Clutch Failed

I have a Volvo S40 T5, 48,000 miles, original clutch. The clutch failed on me as I was on the highway in 6th gear and slowing to a stop sign. I pushed the clutch pedal to the floor while I was braking, heard a small bang, and tried to move the shifter into first as I was nearing the stop but it was blocked and I couldn't. The pedal stuck where it was. I smelled it burning and pulled it over.

The mechanic said the clutch crumbled and that likely caused the pedal to stick to the floor and that happened because of overheating. My question is have you ever heard of a clutch just crumbling like that, especially after highway driving? They claim its from wear and tear and won't warrenty it but shouldn't a non-defective clutch just wear itself thin until it starts slipping? Any ideas/suggestions let me know.

the question that is hard to answer, is was the clutch operating correctly before the failure? The reason I say its hard to answer is, a lot of people aren't "aware" enough to accurately know the answer. If it had been slipping slightly for the last 10K miles and you were unaware of it, then the failure isn't surprising at all.

I don't mean to suggest you are incapable of being knowledgable of the clutch failing, but speaking as a mechanic, few people are aware when their clutch is failing. Time and time again, I'll find a completely toasted clutch and the customer will have no awareness of it (and will argue with our diagnostics even though the car won't even move because the clutch is so bad)

Of course, the clutch could have suddenly imploded due to defective parts. But knowing for a fact that it was defective parts that caused the failure is nearly impossible with third-person subjective hindsite

as for the warranty issue. If they take apart the clutch and find severe hot spots combined with clutch implosion, their assessment is probably accurate IMO. The hot spots don't happen from the part failure. They happen from either abuse, or long-term failure, and both situations point to at least an unattentive/unaware driver

I had a clutch shatter before, it gave no warning whatsoever. It was in a 1991 Geo Metro and had about 20,000 miles on it when it went. I know because of the car it wasn't subjected to sustained blistering speed or horsepower, it just went.

hp and speed has very little to do with clutch failure. I can destroy a CT90's clutch in about ten minutes. it has about 5hp and can't break 30mph.

Yeah, I know the sense that you mean. I should have said that when I drove the Metro i didn't drive it agressive, espescially when if I gave it too much gas it would suck down oil through the valve seals. Basicaly it was babied and failed.