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

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.

Block the flywheel

Fig 1: Blocking The Flywheel Using Gear Sector 999 5112

Courtesy of VOLVO CARS OF NORTH AMERICA.

Align gear sector 9995112 .

Set the clutch automatic adjustment

Use counterhold 9995677 .

Align the counterhold. See Aligning the counterhold for automatic clutch adjustment .

Aligning the counterhold for automatic clutch adjustment

Fig 2: Aligning Counterhold For Automatic Clutch Adjustment

Courtesy of VOLVO CARS OF NORTH AMERICA.

The three pins on the counterhold lock the automatic adjustment.

Position the tool as shown.

Ensure that all the three pins as shown enter the groove in front of the tension springs for the automatic adjuster.

Press the ring against the pressure plate. Pull out the counterhold springs. Secure the three hooks in the center holes of the outer edge. See Block the flywheel .

Installing the compression tool

Fig 3: Compression Tool 999 5662 Installed

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install compression tool 9995662 , together with the conversion kit on the clutch. The tool is modified as described in the Workshop Guide.

Ensure that the hooks engage correctly. Ensure that the hooks do not trap the adjuster springs.

Center the compression tool.

Screw in the compression tool, at the same time checking that the tool hooks are in place.

Compress the clutch so that the automatic adjuster is not under load.

If the clutch is worn, turn the counterhold for automatic adjustment to the original position marking. The marking consists of two stamped arrows.

Then continue to screw in the compression tool until the diaphragm spring has pressed the pressure plate to a free position.

A click can be heard when the clutch pressure plate snaps out.

Removing the clutch and the clutch driven plate

Relieve the load from the diaphragm spring

Fig 4: Identifying Clutch Diaphragm Spring

Courtesy of VOLVO CARS OF NORTH AMERICA.

NOTE: Do not allow the diaphragm spring to be under load for a long period of time. Remove the load as soon as possible. Leave the compression tool in position.

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.

Checking the clutch

Fig 5: Checking The Clutch

Courtesy of VOLVO CARS OF NORTH AMERICA.

Leave the compression tool and fixing ring on the clutch if the clutch is to be reinstalled.

Wipe the clutch with a dry cloth.

Check carefully for damage through over heating, cracks, scoring or other damage to the friction surface.

Check that spring is not damaged or broken.

Check the pressure plate for out-of-true

Fig 6: Checking Pressure Plate For Out-Of-True

Courtesy of VOLVO CARS OF NORTH AMERICA.

Wipe the pressure plate friction area clean.

Check any out-of-true carefully. Use a ruler and a feeler gauge. Out-of-true is permitted in one direction only.

Out-of-true must not exceed 0.2 mm . If out-of-true is greater, replace the clutch.

The clutch must be replaced as a complete unit.

Checking the clutch driven plate

Fig 7: Checking Clutch Driven Plate

Courtesy of VOLVO CARS OF NORTH AMERICA.

Wipe off clutch driven plate using a dry cloth. The cloth must be free of oil and contaminants.

Check the clutch carefully for signs of wear, damage through overheating, cracking or other damage.

NOTE: The clutch driven plate must always be replaced if there are radial ripples on the friction coating. The clutch driven plate must also be changed if there is oil or grease on it.