Clutch driven plate and pressure plate, replacement and checking

Special tools: 

9995112

9995487

Replacing the clutch plate and pressure plate 

See New tool for installing clutch driven plate and pressure plate. .

Removing the clutch driven plate and pressure plate 

Fig 1: Identifying Tool 9995112

Courtesy of VOLVO CARS OF NORTH AMERICA.

• Use tool 9995112 to lock the flywheel.
• Remove the six screws, undo them in the order in which they are fitted.
• Remove the pressure plate and clutch plate.

Remove the throwout bearing 

Fig 2: Identifying Throwout Bearing, Guide Sleeve And Release Fork

Courtesy of VOLVO CARS OF NORTH AMERICA.

• Remove the throwout bearing from the guide sleeve and the release fork.

Remove the fork and dust boot 

Check that the guide sleeve is not damaged.

If the guide sleeve is worn, has burrs or similar then it must be replaced.

Clean the parts 

Fig 3: Identifying Throwout Bearing, Fork And Dust Boot

Courtesy of VOLVO CARS OF NORTH AMERICA.

Check: 

• the throwout bearing. Rotate the bearing under light load, the bearing should rotate freely and silently.
• the fork for cracks and wear.
• that the dust boot is intact.

Checking the pressure plate and flywheel 

Fig 4: Identifying Pressure Plate And Flywheel

Courtesy of VOLVO CARS OF NORTH AMERICA.

Carefully check for traces or overheating, cracks forming, scratches or other damage to the friction surfaces.

Check that the diaphragm spring is not cracked or damaged.

• The pressure plate cannot be dismantled, replace it as one complete unit.

Checking the pressure plate for distortion. 

Fig 5: Identifying Pressure Plate

Courtesy of VOLVO CARS OF NORTH AMERICA.

• The pressure plate does not need to be replaced if the distortion does not exceed 0.2 mm  .

Check that the flywheel has no cracks forming and major scratches 

Fig 6: Identifying Flywheel

Courtesy of VOLVO CARS OF NORTH AMERICA.

Checking the clutch driven plate 

Fig 7: Identifying Clutch Driven Plate, Damping Springs And Clutch Plate Hub

Courtesy of VOLVO CARS OF NORTH AMERICA.

• The clutch driven plate must be completely free of oil and impurities.
• The damping springs in the center must be in good condition.
• The clutch plate hub must be free so that it can move slightly.

Replace the clutch plate if necessary. 

Installing the clutch fork 

Fig 8: Identifying Input Shaft

Courtesy of VOLVO CARS OF NORTH AMERICA.

Lubricate the following surfaces on the release fork with assembly compound, part no. 1161246-2:

• the seat for the joint ball
• all surfaces on the fork in contact with the throwout bearing
• the seat for the control cylinder push rod.

Install: 

• the release fork and the dust boot.
• the throwout bearing.
• fit the throwout bearing in the fork and on the sleeve. Secure the fork with a strap to keep the throwout bearing in position during installation.

Replacing the clutch plate and pressure plate 

See New tool for installing clutch driven plate and pressure plate. .