Thought I'd update you all.
Last week I finally had my clutch/SMF combo installed. What a balls ache it was, well, not for me but for the garage anyway!
The long story - short......
Drove down to Kings Motor Services in Westbury at stupid o'clock in the morning on Monday (with the girlfriend - as we were making a short break of it). Arrived at 0930 and handed over the keys to ma car (nervously) and they handed me the keys to an S60 2.0T...sweet!! Off we went to BATH, to spend the day sightseeing, followed by an overnight at Bannatynes Charlton House Spa Hotel in Shepton Mallet. Loverly!!!
I'll have a Swedish massage thankyou!
Next day.... Rang garage at 1100 for update...
They'd literaly just got back from a very short road test. Result was the clutch was slipping at very low revs and the clutch pedal felt very odd at the bottom. It was now back on the ramps and the gearbox being removed to inspect/investigate the issue.
(Now I'm stressed and looking forwards to my Swedish massage!)
Eventually, they found the problem. One that I wasn't aware of, neither was Elk Performance or Don at Kalmar Union.
Apparantly, after I rang TTV (whom makes the flywheel) I spoke with Ben, a very helpful chap, who went on to explain the differences between the early 03-04 clutch and the later 05-07 clutch. The early clutch was not compatible with the TTV flywheel. This was because the clutch adjuster had not released due to insufficient clearance.
There's only a few mm in it, but I ended up having to install the later clutch kit form an 05-07 R. SO, despite the fact I had to pay the labour twice
Kings did me a really cheap rate on labour and supplied the clutch kit at cost to help keep the bill down
It's worth noting that the springs on the later clutch are significantly larger, the pressure plate fingers are stronger and there's no cage on the back of the fingers to prevent the CSC travelling too far.
Works carried out:
Strip out and replace clutch kit, CSC, rear main seal and DMF with later clutch kit and TTV SMF.
Parts:
Sub frame bolts x4
Gearbox seal x1
Rear main seal x1
Volvo clutch kit #VOL31359568 x1
Flywheel bolts x10
Clutch cover bolts x8
Driveshaft retaining bolts x2
Bottom ball joint retaining nuts x2
Driveshaft insulator x2
Driveshaft seal x2
Brembo Dot 5.1 clutch/brake fluid 500ml.
Summary
Gone is the surging under mild acceleration. Gone is the slipping at peak torque. Gone is the judder when taking up drive and best of all....gone is the backlash in the driveline which resulted in a dull 'clonk' when taking up drive and getting the biting point.
Now the pedal is lovely and light with a subtle bit of give at the bottom as the CSC overcomes the clutch pressure plate force.
Biting point is perfect, just up from the bottom of the pedal travel.
I can now pull away smoothly and progressively and application of the throttle is much more responsive due to the lightened mass of the flywheel! Acceleration is much more brutal than before too!
The trade off with having a SMF is often gearbox chatter and a subtle rattle on idle. I'm very pleased to say that I have no chatter on idle at all! This is a result of using a thicker gear oil...Redline 75W
140NS. Many thanks to Don and Ashok for their advice on this.
I also had a Gold magnetic plug installed along with new driveshaft seals, new rear main seal, new CSC seal, new driveshaft damper seals (the ones that fit inside the front hub assembly).
Gear changes are smoother, slicker and more positive.
The odd, subtle vibration I had at around 60-70mph has now also gone!
When switching the engine off, it dies much quicker as there's less inertia, and it now starts much quicker on crank.
The result is a resounding success and to say I'm pleased, is an understatement!
A first for Kings Motor Services in Westbury, whom did a cracking job....they even washed my car for me, even though it wasn't that dirty as I'd already washed it the day before.
Cheers guys!!
A big thankyou to Ashok at Elk Performance for supplying me the bits (not inc SMF) and a big thankyou to Don at Kalmar Union for his aftersales care
.................The drive home was an absolute gem!
To anyone else thinking about going SMF/stock clutch - I highly recommend it!
I just need to have a four wheel alignment which I'll do next month, when the winters go on.
Right....what's next?
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