Removal and Replacement
New clutch control and new clutch introduced on C70/S70/V70. New clutch only applies to the following engines: B5204T3, B5234TX and B5254T
Special tools:
999 5112 GEAR SECTOR 999 5112 Gear Sector
999 5662 Compression tool 999 5662 Compression Tool
999 5663 Centering tool 999 5663 Centering Tool
999 5677 Counterhold 999 5677 Counterhold
A new self-adjusting clutch with code SAC (Self Adjusting Clutch) and a concentric placed throwout bearing with integrated hydraulic clutch slave cylinder introduced in week 20 1997
A new clutch control with centrally positioned throwout bearing and integrated clutch slave cylinder has the following advantages:
- Fewer mechanical components.
- Hydraulic system to throwout bearing.
Note! Introduced on all models C70/S70/V70.
A new clutch with self-adjusting pressure plate has the following advantages:
- Automatic adjusting of work point on pressure plate ensures lower clutch release power.
- The clutch is designed for high torques > 250 Nm.
Note! Introduced on all turbocharged engines.
Replacing clutch
Remove transmission.
Removing transmission: Transmission, removal Transmission, Removal.
Note! Changes to method in operation D5 as follows:
- Clamp hose running between brake fluid reservoir and clutch master cylinder using hose pliers.
- Before disassembling clutch line put paper under the adapter on the side of bell housing to catch any spilled fluid.
- Remove clutch line from adapter by pulling out the locking tongue which locks quick-release connector to adapter.
- Remove quick-release connector from adapter.
- Make sure that any brake fluid that leaks out is wiped off.
- Reinstall locking tongue in adapter.
- Attach a plastic bag with an elastic band to the open end of the clutch line to catch any fluid that runs out.
- Lift up pipe from holder on side of transmission and place it to one side.
- Remove ground lead from transmission.
- Remove clamps from engine cable harness.
- Then continue with operations D6 to D26 to remove transmission.
Removing clutch slave cylinder
- Remove bell housing rubber seal and feed it into pipe towards clutch slave cylinder.
- Pull out the striker plate that locks the pipe to the quick release connector to the adapter.
- Reinstall locking tongue in adapter.
- Remove adapter. Keep the adapter in a plastic bag to make sure it is clean.
- Remove the two screws.
- Lift out clutch cylinder with pipe.
- Apply a protective plug to end of pipe.
- Clean mating surfaces in bell housing and check leakage from transmission if necessary.
Replacing seal: Transmission, input shaft seal, replacement Transmission, Input Shaft Seal, Replacement.
Checking clutch slave cylinder and throwout bearing
- Clean clutch slave cylinder.
- Check signs of wear and play on clutch release bearing.
The plain surface pressing down on clutch must be free from deep ridges.
- Check for signs of wear and cylinder seal, also protective bellow.
Do not remove the protective bellow!
Clutch slave cylinder with clutch release bearing and pipe are replaced as an assembly.
Replacing clutch slave cylinder
Installing clutch slave cylinder.
- Install clutch slave cylinder.
Tighten screws to: 10 Nm .
- Thread rubber seal through the pipe with boot turned towards clutch slave cylinder.
Install adapter and rubber seal
- Remove protective socket on end of pipe before installing adapter there.
Always use a new quick-release connector with rubber seal.
- Lubricate rubber seal with a drop brake fluid to facilitate installation.
- Check that striker plate is located in adapter.
Then secure adapter so that striker plate clicks into place.
- Install rubber seal in bell housing as shown.
Ensure that it seals all the way round.
If clutch slave cylinder alone needs to be replaced, reinstall the transmission.
See Remove tools
Replacing clutch
Procedure for replacing the clutch and clutch driven plate as follows:
In order to replace clutch first remove transmission according to: Replacing clutch.
Illustration shows self-adjusting clutch.
Illustration shows clutch driven plate when attached to self-adjusting clutch.
Removal of clutch
Secure clutch automatic adjustment.
- Before removal the automatic adjuster on the clutch must be locked.
- The three arrows in the illustration show where the clutch automatic adjuster can be locked.
Installing tool
Use counterhold: 999 5677 Counterhold 999 5677 Counterhold.
The three pins of counterhold lock automatic adjustment.
- Position counterhold as illustrated.
Ensure that all three pins fit in front of tension springs for automatic adjustment.
See inset.
- Press ring to clutch and slide out counterhold three hooks.
Secure hooks in outer edge middle holes to torque as illustrated: Lock flywheel.
Lock flywheel
Flywheel must be locked before clutch can be removed.
- Lock flywheel with gear sector: 999 5112 GEAR SECTOR 999 5112 Gear Sector.
Visibly up on right of illustration.
Compress clutch
Use press tool: 999 5662 Compression tool 999 5662 Compression Tool , changed according to: Workshop Guide no. 213, with conversion kit: 998 9741 Conversion kit 998 9741 Conversion Kit.
- Ensure that hooks engage properly but do not compress adjustment springs.
- Center press tool and position screws.
- Fasten press tool with one hand and hold in place with the other.
- Compress clutch to relieve automatic adjustment mechanism.
- If the clutch is worn the counterhold automatically turns plastic holder under spring counter-clockwise until it comes in line with marking on cover.
Marking two stamped arrows.
- Then continue to screw in press tool until diaphragm spring has pressed pressure plate to a free position.
Caution! Plate clicks out.
- Remove 6 screws crosswise attaching clutch to flywheel.
- Lift down clutch and clutch driven plate.
Remove clutch
Screw center screws back on to press tool to relieve spring but do not move tool.
Caution! Do not put pressure on diaphragm spring longer than necessary. Relieve pressure on the diaphragm spring as soon as possible.
Check clutch
Check for signs of wear.
Leave press tool and counterhold on clutch if it is to be reinstalled.
Not shown in illustration.
- Dry off pressure plate.
- Check for damage caused by overheating, cracking, scoring or other damage on friction surface.
- Check that spring is not damaged or broken.
Replacing clutch assembly.
Check the clutch for distortion
Check for distortion.
Use a workbench.
- Check that pressure plate is level with a ruler and a feeler gauge.
Ensure that level does not exceed: 0.2 mm .
Replace clutch if a greater distortion is measured.
Distortion is only allowed when aligned as illustrated.
Check clutch driven plate
Check clutch driven plate.
- Dry and blow clutch driven plate clean.
Clutch driven plate should not be oily or dirty.
Check for signs of wear, damage from overheating, cracking or other defects.
Change the clutch driven plate if there are no radial grooves left on the friction coating.
Install clutch
Install centering tool.
Use centering tool: 999 5663 Centering tool 999 5663 Centering Tool , changed according to: Workshop Guide no. 213, with conversion kit: 998 9742 Conversion kit 998 9742 Conversion Kit.
- Remove black cone from centering drift.
- Install centering drift in crankshaft center.
- Press in as far as possible.
- Use a wrench as a counterhold and then tighten the outer socket until the tool expander locks centering drift.
Make sure that centering drift is secure in crankshaft.
Install clutch driven plate and center
Install clutch driven plate.
Install clutch driven plate on centering drift.
Caution! Turn longer part of hub in towards flywheel. Marking on clutch driven plate.
- Screw on centering drift black cone and secure clutch driven plate.
- Tighten cone by hand to center the clutch driven plate.
- Damage to clutch driven plate can occur when tightening with tool.
Replacing new clutch
When replacing a new clutch the counterhold: 999 5677 Counterhold 999 5677 Counterhold is positioned on clutch according to: Installing tool.
- Hold counterhold securely with hooks.
- Install press tool according to: Compress clutch.
- Tighten centre screw and then compress clutch.
Install clutch
Install clutch.
- Check that clutch automatic adjustment is secured with counterhold: 999 5677 Counterhold 999 5677 Counterhold.
- Install clutch and locate guide pins.
Press tool center screw is hollow so the centering drift can be installed.
- Check that clutch is in contact with the flywheel all around its circumference.
- Carefully tighten 6 screws crosswise so that clutch is guided onto the guide pins and is in contact with flywheel all the way round its circumference.
- Tighten screws. crosswise with: 25 Nm .
Remove tools
Remove press tool and counterhold.
- Unscrew center screw and remove press tool.
- Remove clutch driven plate centering cone.
- Remove socket and then tap on centering tools with a rubber mallet so expander is released.
Rubber mallet is used so as not to damage threads.
Remove centering drift.
- Remove hooks and remove counterhold.
- Remove gear sector locking flywheel.
Install transmission
Install.
- Transmission.
Note! Changes to method in operation E21 as follows:
Install.
- Wiring. Clamp cable trunks and ground lead.
- Install new quick-release connector on clutch line terminal.
Lubricate rubber seal with a drop brake fluid before joining.
Caution! Ensure everything is clean when working with hydraulic components.
- Check that striker plate is located in adapter.
Then secure clutch line in adapter so that striker plate clicks into place.
- Install clutch line in holder on side of transmission as illustrated.
- Remove hose clip from hose in clutch master cylinder.
- Bleed system and fill brake fluid if required.
Use Volvo Genuine parts brake fluid only.
Now continue with operations E22 to E25.
Check and test driving
Check and test drive.
- Clean and check that everything is in position.
- Start up car and check first with gear in neutral.
- Shift gears quickly up and down a few times.
Then test drive car without putting pressure on clutch at first.
Once the engine has reached operating temperature and the clutch feels normal, drive the car changing gear quickly. No jolts or vibrations should be noticed.
Caution! Inform the customer that clutch has been changed.