Hi everyone,

I’m looking for help diagnosing a clutch issue on my Volvo V60 (2011) Diesel D2, manual transmission.

About 6 years ago, the clutch system was replaced, including the gearbox and both clutch cylinders (not original Volvo parts).
A few weeks ago, the clutch pedal started feeling “shorter” than normal for a few days (reduced travel / bite point changing). After that, the pedal started getting lower and lower until it eventually went all the way to the floor.

I took the car to Mechanic #1. He found no leaks, so he bled the clutch system and changed the fluid. After that, the clutch worked normally for about 2 days. Then the problem slowly returned over the next 5 days, until the pedal suddenly dropped to the floor again.

Before bringing it back to him, I tried pumping the clutch pedal several times (my father suggested it). Pumping helped it recover partially, but not 100%. I left the car at the shop overnight. The next day the mechanic told me the clutch was working perfectly and he couldn’t find any problem.

Since the issue was clearly coming and going, I took the car to another mechanic. He also found no external leaks and the fluid level was not dropping. Still, we decided to replace the clutch master cylinder because it’s a common cause of these symptoms. After replacing the master cylinder, the clutch worked well… but only for a few hours. Then the exact same problem came back.

At the moment, the clutch pedal stays almost always on the floor and does not return by itself. ( I need to pull it back up manually).

Pumping the pedal has helped a few times, but only briefly and inconsistently (sometimes it works, sometimes it doesn’t). When the pedal is down, shifting gears becomes difficult.

Other details:

• Brake pedal feels normal
  
• Fluid level stays the same
  
• No visible leaks (inside cabin or under the car)
  
• No unusual noises noticed
  

At this point I’m a bit lost (and so is my mechanic). Any advice on what to check next would be appreciated! Slave cylinder/CSC, bleeding procedure, hydraulic hose issues, or something mechanical?

Thanks!

 

i had a similar problem with a Austin ambassador about 30 years ago it had a shared dual clutch & break servo in which the clutch connection was always leaking so i managed to get a slightly oversized pipe & Union made and bypassed the servo which stopped the problem.



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