clutch replacement volvo 240

benny1314

Hi,
I replaced the clutch in my 240 and when the car was all back together the pedal felt wrong. The pedal had no pressure (hydraulic) or resistance. The cylinder that pushes the clutch fork is definitely moving. I removed the gearbox again and pulled the clutch back off to ensure nothing was wrong ( I couldn't see anything obvious). I put the clutch back together and noticed that when its bolted tight against the flywheel there is a gap between where the tool originally sat and the fingers of the pressure plate, is this right? Also I noticed the cylinder for the fork push rod seems to sit about half way rather than being fully retracted when the clutch is not engaged, I am not sure if this may be an issue also.
Any help or tips would be greatly appreciated.

perko

The cylinder is hydraulic so won't retract fully on its own. Be wary when tightening the clutch up to the torque spec as you need to get the outer touching the flywheel before you get a torque wrench in there, there is spring tension so it can feel like you're nipping up the bolts when in fact it's still a few mm off the flywheel surface.

Also the obvious stuff like making sure the clutch fork and the little doodad on the end (that pushes the pressure plate) are all in position properly. If you pop the rubber boot off the fork you can get a camera (or your head) up there to have a look and see what isn't moving properly.

timbo

Check the clutch fork and pivot as it is common for the fork to bend/break. The pivot ball also wears out

benny1314

Thanks for the info, I will have a look