two just to make sure there's time for anything unexpected (the bill will stay the same). The lady who I initially spoke to there said that about 50% of the time the DMF does need changing but the chap who I spoke to in the workshop said there is a solid flywheel conversion available for these cars to replace the DMF, and it's a lot less money too - something I need to look in to!

I'm going to book the car in for August (after pay day of course) and go from there. I'll keep you all posted and hopefully this time, the car will actually get fixed (I can't wait). I just hope the pinion shaft bearing holds out until then!

I'll keep you posted! :B_thumb:

SMF conversion is £350-450 iirc mate. Worth a look. I got my DMF for £370 so was happy with that.

[graemewelch]

gave 250 for my R dmf and clutch. almost new

[JamesT5]

gave 250 for my R dmf and clutch. almost new

Yes, why doesn't that surprise me!

[JamesT5]

The car is going in and it will have what I can afford, at the moment I'm just sick of driving on tenterhooks waiting for a big bang. At the moment other than the relatively easy ABS/Tracs issue, the gearbox is the only major mechanical issue left that's letting my car down. Once fixed, the rest is easy and the car will be pretty damn solid!

[graemewelch]

Yes, why doesn't that surprise me!

what im getting at is theres bargins out there

[claymore]

http://www.volvoforums.org.uk/showthread.php?t=183853

[JamesT5]

Gave the guy a PM to ask about that DMF on the S60, I've also got my eye on another one too from someone on VOC.

Driving the car at the moment is a white knuckle experience as the sound is getting really bad (much worse than the video). I just hope it can hold off for another 4 weeks but in the meantime I'm just driving carefully as well as preparing for a big bang! It's definitely the pinion shaft bearing that's failed or nearly failed because the car is whining like made around 35 - 40 mph and grinding it's nuts off on all gears plus neutral.

[oblark]

Gave the guy a PM to ask about that DMF on the S60, I've also got my eye on another one too from someone on VOC.

Driving the car at the moment is a white knuckle experience as the sound is getting really bad (much worse than the video). I just hope it can hold off for another 4 weeks but in the meantime I'm just driving carefully as well as preparing for a big bang! It's definitely the pinion shaft bearing that's failed or nearly failed because the car is whining like made around 35 - 40 mph and grinding it's nuts off on all gears plus neutral.

If it`s making a grinding noise in neutral it`s not a pinion brg it`s the imput shaft brg

[JamesT5]

If it`s making a grinding noise in neutral it`s not a pinion brg it`s the imput shaft brg

If it's in neutral then the wheels are turning something in the gearbox and it's grinding. The Gearbox garage stated it was the pinion shaft bearing and having done some research online and watched some Youtube videos I'm inclined to agree with them.

If it's the input shaft bearing, I've also read the noise should go away when the clutch pedal is depressed but it makes no difference whether the clutch is engaged or not, it just grinds 100% of the time and then there's the whine at around 35 - 40 mph.

Either way, it's knackered.

[claymore]

well in that case it's just the diff that's gone, but I suppose it's just as easy to swap the whole gearbox

[JamesT5]

well in that case it's just the diff that's gone, but I suppose it's just as easy to swap the whole gearbox

Should get a Limited Slip Diff and then I can try it out at a track day. :D

[silverhorse]

Should get a Limited Slip Diff and then I can try it out at a track day. :D

Er, no!!

[JamesT5]

Er, no!!

:D :hilarious

[graemewelch]

theres a s60r clutch and dmf on ebay. id make a cheeky offer. 200 ish. make sure you have right box though. im lost off with what spline you have. s60r clutch is a good set up in mine

[JamesT5]

theres a s60r clutch and dmf on ebay. id make a cheeky offer. 200 ish. make sure you have right box though. im lost off with what spline you have. s60r clutch is a good set up in mine

I've got a brand new clutch sitting in a box right here, waiting to go on. Unfortunately, at £200 it's too expensive, I'm looking at a budget of £40 - £50 for a flywheel (second hand) so long as it's serviceable.

[graemewelch]

guess your fitting the old one then.

[JamesT5]

guess your fitting the old one then.

Not necessarily, you said yourself, "there's bargains out there". :D