AWD Transmission: Clutch & Flywheel

[Octoman]

Hello All,

I own a 2007 D5 XC90 manual which has recently developed a fault. When pulling away and taking up drive with the clutch, the vehicle judders violently. The problem is only apparent first thing in the morning when the engine is cold and gradually disappears after a few miles as the car warms up.

I spoke to a good friend of mine who is a master technician and he stated that that the most likely cause is a leaking slave cylinder which is contaminating the clutch plate. He advised me to check the fluid level in the master cylinder and I found the level very low so I topped it up to maximum. I've been monitoring the level for the last couple of weeks and it is progressively dropping so there is definitely a leak somewhere.

I have spoken to my local main dealer and volvo independent specialist and they have both confirmed that a replacement slave cylinder, clutch kit and possible dual mass flywheel is required. The quote from the main dealer made my eyes water and I do not know how they can justify labour rates of £110 + VAT. The independent specialist came in at £1500 all in which I think was very reasonable given the amount of work involved.

Has anybody had similar issues with a XC90 manual? I appreciate vehicles can suffer mechanical breakdown and certain items are deemed to be wear and tear, however should a slave cylinder fail on a 5 year old 50k mile vehicle that has full main dealer service history? Is it worth contacting Volvo to see if they will contribute anything as a gesture of goodwill?

Any help or advice would be much appreciated.

[ianu]

Hi Octoman,
Prognosis sounds spot on. 1st time i became aware of mine was when the 'low brake fluid' warning appeared.
Had mine done at approx 80k and am about to have it done again this week over 100k later. I dont have a fluid leak - but clutch itself is starting to slip now.
While it's all apart its best to have the lot done as its all got to come out again otherwise.
The slave cylinder is probably the cheapest bit - but its effectively the same job to get to it anyway.
Might be worth checking also a pair of core plugs at the back of the engine while your at it (only a few pounds - but can be a weak point and ones an oil gallery)
Its a days work for whoever does it - so if you have an Indy you trust then you'll certainly save some money over Dealer prices. DMF - an Indy might have a suitable alternative to Volvo that is cheaper - but see what they recommend. The difference might be neglible - but as I said you only want to do this job once every blue moon.
Hth
Cheers
Ian