Engine: B5244: Clutch *DMF - list of items to order

[2.4TSE]

A clunk on engaging gear from rest and increased coarseness/vibration under load indicates that at 120k miles the DMF on my 2003 V70 2.4T is on its way out. Whilst at it I will replace the clutch assembly, the release bearing and the slave cylinder (all parts currently original).

Is there anything else to consider such as stretch bolts that will also need replacing?

Just trying to plan ahead and minimise the time that the car is off the road.

Cheers,
2.4TSE

[Symes]

You might want the rear crank seal and 'core' plug (which is behind the dmf) on hand in case they are leaking (or showing signs of doing so) .

Depending on how prepared you want to be, replacement gearbox fluid if yours is an unknown quantity, gearbox driveshaft seals, new brake fluid for bleeding (generally a pita), new flywheel bolts if they don't come with the dmf, and new subframe stretch bolts.

When I did mine, I also used some short lengths of studding in the gb mounting holes in 3 or 4 places to help the box slide off and back on without straining the main input shaft. I also spent far too long trying to bleed the clutch manually and with an 'easibleed' before using a syringe to reverse bleed from the slave bleed screw!

Have fun! :-)

[2.4TSE]

Thanks, Symes; exactly the sort of info I was after.

"I will replace the clutch assembly" = "I will supply and my village garage will replace" as unfortunately the time to do such tasks myself (which I enjoy) doesn't exist any more!

[bournricha]

The lengths of studding is a really good idea to prevent straining the input shaft.I have just struggled before .Thanks !

[Backo]

Hi Guys
I’m in the middle of the procedure myself – gearbox on the table, new clutch set arrived –DMF (with bolts as a part of the set), friction/pressure plates, slave cylinder (Luk from online retailer) – all for 515 delivered. I’m awaiting gearbox and crankshaft seals from FRF. I also ordered the core plug, but I don’t think it needs replacing in my case.
Here is a practical question – the new clutch pressure plate lacks the plastic adjuster that needs to be pre-set before installation (according to Haynes and other posts here). In fact the original pressure plate that came off the vehicle also lacks it – in this case I wonder do I need to compress the diaphragm spring before installation?


That's the new one:



And there's nothing like that:


Can someone experienced explain the difference please?

Cheers

p.s.
I'm talking about V70 on B5244S2 engine

[2.4TSE]

Hi Backo,

Thanks for joining the thread and I await seeing the answer you receive in case I need to share it with the village garage that will fit my clutch / dmf / etc assembly; they are highly competent guys and have my complete trust for a proper job but I think my V70 will be the first time they have done the job on a P2 platform Volvo.

Out of interest; where did you order your LUK components from, please? Unless the B5244T3 DMF is a lot more expensive than for an atmo engine the price you have got is a lot better than what I have found (£475 for the DMF plus £220 for the clutch assembly with slave cylinder). All LUK items.

Cheers,
2.4TSE

[Backo]

That was the cheapest Luk I could find :
http://www.ebay.co.uk/itm/LUK-DUAL-M...item3ce231dc84


"Techniclutch" on ebay in case link fails. You get a better deal for the whole set (DMF+pressure/friction plates+CSC)

I wouldn't be surprised if diesel or higher output turbocharged engines are fitted with different/stronger clutches.

The question remains though - do I need to depress the spring before installation, or can I just bolt on the pressure plate?

[Symes]

Hi Backo,

I thought that the pressure plates were the same for all of the models, AFAIK the one with the spring in your second photo - the mechanism adjusts the pressure plate as the friction plate wears so that the 'bite' point is roughly in the same place throughout it's life.

However a bit of googling shows that the part number (123033910) is used in V70 P2 models although most of the 'hits' seem to be from European sites, so perhaps they were more widely fitted there. The compatibility list on your Ebay link lists the 2.0t as well, and using that as a basis for a vehicle on the EuroCarParts website the 'product details' mention replacement of the DMF, but don't mention that the clutch requires 'specialist tools' to fit, so it tends to suggest that what you have is a 'standard' pressure plate that can be bolted on without pre-tensioning (which can be done using a 3-leg puller and appropriate centre billet by the way) - just remember to gently tighten the cover bolts on diagonal opposites a little at a time to as evenly as possible clamp the friction plate (apologies if I'm teaching you to suck eggs!).

2.4TSE, your pressure plate is almost certain to be the self-adjusting type and will therefore need to be 'set' before bolting to the flywheel. They're not unique to Volvo, so your garage has probably come across them before!

[Backo]

Thanks, Symes!
That pretty much confirms my thoughts. It's just the fact that all topics on the subject in the forum showed adjustable plate and I kinda expected to see it live... but more importantly the original one is the same as the new one, so it looks promising.

[D5meister]

This vid is close to yours praps?
https://m.youtube.com/watch?v=Tp5KeAQntGM