Hi Everyone,

This is my first time posting and I'm relatively new both to my volvo s40 and to the world of cars. I apologise in advance for any incorrect terminology - I'm really stuck with a problem and hoping I can find some possible ideas!

I have been reading the other threads for volvo S40 owners about clutch issues -I'm posting because I haven't yet found the answer to my issue.

Last week whilst driving I found it difficult to shift gear. I own an '09 plate manual S40 (UK). The next day whilst driving I was unable to shift gear from neutral. I pulled over, turned the car on and off, managed to get into 2nd and drove home. The next day I couldn't get into any gear out of neutral. The clutch was not on the floor, it had pressure on it, but the gear stick wouldn't move. I had the car towed to my local garage.

They've had a look at it and have so far topped the clutch fluid up. They said when they opened the bonnet the clutch fluid was incredibly low and they thought there must be a leak. However, they can't seem to work out if it's the master cylinder or the slave cylinder, as apparently there's no leak inside the gearbox which they said they'd normally expect to see if it was the slave cylinder.

I haven't got a lot of cash (postgrad) and I don't want to replace one part if the problem lies with the other. So, yesterday I went and picked the car up - they've suggested I drive it around a bit and see if I can spot a leak or if there is any further development. When I got in the car I couldn't shift gear, however the mechanic told me to pump the clutch repeatedly until I can get it in gear. This worked and I was able to drive it home. The clutch pedal felt variable in terms of pressure and bite position on the way back - it seems the more I pump the clutch the more consistent the clutch pedal is.The clutch fluid in the reservoir already seems to have decreased since yesterday and I've only driven 2 miles. However, I cannot see any evidence of leak underneath the car. I've been reading on here as there are other posts on this matter and I've been looking at some videos online (not volvo specific) for ways to try and diagnose the problem. So far, I've checked the driver's seat floor behind the clutch where the bolts are as per one online suggestion and can find nothing and around the clutch fluid reservoir, which was wet when I looked yesterday. I've wiped that down and am going to wipe it again before I go for a short drive today (to Halfords - for clutch fluid) to see if any wetness reappears. The mechanic said to look for any drip between the engine and the gearbox but I can't seem any or in truth locate the gearbox. I've also been trying to locate the slave cylinder as I have read on this forum elsewhere that pulling back the rubber dust cover that is a way of seeing if the leak lies there - although am I correct in thinking the slave cylinder is inside the gearbox and so possibly a bit ambitious for someone without much experience? I've tried to follow the the lines that run out of the reservoir, they seem to be clipped onto the back panel of the engine compartment and seem to disappear behind the battery.

I'm really stumped. The non volvo specific videos I've seen online seem to demonstrate reasonably straightforward of following the clutch fluid lines to the slave cylinder and checking there - they also demonstrate the process of bleeding the clutch in case air in the system is part of the problem. More than anything I want to find the leak so I can keep driving my car with confidence. I'm due to start a job in two weeks which will mean more time on the road again.

So if anyone has any experience of a clutch fluid leak without any obvious sign of leakage or any tips on how to further diagnose or any advice to help a newbie find the slave cylinder (if accessible) I"d be enormously grateful. I rely on my car a lot as do many, and I'm quite worried about it - mostly at the thought of getting repair work done that isn't the source of the problem.

Apologies for the long post - I thought I'd get as much detail in as possible - if anyone can shed any light I'd be hugely grateful. Thank you!

 

Your shop is correct, there should be evidence of brake fluid dripping from the bell housing if the slave cylinder is leaking, because that's where it is. Unfortunately to replace it requires transmission removal and at that point you would replace the clutch while everything is apart. I'm sure you've found that's a pretty expensive repair.

You said they topped up the fluid - if you have to pump the pedal there could still be air in the system and bleeding the air out might restore proper hydraulic function (until it leaks down and air gets into the system again) You did not mention bleeding, just topping up. If it's a slow leak it could be possible to just carry fluid with you and top up as needed.

 

I agree with hoonk - there's most likely air in the clutch line between the master and slave cylinders (normal if the fluid level got low enough for the master to pump air instead of fluid, which is when your clutch stopped working).

You really ARE going to have to figure out where that leak is to get it fixed, and - as hoonk said - you should start hoping that it's NOT the slave cylinder.

FWIW, my 1996 Jeep has the same issues - I have replaced the "system" (master, slave and lines) but it will eventually (over a few years) lose enough fluid for the clutch to get a little wonky. I just pour in an ounce or two of fluid, and drive for another couple years... I don't really care where it's leaking... it's a Jeep, so it's SUPPOSED to leak (that's how you tell they still have oil or fluid in them). ;-)

 

Dear Hoonk and habbyguy,

Thanks a lot for reaching out and giving your advice - I really appreciate it. It definitely seems like there is air in the system - I've taken two drives since I posted and it confirmed that the more I pump the clutch the better the clutch gets.

I've been pulling my hair out trying to find the leak AND it must have paid off (even if I'm balder) as I've finally found where it's leaking. The first place I checked after getting my car back from the garage was under the clutch pedal and it was dry as a bone. But this evening (UK time) I topped up the reservoir and ran the car on my driveway pumping the clutch. So thankful I looked in every possible area (thanks to a 1989 NZ article online) and under the clutch pedal there was quite a lot of fluid. I wiped it down and repeated and found fluid running down the clutch pedal arm. So I think I'm right in saying that it's the master cylinder seals that have gone. I'm so pleased to finally have found the leak - especially as it's not the slave cylinder.

At some point I think I'd like to get an older volvo so these elements might be a bit easier to access - I still haven't found the slave cylinder (but I think that's because in the 09 S40 it lives in the gearbox and I don't think I've got the credentials or knowledge to go in there) as it's incredibly rewarding to spend time with your car and to get answers - I'd definitely like to be able to do a bit more work myself moving forward.

My car is going back into the garage tomorrow (for another job - replacing a wheel bearing - I can't hear myself think when driving at the moment) so should be able to discuss the master cylinder then.

Once again thanks and I'll post any updates as they come!

 

Great news! You flipped a coin, and it came up heads. ;-)

I can't imagine that the master cylinder would be all that tough a fix, though I don't have any info on your car (apparently no one in the US can drive a manual Volvo... sigh). ;-)

I have done wheel bearings, and they're really not that bad, especially if you happen to have a press. I did a quickie video of the process here: Might give you a feeling for what the shop will be doing (in case they try to make it sound like a huge job!). ;-)

 

Hi all,

Thanks for your advice so far. I got my clutch master cylinder replaced last week and picked the car up. Driving the car home was a real pleasure as the clutch was so smooth and there was full pressure in the clutch.

However, since picking the car up (Monday 20 July) the clutch has been playing up again. In first gear or reverse the gear would get stuck and I was unable to drive without turning off the ignition, pumping the clutch and then turning on the ignition on again before driving off.

Yesterday evening I drove 250 miles, with no incident. Today, the 'low brake fluid' warning sign came on. I pulled over and popped the hood - the clutch/brake fluid reservoir was practically empty. The problem before I had the master cylinder replaced was I couldn't find the leak - which I eventually discovered around the clutch pedal.

Today when I looked under the hood, I found what seems to be a huge leak - the insulation on the firewall was soaked through. I've attached a photo. Anyone come across this before? From what I've read, generally the leak is either at the clutch pedal or in the slave cylinder (so in an S40's case - inside the gearbox).

Any insight anyone has would be massively appreciated.

 

Ouch. Your only hope is to find the actual leak. The soaked firewall insulation might be from the pre-repair leak (or not). Could be that they did something wrong, and there's a leak at the fitting, or with the new master cylinder.

Or - ouch again - it's the slave cylinder. Really not much to that circuit - the master, slave, and the line between them. Maybe you could put a piece of paper under the area of the slave cylinder and pump the clutch pedal (you could pin it down with a chunk of wood, using the seat as the anchor). Then re-pump it and pin it down again. If it's leaking badly (and it sounds like it is) you should start seeing where the fluid is all going.

 

Thanks - great idea. I've got a day off work tomorrow so I'll try that and see what I come up with.

I've also had 'low beam failure' today and noticed the fan blower no longer works in the car. I've experienced the low beam failure a few times in the past (drove a C30 before my S40 and a v50 before both and often had a bulb go) - however this is the first time that I've had both bulbs die simultaneously.

It could be coincidence, but I'm wondering if the leak is connected to this and is short circuiting stuff - is that remotely possible?

 

Thanks for your advice! I did as you suggested and it was very rapidly clear where the leak was coming from - the CSC hydraulic line attached to the master cylinder. I took the line off to see what was going on - it turns out the garage that did the work forgot to put an o-ring on the end of the line. I'm hoping to get one tomorrow. I believe I'll need to then bleed the system, which I'd quite like to do myself after this experience with the garage! Do you know if that means I'll need to access the gearbox?

 

Nope - just replace the O-ring, refill the reservoir, and pump the devil out of the clutch pedal. It'll probably be "almost right" pretty quickly, though it might take quite a while for all the air to leave the line. There's really not much of another option, since the slave cylinder end of the circuit isn't accessible (without draconian measures, at least).

Congrats on finding the problem, and on dodging the REAL problem (having to pull the tranny to fix the slave cylinder). Your problem is just another example of why I always twist my own wrenches - I'm far from the best mechanic in the world, but what I lack in skills I more than make up for in motivation! ;-)