XClutch 05-07 Volvo S40 T5 2.5L Stage 2R Extra HD Sprung Ceramic Clutch Kit

The 2005-2007 Volvo S40 T5 with the turbocharged 2.5-liter five-cylinder and a manual gearbox responds well to tuning, and that is usually when the factory clutch starts to slip. If your T5 flares on the boost in the upper gears, smells hot after a track session, or simply will not hold the torque your tune makes, the XClutch XKFD24637-1R is the motorsport step in XClutch's single-disc range: a Stage 2R kit with a sprung ceramic disc and a high-clamp pressure plate. It is not a daily-driver clutch, and this page explains why before you buy.

What the Stage 2R clutch kit does in an S40 T5

A single-disc clutch holds torque through two things: how hard the pressure plate squeezes the disc and how much grip the friction facing has. Stage 2R raises both. XClutch builds its Stage 2R kits for motorsport use, pairing a pressure plate with increased clamping force with a ceramic friction disc, and says they give more torque and heat capacity than its Stage 2 equivalents. XClutch's FAQ describes the -1R kits as an extremely high clamping force clutch for track use or very high horsepower cars that need to keep a single plate.

Ceramic facings tolerate heat that would glaze an organic disc, which is why they suit repeated launches and track sessions. The trade is street manners: ceramic grabs faster, so engagement is shorter and takeoff from a stop takes more care. The sprung hub on this disc softens that bite and reduces shock on the gearbox and, on AWD cars, the rear drive coupling.

Symptoms that call for a stronger clutch

• Revs flare without more speed when boost builds in fourth, fifth or sixth
• Slip that only appeared after an ECU tune or a turbo upgrade
• A burnt smell or fade after back-to-back hard runs or a track session
• A previous organic clutch that glazed or wore out quickly under hard use
• Chatter on takeoff from a heat-damaged disc or flywheel

A slipping clutch sets no trouble code, but a boost leak or a fueling fault can feel just like one. Scan for engine codes and fix those first.

How to confirm it before you buy

Confirm the slip with a full-throttle pull in a high gear from low rpm; if the tachometer runs ahead of road speed, the clutch is slipping. Then decide honestly how the car is used. XClutch's own advice is that ceramic suits track use but is less drivable on the street and can wear faster there, while organic suits street driving. If the T5 is mainly a road car, the XClutch Stage 1 sprung organic kit for the same car is the better choice. Our manual versus automatic repair cost guide covers what the clutch job itself costs in labor.

Fitment

This listing is for the 2005-2007 Volvo S40 T5 2.5L turbo with a manual transmission. XClutch's application data for this part number also lists the 2010 S40 T5 R-Design, the 2008-2013 C30 T5 and T5 R-Design, and the 2004-2007 S60 R. Automatic cars cannot use it, and the non-turbo 2.4i is not a T5. Because these cars were sold with more than one manual gearbox and clutch release setup over the years, check your transmission against the kit or send us the year and VIN before ordering. For the same cars we also carry the Spec Stage 2+ sprung kit and the milder Spec Stage 1 kit.

Install notes

• Resurface or replace the flywheel. XClutch requires it for warranty, and a ceramic disc on a glazed or heat-checked surface will chatter.
• Replace the release bearing and pilot bearing at the same time, and inspect the clutch hydraulics while the gearbox is out.
• Keep the friction surfaces clean and dry, grease only the input spline, align the disc and torque the pressure plate bolts evenly in a cross pattern.
• Bleed with fresh fluid. XClutch suggests DOT 4 or 5.1 for performance use and warns against ever mixing in DOT 5.
• Bed the disc in with gentle, low-rpm engagements for the first 1,000 km, about 620 miles.

One more point worth knowing: XClutch's warranty, 12 months or 12,000 miles, does not cover clutches used in racing, time trials or other motorsport, or damage from heat caused by slipping. If the car will see the track, budget for the clutch as a wear item.

Is the Stage 2R clutch okay for daily driving my S40 T5?

XClutch builds Stage 2R kits for motorsport use. The ceramic disc grabs faster than organic and is less drivable in traffic. For a mostly street car, the Stage 1 organic kit is the better match.

What is the difference between Stage 2 and Stage 2R?

XClutch says Stage 2R pairs a ceramic disc with a motorsport pressure plate that has more clamping force, giving higher torque and heat capacity than the Stage 2 equivalent.

Does it fit the S60 R or C30 T5?

XClutch's application data for XKFD24637-1R also lists the 2004-2007 S60 R, the 2008-2013 C30 T5 and the 2010 S40 T5 R-Design. Send us the year and VIN and we will confirm it against your car.

Do I need a new flywheel?

The flywheel must be resurfaced or replaced before fitting. XClutch requires proof of that for any warranty claim, and a ceramic disc chatters on a worn surface.

Is the clutch covered if I race the car?

No. XClutch's warranty excludes speed trials, racing, time trials and other motorsport use, as well as heat damage from slipping.

• Automatic vs. Manual Transmission Repair Cost: What to Actually Expect