Volvo 240/740/760/780/940/960 1990-1998

Clutch Cable

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REMOVAL & INSTALLATION



This procedure does not apply to hydraulic clutches.

  1. Raise and support the vehicle safely.
  2.  
  3. Disconnect the clutch cable from the clutch fork. Some vehicles are equipped with a release bearing that rotates. These vehicles will have a clutch return spring at the pedal assembly.
  4.  
  5. Disconnect the cable at the pedal assembly.
  6.  
  7. Remove the cable. On some early vehicles, the clutch cable is fitted with a weight. Do not replace the weight when installing the new cable.
  8.  

To install:
  1. Install the cable in the vehicle.
  2.  
  3. Connect the clutch cable at the clutch fork and the pedal assembly.
  4.  
  5. Adjust the clutch cable.
  6.  

CLUTCH ADJUSTMENT



See Figures 1 and 2

  1. Clutch play is adjusted under the vehicle at the clutch fork.
  2.  
  3. Loosen the locknut on the fork side of the cable bracket and turn the adjust nut until the proper play is achieved.
  4.  
  5. Tighten the locknut.
  6.  

Vehicles equipped with hydraulic clutch assemblies are not adjustable.

  1. Clutch play for all engines except turbocharged is 0.12-0.20 in. (3-5mm). Turbocharged engine clutch play (free movement rearward) is 0.04-0.12 in. (1-3mm).
  2.  



Click image to see an enlarged view

Fig. Fig. 1: Checking the clutch negative play



Click image to see an enlarged view

Fig. Fig. 2: Adjust the clutch cable by turning the locknut

 
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