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

Driven Disc and Pressure Plate

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REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15 and 16

Rear Drive Models
  1. Remove the transmission.
  2.  
  3. Scribe alignment marks on the clutch and flywheel.
  4.  
  5. Slowly loosen the bolts holding the clutch to the flywheel in a diagonal pattern.
  6.  
  7. Remove the bolts and lift off the clutch and pressure plate.
  8.  
  9. Inspect the pressure plate for heat damage, cracks, scoring or any other damage.
  10.  
  11. Place a ruler diagonally over the pressure plate friction surface and measure the distance between the straightedge of the ruler and the inner diameter of the pressure plate. This measurement must not be greater than 0.008 inch (0.2mm). In addition, there must be no clearance between the straightedge and the outer diameter of the pressure plate. This check should be made at several points.
  12.  

To install:
  1. Clean the pressure plate and flywheel with solvent to remove any traces of oil and wipe them clean with a cloth.
  2.  
  3. Position the clutch assembly with the longest side of the hub facing away from the engine. Fit it to the flywheel and align the bolt holes.
  4.  
  5. Insert centering tool 5111 or equivalent or an input shaft from an old transmission of the same type, through the clutch assembly and flywheel. This centers the assembly and pilot bearing.
  6.  
  7. Install the clutch retaining bolts and tighten them in a diagonal pattern, a few turns at a time. After all the bolts are tightened, remove the centering tool.
  8.  
  9. Install the transmission.
  10.  

Front Drive Models
  1. Remove the transaxle.
  2.  
  3. Lock the flywheel in position.
  4.  
  5. Remove the six bolts retaining the pressure plate and disc, loosen them in rotation.
  6.  
  7. Remove the pressure plate and disc.
  8.  
  9. Remove the throwout bearing from the sleeve and fork.
  10.  
  11. Remove the fork and dust cap from the transaxle.
  12.  
  13. Clean and check the throwout bearing, It should rotate freely and quietly.
  14.  
  15. Clean and check the fork for cracks and wear and that the dust cap is intact.
  16.  
  17. Check the pressure plate carefully for signs of overheating, cracks, scoring or other damage to the friction surface. Make sure that the diaphragm spring is not split or damaged. If any part of the pressure plate is damaged, it must be replaced.
  18.  
  19. Check the pressure plate for warpage by laying a straightedge across the contact surface and checking the distance with a feeler gauge. The maximum width is 0.008 in. (0.2mm).
  20.  

Warpage is permitted in one direction only.

  1. Check the flywheel for cracks and heavy scoring. If it is damaged it must be replaced.
  2.  
  3. Check the clutch disc for oil or dirt and clean if necessary.
  4.  

To install:
  1. Install the throwout bearing fork, and lubricate the ball joint with grease.
  2.  
  3. Install the throwout bearing and dust cap.
  4.  
  5. Secure the fork to the transaxle, so that it cannot be moved during installation.
  6.  
  7. Install the clutch disc and pressure plate using centering drift 999 5487 or equivalent clutch alignment tool.
  8.  
  9. Install the clutch bolts, tightening them in rotation so that the clutch slides over the locating pins and lies evenly against the flywheel. Then tighten the bolts to 18 ft. lbs. (25 Nm). Remove the centering drift.
  10.  

Do not apply any grease to the splines on the transaxle input shaft.

  1. Install the transaxle and check the clutch operation.
  2.  



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Fig. Fig. 1: Typical clutch alignment tool, note how the splines match the transmission's input shaft



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Fig. Fig. 2: Loosen and remove the clutch and pressure plate bolts evenly, a little at a time ...



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Fig. Fig. 3: ... then carefully removing the clutch and pressure plate assembly from the flywheel



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Fig. Fig. 4: Check across the flywheel surface, it should be flat



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Fig. Fig. 5: If necessary, lock the flywheel in place and remove the retaining bolts ...



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Fig. Fig. 6: ... then remove the flywheel from the crankshaft in order replace it or have it machined



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Fig. Fig. 7: Upon installation, it is usually a good idea to apply a threadlocking compound to the flywheel bolts



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Fig. Fig. 8: Check the pressure plate for excessive wear



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Fig. Fig. 9: Be sure that the flywheel surface is clean, before installing the clutch



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Fig. Fig. 10: Install a clutch alignment arbor, to align the clutch assembly during installation



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Fig. Fig. 11: Clutch plate installed with the arbor in place



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Fig. Fig. 12: Clutch plate and pressure plate installed with the alignment arbor in place



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Fig. Fig. 13: Pressure plate-to-flywheel bolt holes should align



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Fig. Fig. 14: You may want to use a threadlocking compound on the clutch assembly bolts



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Fig. Fig. 15: Install the clutch assembly bolts and tighten in steps, using an X pattern



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Fig. Fig. 16: Be sure to use a torque wrench to tighten all bolts

CLUTCH INSPECTION



Check the pressure plate for heat damage, cracks, scoring, or other damage to the friction surface. Check the curvature of the pressure plate with a steel ruler.

Place the ruler diagonally over the pressure plate friction surface and measure the distance between the straight edge of the ruler and the inner diameter of the pressure plate. This measurement must not be greater than 0.008 inch (0.2mm). In addition, there must be no clearance between the straight edge of the ruler and the outer diameter of the pressure plate. This check should be made at several points. Additionally, inspect the tips of the diaphragm springs (fingers) for any sign of wear. Replace the clutch as a unit (disc, pressure plate and throwout bearing) if any fault is found.

Check the throwout bearing by rotating it several times while applying finger pressure, so that the ball bearings roll against the inside of the races. If the bearing does not turn easily or if it binds at any point, replace it as a unit. Also make sure that the bearing slides easily on the guide sleeve from the transmission.

Inspect the clutch disc for signs of slippage (burns) or oil contamination. Make sure the rivets are not loose and that the clutch contact surfaces are well above the rivet heads. The thickness of the disc above the rivet heads is the remaining life of the disc; always replace the disc if in doubt.

When reassembling, apply grease to the splines and end shaft, the throwout bearing and the pivot ball and seat of the clutch fork.

 
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