Urgent help needed! clutch parts and flywheel confusion 2004 xsara picasso

[cupofcoffee]

2004 Citroen Xsara Picasso Exclusive Diesel 1.6

VF7**************[VIN obfuscated, can be read by forum staff]

Hi, I think I need some help here and am very grateful to have found your site. The donation definitely looked well worth it to keep you going with such a great service.

Situation is that my garage is pretty certain that I need a new clutch and flywheel and my gearbox is OK. Problem was it works only in reverse all of a sudden.

They are quoting 2100, which seems huge, so I asked how much is labour. They said 630. Then I said where are you getting the parts, and they said LUK, via some local motor factor.
I figured perhaps they made an error so I checked.

So I put my registration number into the Halfords site and it looks like that lot, everything they have connected to 'clutch', with flywheel, costs about 500.
But I'm not sure what exactly one needs. There seem to be alternatives. Not enough to alter the price much. And Halfords isn't cheap.

I looked on 'online car parts' too for 'clutch kit' and there I met with confusion.
The page, https://www.onlinecarparts.co.uk/car-br ... brand%5D=6
seems to contain a profusion of parts and alternatives, all for my registration plate.

Can you sort me out, please? If I am sorted out, it looks like I can point out that they have fat-fingered it and added a thousand by mistake. Or I can just buy the parts myself and arrive with an armful.

Thank you very much for the help!
Stephen

[shtu]

The catalogues and service info that the staff use are the Citroen ones, so can't help on aftermarket fitments.

However, LUK have a technical support dept that will be able to advise.

https://vehiclelifetimesolutions.schaef ... gb/contact iirc the phone line didn't work when I tried it, but email was pretty swift.

Email them with your vehicle registration, chassis number, etc., and they should be able to advise exactly what kit you need. I found the parts factors were trying to sell me the wrong stuff, because Citroen, and "it's the one that fits all those mate".

They do have a parts catalog on there too. Using your limited information above, it gave me the part below, but YOU MUST CHECK AND CONFIRM FOR YOURSELF,

https://vehiclelifetimesolutions.schaef ... v-TA-17961

That's a £300 kit. There might be some additional peripheral parts like the guide tube on the nput shaft, output shaft seals, that sort of thing. Kind of stuff you may as well do while it's apart, the bits are a few £ each. If you want, I can dig out the list I did.

Also - once the gearbox is off, the garage should be able to test the gearbox works in all gears, by just selecting each gear and turning the input shaft.

[Paul-R]

Is the engine fitted with a dual mass flywheel? And if so, does the LUK kit include the flywheel? I doubt it does for that price.

[cupofcoffee]

Is the engine fitted with a dual mass flywheel? And if so, does the LUK kit include the flywheel? I doubt it does for that price.

Thanks shtu,

chassis number I guess is same as VIN. (Could you read my VIN? Not sure how this works.)

I will look at those refs.

Looking at replacing clutch and flywheel. So you're saying that it's mainly clutch kit and flywheel, but there might be some other bits.

I'm actually trying to avoid a massive mark up at my garage on parts. Like 200%.

Regards,
Stephen

[PaulC5]

Have you tried a Citroen dealer for a price to replace the clutch ?

I would not buy the parts yourself and ask a garage to fit them, this can give problems with any warranty since the garage would only warrant the labour but if the parts are faulty they would likely not cover any costs.

[cupofcoffee]

The catalogues and service info that the staff use are the Citroen ones, so can't help on aftermarket fitments.

However, LUK have a technical support dept that will be able to advise.

https://vehiclelifetimesolutions.schaef ... gb/contact iirc the phone line didn't work when I tried it, but email was pretty swift.

Email them with your vehicle registration, chassis number, etc., and they should be able to advise exactly what kit you need. I found the parts factors were trying to sell me the wrong stuff, because Citroen, and "it's the one that fits all those mate".

They do have a parts catalog on there too. Using your limited information above, it gave me the part below, but YOU MUST CHECK AND CONFIRM FOR YOURSELF,

https://vehiclelifetimesolutions.schaef ... v-TA-17961

That's a £300 kit. There might be some additional peripheral parts like the guide tube on the nput shaft, output shaft seals, that sort of thing. Kind of stuff you may as well do while it's apart, the bits are a few £ each. If you want, I can dig out the list I did.

Also - once the gearbox is off, the garage should be able to test the gearbox works in all gears, by just selecting each gear and turning the input shaft.

Hi Shtu,

I took a look that catalogue with my VIN and it gave a unique flywheel.
But it gives three clutch kits even just from LUK.

https://vehiclelifetimesolutions.schaef ... v-TA-17961

https://vehiclelifetimesolutions.schaef ... v-TA-17961

https://vehiclelifetimesolutions.schaef ... v-TA-17961

How do I decide? I'm lost.
The flywheel was https://vehiclelifetimesolutions.schaef ... v-TA-17961

Edit:
Your list of extras would be useful, or probably essential! And yes, I just noticed that the first link here has a flywheel included.
The second one has a slave cylinder instead. No idea if I need that.
And many thanks for replying, by the way!

Regards,
Stephen

[shtu]

I'm not staff, I can't read your VIN - and to be honest, I don't want to. Working out the right parts is YOUR job.

I took a look that catalogue with my VIN and it gave a unique flywheel.
But it gives three clutch kits even just from LUK.

https://vehiclelifetimesolutions.schaef ... v-TA-17961

https://vehiclelifetimesolutions.schaef ... v-TA-17961

https://vehiclelifetimesolutions.schaef ... v-TA-17961

How do I decide? I'm lost.
The flywheel was https://vehiclelifetimesolutions.schaef ... v-TA-17961

In order posted, (this info is just copied off the linked pages)

Repset DMF
Contains parts ...
Clutch Pressure Plate, 123 0475 10
Clutch Disc, 323 0701 10
Clutch Release Bearing, 500 1490 10
Flywheel LuK DMF, 415 0396 10
Screw Set, flywheel, 411 0166 10
This set does not contain a slave cylinder. You probably don't need one.

Repset Pro
Contains parts ...
Clutch Pressure Plate, 123 0475 10
Clutch Disc, 323 0701 10
Clutch Release Bearing, 500 1490 10
Slave Cylinder, clutch, 512 0018 10
This set does not contain a DMF flywheel or bolts.

Repset
Contains parts ...
Clutch Pressure Plate, 123 0475 10
Clutch Disc, 323 0701 10
Clutch Release Bearing, 500 1490 10
Like the Repset Pro, but without a slave cylinder

Flywheel
LuK 415 0396 10
That's the same flywheel as in the "Repset DMF" - look at the part number. It's not "unique", it's that they will supply it seperately.

As the garage has suggested a flywheel is required, the Repset DMF is the most suitable option of the three. If you DO need a slave cylinder, which isn't likely, they're a cheap and external part.

As for "I doubt it does for that price." - literally seconds on eBay https://www.ebay.co.uk/itm/175648121846 and that's a typical price.

The non-DMF kit is only about £90. It's labour that's the killer on this job, and frankly £600 is really cheap. I suspect some of the labour is hidden in markup on the parts. I've actually done this job with my own fair hands, I know what a swine it is.

As above, very few garages will fit customer-supplied parts. In your situation, I would email schaffler directly to confirm which kit is correct, then go back to the garage and get them to quote based on that kit. But it's certainly not a £1500 item.

[shtu]

The list of parts what I changed. This may be different from yours as my application was a Berlingo, but it gives you a guide to the "may as well while it's apart", as some of these are cheap to do now, but expensive later, eg, the crank seal.
Where I have links in my notes, posted them, no idea if they still work. Other brands are available.

Clutch kit - pressure plate, friction place, release bearing. I do not have a DMF, so the "Repset" kit was appropriate for me.

Things I would recommend doing at the same time.
https://www.ebay.co.uk/itm/235158461486 crank seal 104315 Febi
https://www.ebay.co.uk/itm/234862008723 diff seals 173279 Febi
https://www.ebay.co.uk/itm/334878849361 guide tube\input seal SACHS 3114600001
https://www.ebay.co.uk/itm/235147000611 clutch fork Blueprint ADP153316

Things you probably don't need.
https://www.ebay.co.uk/itm/155788408007 clutch lever bearing. Citroen 9676898980 Yes, I was sad enough to replace the brand-new bearing in the fork with an OEM one.
https://www.ebay.co.uk/itm/401781166714 fork ball joint. Citroen 212050 This screws into the gearbox casing, it's the pivot for the clutch fork. Unlikely you actually need one, mine looked fine.

[GiveMeABreak]

2004 Citroen Xsara Picasso Exclusive Diesel 1.6

VF7**************[VIN obfuscated, can be read by forum staff]

Hi, I think I need some help here and am very grateful to have found your site. The donation definitely looked well worth it to keep you going with such a great service.
Stephen

Hi Stephen

I've only just got round to your post. Thanks for your Forum donation. Any future parts requests, please post them up here:Official Parts Thread

Here are the official part numbers for your vehicle. You can use these to search for cheaper aftermarket alternatives, but these are the original options as fitted from factory:

Clutch

You have choice of components or a clutch kit.

(1) Clutch, part: 2004AN, £225.94
(2) Clutch Plate, part: 2055CL, £185.30
(3) Clutch Release Bearing, part: 1611266780, £46.76
(4) Declutch Fork Ball Joint, part: 212050, £6.76
(5) Declutch Fork, part: 211766, £62.86

Clutch Kits Includes (1) + (2) + (3)

(6) Pro Clutch Kit Valeo, part: 2052L2, £462.26
E Clutch Valeo, part: 1636267680, £128.62
Standard Exchange Clutch Kit Valeo, part: 2051T7, £251.16

Flywheel / Flywheel with Clutch Option

(10) OEM, Clutch Kit with Dual Mass Flywheel, part: 2052X4, £462.26

Dual Mass Flywheel, part: 0532P7, £509.40
Standard Exchange DMF, part: 1613938580, £577.57
E Clutch PSA, part: 1680364780, £224.59
Flywheel Screw, part: 203708, £2.10

[GiveMeABreak]

Note: I've deleted your duplicate thread on this - please don't create multiple topics for the same issue as it creates additional work and duplication, thanks.

Please see the answers above to your questions.

[cupofcoffee]

Many thanks, Shtu, huge help.
My know-how has quantum leapt!
Regards,
Stephen

Things I would recommend doing at the same time.
https://www.ebay.co.uk/itm/235158461486 crank seal 104315 Febi
https://www.ebay.co.uk/itm/234862008723 diff seals 173279 Febi
https://www.ebay.co.uk/itm/334878849361 guide tube\input seal SACHS 3114600001
https://www.ebay.co.uk/itm/235147000611 clutch fork Blueprint ADP153316

[cupofcoffee]

2004 Citroen Xsara Picasso Exclusive Diesel 1.6

VF7**************[VIN obfuscated, can be read by forum staff]**************[VIN obfuscated, can be read by forum staff]

Hi, I think I need some help here and am very grateful to have found your site. The donation definitely looked well worth it to keep you going with such a great service.
Stephen

Hi Stephen

I've only just got round to your post. Thanks for your Forum donation. Any future parts requests, please post them up here:Official Parts Thread

Here are the official part numbers for your vehicle. You can use these to search for cheaper aftermarket alternatives, but these are the original options as fitted from factory:

Clutch

You have choice of components or a clutch kit.



(1) Clutch, part: 2004AN, £225.94
(2) Clutch Plate, part: 2055CL, £185.30
(3) Clutch Release Bearing, part: 1611266780, £46.76
(4) Declutch Fork Ball Joint, part: 212050, £6.76
(5) Declutch Fork, part: 211766, £62.86

Clutch Kits Includes (1) + (2) + (3)

(6) Pro Clutch Kit Valeo, part: 2052L2, £462.26
E Clutch Valeo, part: 1636267680, £128.62
Standard Exchange Clutch Kit Valeo, part: 2051T7, £251.16

Flywheel / Flywheel with Clutch Option



(10) OEM, Clutch Kit with Dual Mass Flywheel, part: 2052X4, £462.26

Dual Mass Flywheel, part: 0532P7, £509.40
Standard Exchange DMF, part: 1613938580, £577.57
E Clutch PSA, part: 1680364780, £224.59
Flywheel Screw, part: 203708, £2.10

Thank you GiveMeABreak, this is excellent.

It's taught me that on the online sites, part numbers from LuK, Valeo, etc, tend to point to several OEMs, and vice versa, making it pretty complicated.
I also found that the database used by my local factor used the registration plate and almost had me buying a part that might well not have fit because of car construction date, which I only picked up on onlinecarparts.
You'd think it would be sorted out better, really, but perhaps there are good reasons why it's not.

In the end, I got a LuK match for (6) above, pro clutch kit valeo, and a valeo match for the DMF, 0539P7 above.
Crossing my fingers that I didn't mess up.

Regards,
Stephen.

[GiveMeABreak]

You're welcome.