Volvo Cars 1999-05

Driven Disc & Pressure Plate

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Removal & Installation



  1. Remove the transmission.
  2.  
  3. Block the flywheel using gear sector 999-5112.
  4.  
  5. Secure the clutch automatic adjustment with counterhold 999-5677.
  6.  
  7. Install compression tool 999-5662 on the clutch. Center the tool and tighten the screw to make light contact with the diaphragm spring.
  8.  
  9. Compress the clutch so the automatic adjuster is not under load. Screw in the compression tool until the diaphragm spring has pressed the pressure plate to a free position.
  10.  
  11. Remove the pressure plate and clutch disk.
  12.  

To install:

  1. Install compression tool 999-5662 on the clutch. Center the tool and tighten the screw to make light contact against the diaphragm spring, then compress the clutch.
  2.  
  3. Ensure the clutch automatic adjustment is secured with counterhold 999-5677.
  4.  
  5. Install the clutch, ensure the clutch is in contact with the flywheel all around its circumference, and tighten the six bolts crosswise and tighten to 18 ft. lbs. (25 Nm).
  6.  
  7. Remove the compression tool and gear sector.
  8.  
  9. Install the transmission.
  10.  


    Click image to see an enlarged view

    Fig. Secure the clutch automatic adjustment

    Secure the clutch automatic adjustment

    Click image to see an enlarged view

    Fig. Install the compression tool onto the clutch to release the load.

    Install the compression tool onto the clutch to release the load.

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove the transmission or transaxle.
  4.  
  5. Remove the throw-out bearing from the sleeve and fork.
  6.  
  7. Unbolt the pressure plate in a crossing pattern and in several passes.
  8.  
  9. Remove the pressure plate and clutch disk.
  10.  

To install:

  1. Install the clutch disk and pressure plate. Tighten the bolts in a crossing pattern and in several passes to 18 ft. lbs. (25 Nm).
  2.  
  3. Install the throw-out bearing.
  4.  
  5. Install the transmission or transaxle.
  6.  

  1. Remove the transmission.
  2.  
  3. Block the flywheel using gear sector 999-5112.
  4.  
  5. Secure the clutch automatic adjustment with counterhold 999-5677.
  6.  
  7. Install compression tool 999-5662 on the clutch. Center the tool and tighten the bolt to make light contact with the diaphragm spring.
  8.  
  9. Compress the clutch so the automatic adjuster is not under load. Screw in the compression tool until the diaphragm spring has pressed the pressure plate to a free position.
  10.  
  11. Remove the pressure plate and clutch disk.
  12.  

To install:

  1. Install compression tool 999-5662 on the clutch. Center the tool and tighten the bolt to make light contact against the diaphragm spring, and then compress the clutch.
  2.  
  3. Ensure the clutch automatic adjustment is secured with counterhold 999-5677.
  4.  
  5. Install the clutch, ensure the clutch is in contact with the flywheel all around its circumference, and tighten the six bolts crosswise and tighten to 18 ft. lbs. (25 Nm).
  6.  
  7. Remove the compression tool and gear sector.
  8.  
  9. Install the transmission.

    Click image to see an enlarged view

    Fig. Secure the clutch automatic adjustment

    Secure the clutch automatic adjustment

    Click image to see an enlarged view

    Fig. Install the compression tool onto the clutch to release the load.

    Install the compression tool onto the clutch to release the load.
  10.  

  1. Remove the transmission.
  2.  
  3. Block the flywheel using gear sector 999-5112.
  4.  
  5. Secure the clutch automatic adjustment with counterhold 999-5677.
  6.  
  7. Install compression tool 999-5662 on the clutch. Center the tool and tighten the bolt to make light contact with the diaphragm spring.
  8.  
  9. Compress the clutch so the automatic adjuster is not under load. Screw in the compression tool until the diaphragm spring has pressed the pressure plate to a free position.
  10.  
  11. Remove the pressure plate and clutch disk.
  12.  

To install:

  1. Install compression tool 999-5662 on the clutch. Center the tool and tighten the bolt to make light contact against the diaphragm spring, and then compress the clutch.
  2.  
  3. Ensure the clutch automatic adjustment is secured with counterhold 999-5677.
  4.  
  5. Install the clutch, ensure the clutch is in contact with the flywheel all around its circumference, and tighten the six bolts crosswise and tighten to 18 ft. lbs. (25 Nm).
  6.  
  7. Remove the compression tool and gear sector.
  8.  
  9. Install the transmission.

    Click image to see an enlarged view

    Fig. Secure the clutch automatic adjustment

    Secure the clutch automatic adjustment

    Click image to see an enlarged view

    Fig. Install the compression tool onto the clutch to release the load.

    Install the compression tool onto the clutch to release the load.
  10.  

 
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