Yes that’s true Matt, it’s been running fine although my economy hasn’t improved in fact it seems to be worse. I have a bad injector so going to try replacing that but if it carries on it’s going to have to be remapped as less than 40mpg really isn’t sustainable. I’m surprised at myself for not throwing in the towel when it didn’t go to plan but I was desperate to take this car to Germany, thankfully got away with it with zero time to spare.
Hi , great video, I remember seeing on the Volvo forum about the 185 flywheel, it is that the metal sensor parts on the flywheel are slightly different were the large open space is, I think the user that did the mode moved 2 of the blocks, buy re welding them, there are photos on the forum some were, it was some years ago, Good luck Dave Davebb on the Volvo forum
Hi Dave, perhaps I should’ve took the time to look on the forums but I’m just the kind of person that digs in and learns from my mistakes (of which there are many). Cost me dearly on this occasion but I powered through much to my surprise. I was thinking the sensors sit at different levels, I put the flywheels side by side and couldn’t see any difference whatsoever. Never mind I got it going now and 3,000 miles trouble free since.
Epic video & really fascinating to watch. Having successfully rebuilt the head of my son’s D5, i’m not quite ready to do a clutch change just yet but you have given me the confidence knowing that it can be done. I was interested to see the the Crank Position sensor had such an effect on the engines ability to start. It’s got me thinking as my son’s D5 is a real pain to start as it has to crank over for about 5-10 seconds before it fires into life. Thanks
Hi Mark, thanks very much, I hope this was a bit more interesting than the usual “how to”. Regarding your son’s D5; if you have suitable diagnostic equipment I’d check the fuel correction on the injectors to check for one on its way out and I’d also check fuel pressure and the regulator to see if there’s any issue there. Mine is similarly bad at starting especially on a morning after being left.
Hi, A couple of years ago i had a garage fit a new clutch in my 2003 v70 D5 2.4, some time later, a few months in fact i found they had crushed the fuel line and it was then running on the bottom pulley, it punctured through 160 miles away from home in Anglesey, what a nightmare and mess. good video.
Volvo is a nightmare regarding the spare sparts inconsistency. Same Engine, different Parts. VIN doesnt help. Especialy clutches an Flywheels is a mather of science to find the right one. Respect for the job
I'm pretty sure that friction plate with springs is for the awd models. I personaly prefer to get the engine out instead of bothering with the subframe and steering rack, lifting this gearbox in and out is a pain in the back.
Good day Warm greetings from Germany May I ask if you have already fixed the problem with the cruise control in the 6-speed and have you noticed a difference in fuel consumption compared to the 5-speed gearbox? I would be happy about an answer. thank you from Germany
Your video was a great motivation for me to do the same and I've just collected everything needed. I am curious if you have done something for the reverse gear lockout? Is it present on the 5 speed cars?
That’s great to here and I hope the job goes well for you. I don’t know about the reverse lock out but what I do know is I can now flash my reverse lights at any speed by pushing the gear stick to the right so presumably I could put it into reverse and there’s no lockout where there was before on the 5 speed. If you do find out I’d love to hear about it.
I won't be able to do it myself, unfortunately, because I don't have the proper place. But there is this solenoid on the 6 gear selector, which should do exactly that - prevent the stick to go all the way to the right. I am not sure if there is such a thing on the 5 gear cars, because I haven't taken the spaceball cover to see and I can't find info anywhere. My Volvo is a petrol S60 2001, btw.
Very good job! in summary you have replaced: flywheel + clutch and speed sensor 185bhp, intake pipe, 6 speed gear lever. for the reverse sensor? sorry but my english is rusty and i would like to do the same operation as quickly as possible. thank you
Hi mate so ECU wise there's no alteration just get a extra gear my euro 3 really needs this on a long run :) guessing you used the euro 3 crank sensor?
I think I went through it all in the video although I appreciate it’s a long watch. The car will work fine afterwards you just won’t have cruise control in 6th gear. I recorded a follow up video but lost the footage somehow, I had the ECU programmed to add the 6th gear by Shemtek so now everything works as if the car was always 6 speed.
Great job. I'm planning to do the same on my Euro 3 D5 too. Are the original driveshafts and starter from M56 fits to M66? Cruise control works properly, even on 6th gear? Thanks.
Thank you. Driveshafts and starter are the same, yes. The cruise control now only works in gears 1-5. I don’t know what’s involved to get it working in 6th but I’ll get round to it when I have some spare time.
Thank you. Driveshafts and starter are the same, yes. The cruise control now only works in gears 1-5. I don’t know what’s involved to get it working in 6th but I’ll get round to it when I have some spare time.
Wow Tolly I feel for you having to do that job twice. Just to let you know apparently the ratios from 5 sp and 6 are the same so I have been told and gearbox oil is 2 Ltr on the 6sp 2.1 on the 5sp. Last thing you didn’t have a U.K. badge on your car surprised you dint get pulled over.
Hi Gary, yes, it was a bit of a painful moment for me but I surprised myself and just got on with the job again. Another thing is the cruise control still works up to gear 5 just need to find out how to get it working in 6th as well now. I’m surprised about the UK badges too, it was all so last minute I wasn’t prepared at all.
Is there any difference between the 6speed clutch and flywheel to the 5speed ? The other thing is, how did you install the clutch without a self adjusting clutch tool?
Clutch plates are sprung on the Euro 4 but exactly the same size plate. The flywheel I still have no idea what it is that’s different between the 2, they look exactly the same.
@@IAMASPANNER Im confused about this because there is different part number between 2007 v70 5gear and 2008 6 gear and also between 2007 6 gear... I have 2007 2.4 126 hp V70 II gen and I chipped it to 205 hp and 450nm so now I need to use clutch at least from 185 hp version... And I dont know which clutch will be correct...
@@kuba1515 I’d have said all the clutches are compatible, the Euro 3 setup is probably more reliable if anything because there aren’t any springs on the friction plate. As long as you use the parts by LUK I think you’ll be fine. The reg on my 185bhp donor car was MM06 CVD if you want to use that to get quotes for parts from suppliers.
Glad to see the old volvo getting some work done, also I'm very grateful for all the info I can find on D5 engines on your channel 👍
Christ what an endeavour
Very glad to help, yes the job really was something else but I’m so glad it worked out eventually and I’ve done 3,000 miles since with no issues.
At least you’re back on the road and track earning a living and living a life👍. I really felt for you with that flywheel and time pressure.
Yes that’s true Matt, it’s been running fine although my economy hasn’t improved in fact it seems to be worse. I have a bad injector so going to try replacing that but if it carries on it’s going to have to be remapped as less than 40mpg really isn’t sustainable. I’m surprised at myself for not throwing in the towel when it didn’t go to plan but I was desperate to take this car to Germany, thankfully got away with it with zero time to spare.
This is absolutely amazing, the amount of details and important comments on the video! The Nurburgring at the end ❤The Ultimate Test for the job!
Hi , great video,
I remember seeing on the Volvo forum about the 185 flywheel, it is that the metal sensor parts on the flywheel are slightly different were the large open space is, I think the user that did the mode moved 2 of the blocks, buy re welding them, there are photos on the forum some were, it was some years ago,
Good luck Dave
Davebb on the Volvo forum
Hi Dave, perhaps I should’ve took the time to look on the forums but I’m just the kind of person that digs in and learns from my mistakes (of which there are many). Cost me dearly on this occasion but I powered through much to my surprise. I was thinking the sensors sit at different levels, I put the flywheels side by side and couldn’t see any difference whatsoever. Never mind I got it going now and 3,000 miles trouble free since.
@@IAMASPANNERgreat it is all good, keep the great videos coming, Dave
Thanks man, great video, tomorrow is time to change the klutch😄
Epic video & really fascinating to watch. Having successfully rebuilt the head of my son’s D5, i’m not quite ready to do a clutch change just yet but you have given me the confidence knowing that it can be done.
I was interested to see the the Crank Position sensor had such an effect on the engines ability to start. It’s got me thinking as my son’s D5 is a real pain to start as it has to crank over for about 5-10 seconds before it fires into life. Thanks
Hi Mark, thanks very much, I hope this was a bit more interesting than the usual “how to”. Regarding your son’s D5; if you have suitable diagnostic equipment I’d check the fuel correction on the injectors to check for one on its way out and I’d also check fuel pressure and the regulator to see if there’s any issue there. Mine is similarly bad at starting especially on a morning after being left.
Hi, A couple of years ago i had a garage fit a new clutch in my 2003 v70 D5 2.4, some time later, a few months in fact i found they had crushed the fuel line and it was then running on the bottom pulley, it punctured through 160 miles away from home in Anglesey, what a nightmare and mess. good video.
Volvo is a nightmare regarding the spare sparts inconsistency. Same Engine, different Parts. VIN doesnt help. Especialy clutches an Flywheels is a mather of science to find the right one. Respect for the job
I didn’t realise the flywheel would be different, as far as I can see there’s no reason it should be, the dimensions are all the same 🤷🏻♂️
Great video and brilliant car!
Thank you 🙏
I'm pretty sure that friction plate with springs is for the awd models. I personaly prefer to get the engine out instead of bothering with the subframe and steering rack, lifting this gearbox in and out is a pain in the back.
The donor car wasn’t AWD, I’m assuming it’s just different on the Euro 4. Engine out would’ve been very tempting given a bit more time and planning.
Good job!
Starter ring gear replacement,instead baying new flywheel, would be cheaper option.
Easy enough to replace.
Thank you! Flywheel wasn’t compatible as the timing system was different.
Good day
Warm greetings from Germany
May I ask if you have already fixed the problem with the cruise control in the 6-speed and have you noticed a difference in fuel consumption compared to the 5-speed gearbox?
I would be happy about an answer.
thank you from Germany
Your video was a great motivation for me to do the same and I've just collected everything needed. I am curious if you have done something for the reverse gear lockout? Is it present on the 5 speed cars?
That’s great to here and I hope the job goes well for you. I don’t know about the reverse lock out but what I do know is I can now flash my reverse lights at any speed by pushing the gear stick to the right so presumably I could put it into reverse and there’s no lockout where there was before on the 5 speed. If you do find out I’d love to hear about it.
I won't be able to do it myself, unfortunately, because I don't have the proper place. But there is this solenoid on the 6 gear selector, which should do exactly that - prevent the stick to go all the way to the right. I am not sure if there is such a thing on the 5 gear cars, because I haven't taken the spaceball cover to see and I can't find info anywhere. My Volvo is a petrol S60 2001, btw.
Very good job! in summary you have replaced: flywheel + clutch and speed sensor 185bhp, intake pipe, 6 speed gear lever. for the reverse sensor? sorry but my english is rusty and i would like to do the same operation as quickly as possible. thank you
Hi mate so ECU wise there's no alteration just get a extra gear my euro 3 really needs this on a long run :) guessing you used the euro 3 crank sensor?
I think I went through it all in the video although I appreciate it’s a long watch. The car will work fine afterwards you just won’t have cruise control in 6th gear. I recorded a follow up video but lost the footage somehow, I had the ECU programmed to add the 6th gear by Shemtek so now everything works as if the car was always 6 speed.
Brilliant job !
"You can't make an omelet without breaking eggs"😂
Much was for adding 6th gear to ECU ?
Great job. I'm planning to do the same on my Euro 3 D5 too. Are the original driveshafts and starter from M56 fits to M66? Cruise control works properly, even on 6th gear? Thanks.
Thank you. Driveshafts and starter are the same, yes. The cruise control now only works in gears 1-5. I don’t know what’s involved to get it working in 6th but I’ll get round to it when I have some spare time.
Thank you. Driveshafts and starter are the same, yes. The cruise control now only works in gears 1-5. I don’t know what’s involved to get it working in 6th but I’ll get round to it when I have some spare time.
Wow Tolly I feel for you having to do that job twice.
Just to let you know apparently the ratios from 5 sp and 6 are the same so I have been told and gearbox oil is 2 Ltr on the 6sp 2.1 on the 5sp.
Last thing you didn’t have a U.K. badge on your car surprised you dint get pulled over.
Hi Gary, yes, it was a bit of a painful moment for me but I surprised myself and just got on with the job again. Another thing is the cruise control still works up to gear 5 just need to find out how to get it working in 6th as well now. I’m surprised about the UK badges too, it was all so last minute I wasn’t prepared at all.
i want to do from 6 speed to 5 speed :D
aisin tf80sc has some problems that i dont need :D
Is there any difference between the 6speed clutch and flywheel to the 5speed ? The other thing is, how did you install the clutch without a self adjusting clutch tool?
The flywheel and crank sensor are different between the Euro 3 and Euro 4, I think I covered it all in the video.
Is the bracket between the gearbox and rear engine mount the same for the M56 and M66?
No
Why did it start like this in the end? Also any idea why your injectors are knocking?
The flywheel needed to be the original Euro 3 one and not the Euro 4.
So what is the difference between 5 gear gearbox flywheel and clutch and 6 gear gearbox flywheel and clutch?
Clutch plates are sprung on the Euro 4 but exactly the same size plate. The flywheel I still have no idea what it is that’s different between the 2, they look exactly the same.
@@IAMASPANNER Im confused about this because there is different part number between 2007 v70 5gear and 2008 6 gear and also between 2007 6 gear...
I have 2007 2.4 126 hp V70 II gen and I chipped it to 205 hp and 450nm so now I need to use clutch at least from 185 hp version... And I dont know which clutch will be correct...
@@kuba1515 I’d have said all the clutches are compatible, the Euro 3 setup is probably more reliable if anything because there aren’t any springs on the friction plate. As long as you use the parts by LUK I think you’ll be fine. The reg on my 185bhp donor car was MM06 CVD if you want to use that to get quotes for parts from suppliers.
Nic video sir 👍👍
Thanks Lovepreet 👍
Heck, I am thinking of leaving this headache to some service guy, way too much work.
Still need to get the ECU tweaked to recognise it has 6 gears and get the cruise control working too.
😪
😂😂😂ai pus volanta de la 185 nul mai pornesti in veci difera unde citeste senzorul