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Discussion Starter #21
Quick update on my car.


Dropped it off at the dealers on Tuesday morning and got a call in the afternoon to ask my permission to remove the gearbox for further investigation *Alarm bells!!!


Call today to advise that they are having to replace the slave cylinder and they also recommended replacing the clutch plate. The garage contacted Volvo UK to see if they would cover a proportion with warranty but due to the car being over 60k miles (78k miles) they have classed it as wear and tear.


So over all it is costing £969.18 for the repair! (Thank goodness it is a company car).


It is ridiculous to thing that a car that was registered in April 2015 is having to have such major work done!


The only upside is that the garage have been accommodating and have supplied a courtesy car (new V40 D2 R-Design).
 

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That's patently rubbish- they are using the high mileage and the fact it's a company car to get out of paying/ A concentric clutch slave cylinder/release bearing should last longer than the clutch They are only having to change the clutch because the slave cylinder has leaked fluid onto it.

78K miles is nothing really, and I bet most of it has been motorways where the clutch isn't getting used.
 

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Hi guys, new to forums in general... need some help. I rented a 2017 v40 d2 1.6 which had 350 miles on it and it broke down on me at 1200 miles. Went uphill then turned left onto a residential road at about 10mph and the car started making rattling noises and over revving, next thing I know it won't go into gear. Car was recovered to garage where head office is registered (Even though I was told it will go to Volvo dealership) and now the company is trying to charge 1200 quid for abusing and damaging clutch. I did not abuse it. I am not a mechanic or lawyer, I rent cars as a carer because it's cheaper than ownership or motability if you have an excess reimbursement policy. How can I prove it wasn't my fault seen as I have noticed some problems with car in question online... I told them about the whole warranty thing and how it is a fault and not abuse that lead to this. They're not having it. Help please.
 

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Hello Andy,

searching through the forums I found your post - I have the same problem with my 2014 V40 D2. Clutch getting stuck when on highways only and doing long drives, no problem in the city. Before I take my car to the garage, how did they solve your problem back in 2014?

Thanks for any info, cheers, Matea
 

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Hello Andy,

searching through the forums I found your post - I have the same problem with my 2014 V40 D2. Clutch getting stuck when on highways only and doing long drives, no problem in the city. Before I take my car to the garage, how did they solve your problem back in 2014?

Thanks for any info, cheers, Matea

See the earlier posts in the thread - the root cause is almost certainly a faulty clutch slave cylinder, a fairly well known fault with the Mk3 Focus and the V40s that use the Ford petrol and Ford/PSA diesel engines and B6 gearbox.
 

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Buzby,

can you please explain, what is this B6 gear box?

In the user's manual I see that there are two types of manual gear boxes - M66 and M76.
I noticed, that on old models of V40 manual gear box have the reverse gear positioned at the left side of the 1-st gear. But, on the new ones(that has M76 gear box) the reverse gear is at the right side of the 6-th gear. My car is MY18 T3 and the gear box is M76.
So, it looks like they changed something, by some reason. I can't be sure if DMF, clutch and master/slave cylinders have some revision or is identical as on the old one.

Meanwhile, there is a very curious mechanism just under the gear stick leather case. There is an electromagnetic lock, that blocks the "track" to the reverse gear, when the car reaches about 30 km/h, and enables it back at about 20km/h. This prevents to put revers gear by mistake at a high speed.
 

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Hello to everyone. new to forum. I did not know if I should start a new topic or wright here. From the discussion it seems relevant. So, I have a volvo v40 D2, 2014 which has 125.000 km. Few days back a noise started that was like a whistle. My local mechanic check it and said that it is the bearings of the gearbox (if translate it correctly from Greek, it is the main and secondary shaft bearings of the gearbox). Local distributor of volvo says that I have to buy a new gearbox and volvo does not sell individual parts of the gearbox. Has anyone come with a solution or has a suggestion to this problem? Bear in mind that a new gearbox costs 1/3 of the current price of the car, so it doesnt worth it.
 

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Hello to everyone. new to forum. I did not know if I should start a new topic or wright here. From the discussion it seems relevant. So, I have a volvo v40 D2, 2014 which has 125.000 km. Few days back a noise started that was like a whistle. My local mechanic check it and said that it is the bearings of the gearbox (if translate it correctly from Greek, it is the main and secondary shaft bearings of the gearbox). Local distributor of volvo says that I have to buy a new gearbox and volvo does not sell individual parts of the gearbox. Has anyone come with a solution or has a suggestion to this problem? Bear in mind that a new gearbox costs 1/3 of the current price of the car, so it doesnt worth it.

It's a Ford/Getrag B6 gearbox (also known as the Getrag 6MTT250) made at the transmisison plant in Halewood near Liverpool, and used in many Ford cars (Mk3 Focus and it's derivatives, some Mondeos and latest version of the Fiesta). It was derived from Ford's 5-speed IB5 gearbox, developed for the Fiesta and Escort back in the early 80s..


As Volvo do not make the gearboxes, the dealers do not repair them, only exchange them with either a new or reconditioned unit. The parts to rebuild oneare available fron Getrag or from third-party suppliers though
https://www.automaticchoice.com/en/transmission-parts/6mtt250-b6-durashift
Any transmission specialist that reconditions FWD gearboxes should be able ot repair it. You should also be able to install a used gearbox from a Mk3 Focus (which are more easily found than gearboxes from crashed Volvos) provided it has the same gear ratios.
 

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Morning, 1st time post....

I’m having same issue on 2016 v40 2.0 litre diesel....38,000 on clock. It’s very frustrating. I’ve been in once when car had service and volvo just greased the pedal. I’ve subsequently sprayed WD40 etc on pedal, but this doesn’t solvethe issue. Having read other posts about ‘clutch and slave cylinder’ I am starting to worry I have a massive bill on the horizon???
My old ‘59 plate 2.0 litre diesel focus did something similar...a plastic rod in the clutch snapped following sticking issues. Local independent garage replaced said rod with a metal rod at not much cost to be fair. Presumably these are similar parts???
 

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Morning, 1st time post....

I’m having same issue on 2016 v40 2.0 litre diesel....38,000 on clock. It’s very frustrating. I’ve been in once when car had service and volvo just greased the pedal. I’ve subsequently sprayed WD40 etc on pedal, but this doesn’t solvethe issue. Having read other posts about ‘clutch and slave cylinder’ I am starting to worry I have a massive bill on the horizon???
My old ‘59 plate 2.0 litre diesel focus did something similar...a plastic rod in the clutch snapped following sticking issues. Local independent garage replaced said rod with a metal rod at not much cost to be fair. Presumably these are similar parts???
It does sound like another case of the faulty slave cylinder, I'm afraid.

The problem the Mk2 Focus/CMax had was with the master cylinder behind the clutch pedal. They had plastic actuators that woudl be easily bent or snapped, and also had poor selas that caused the brake fluid to leak into the footwell. The master cylinder was redesigned with metal parts put back in the critical strength areas.

ONe of the things both Ford and Volvo tried to do once the clucth slave cylinders in the early MY13 Focus and V40 started to fail and caused th pedal to stick down was to replace the return spring (or the whole pedal unit) with a stronger spring to 'assist' the sticking slave cylinder. This was only a sticking plaster-type solution though, as it didn't cure the real problem of the leaking slave cylinder which would eventually fail completely (or would cause the clutch to slip doe to contamination of the friction material)
 

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Dear All, Sadly, I discovered this forum in the (nearly) worst possible circumstances. Driving back from Sicily, my recently purchased, low miles (44k) diesel V40 developed the identical symptoms described above. First, the clutch pedal started sticking in the high gears, having to be returned to position by hooking the toe under the pedal. Then, after about 6 hours on the road (mainly motor ways), we were pulling up to a motorway pay station when the clutch failed to disengage the engine fully and I all but had to force the gears down to come to a halt at the pay booth. Pulling away was equally challenging and I stalled twice, to the noisy frustration of the Italians queued behind me. We proceeded to nurse the car to the nearest hotel, which turned out to be a Novotel buried in a warren of unlit and GPS-unrecognisable half-roads in an industrial estate on the outskirts of Covid riddled Rome. We spent an anxious night during which my wife discovered this forum. Thankfully, we have Saga European breakdown cover (never leave home without it-the hidden heroes of this tale). They had the car recovered to the nearest Volvo dealer which, by a stroke of luck, was a half an hour walk away. The following morning, Volvo Rome took a look and then the mechanic ushered me in to see the damage. First, he pointed out oil leaks around the clutch. Then, he showed me the infamous slave cylinder, confirming it was the defective plastic one mentioned in this string. He said it was finished and the consequent oil leak would also require investigation. Provisional estimate of 10 hours' work. We opted for recovery to the garage that sold us the car at Saga's expense and they then flew us home on a fully rammed Alitalia flight. We are now in anxious quarantine awaiting possible consequences. The car was bought used and is in vendor warranty so we remain hopeful of a happy outcome. My problem is that I can find no evidence of a happy outcome in this string. I would appreciate recommendations on what needs to be done to fully repair this car.
 
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