Checking/replacing the clutch driven plate and self-adjusting clutch: Installation

WARNING: This page is about a different car, the 2004 Volvo S40, 2003 Volvo S40, 2002 Volvo S40, 2001 Volvo S40, and 2000 Volvo S40. However, it is still accessible from the selected car via links, so may be relevant.

Install the clutch driven plate centering tool

Fig 1: Centering Tool Installed On Clutch Driven Plate

Courtesy of VOLVO CARS OF NORTH AMERICA.

Use centering tool 9995663 . The drift is modified as described in the Workshop Guide. The conversion kit is included.

Remove the cone from the centering tool.

Install the centering tool in the flywheel center as far in as possible.

Use a ring spanner as a counterhold. Tighten the outer socket so that the drift expander locks the centering tool.

Ensure by touch that the centering tool is secured in the crankshaft.

Clutch driven plate, installing

Fig 2: Clutch Driven Plate

Courtesy of VOLVO CARS OF NORTH AMERICA.

CAUTION: Turn the slightly longer section of the clutch driven plate hub in, towards the flywheel. There is a marking on the clutch driven plate .

Install the cone on the centering tool. Tighten the cone by hand . Secure the clutch driven plate.

NOTE: Tightening tools must not be used on the cone or damage may be caused to the clutch driven plate.

Install the tools on the clutch

Fig 3: Identifying Clutch Diaphragm Spring

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install counterhold 9995677 . See Aligning the counterhold for automatic clutch adjustment .

Install compression tool 9995662 . See Installing the compression tool .

First tighten the center screw on the compression tool to contact, then compress the clutch.

NOTE: When the center screw comes into contact with the diaphragm spring, the screw should, for a loose clutch, be tightened 4.5 - 5 turns or until a clear click is heard .

Installing the clutch

Fig 4: Clutch Automatic Adjustment Using Counterhold 999 5677

Courtesy of VOLVO CARS OF NORTH AMERICA.

Check that the clutch automatic adjustment is secured with counterhold: 9995677 .

Install the clutch and locate on the guide pins. The compression tool center screw is hollow so that it can be threaded onto the centering drift.

Check that the clutch is in contact with the flywheel all around its circumference.

Carefully tighten the six screws crosswise so that the clutch is guided up onto the guide pins and is in contact all around the circumference of the flywheel.

Tighten the screws crosswise to 25 Nm .

Remove the tools

Fig 5: Clutch Assembly

Courtesy of VOLVO CARS OF NORTH AMERICA.

Screw out the center screw. Remove the compression tool.

NOTE: Keep fingers away from the three clutch rivets when relieving a load or removing the compression tool. There is a risk of clamping injuries.

Remove the clutch driven plate centering cone.

Remove the socket. Tap the centering tool lightly with a rubber mallet so that the expander releases. Use a rubber mallet so that the threads are not damaged. Remove the centering tool.

Remove the hooks. Remove the counterhold.

Remove the flywheel gear sector.

NOTE: To install the transmission on turbocharged engines, see Transmission, installing . For engine B4204S2, see Transmission, installing .