Clutch Change Week

pol · Post by **pol** » Wed Apr 07, 2004 7:58 pm

So I bought a 3pc clutch kit today from GSF car parts for the very reasonable price of $102.23 (...erm cant find the pound sign.. wrong language keyboard here...)...

and I want to fit it this week.

I've helped turbotwat recently do his, but missed out on most of the hard work.

Any tips?
Stuff to look out for?

Engine in or Engine out?

pol

Ben Harris · Post by **Ben Harris** » Wed Apr 07, 2004 10:54 pm

pol wrote:(...erm cant find the pound sign.. wrong language keyboard here

No help for the clutch, but....

Left ALT key, and 156 on the numeric keypad will give you a Â£ sign!

(I used to have a US keyboard on my old PC!)

Ben.

gerrsvolvo · Post by **gerrsvolvo** » Thu Apr 08, 2004 6:19 am

Hoi Pol
It is supposed to be a straight forward job.
Given dealer time ca. 6 hours.
Diy time probably much more (i have done it 4 timers now and used up to a full weekend)
It can be done with the engine in the car.
I did.
But this was alwayd on a ES non turbo. I can thing that with a turbo I would remove the subframe to get the gearbox out from underneath.
So the whole turbo stuff stays in place.
On the ES you only have to loosen the left side of the subframe and than can take lift the gearbox out.
Working order
First get firstclas 15 mm. socket
drain gearbox
remove batery and batteryholder
remove startermotor (there is a nut that holds the gearbox to the engineblock hidden by the startermotor. specialist can sometimes lossenn this nut without removing the startermotor.
take off all the electrical conenctions in question (startermotor, speedometer sensor (allenkey needed) TDC sensor for the ignition, rearlicht swoitch onnteh geasrbox.
losen and take out left driveaxle. If you are carefull you can if you losen the hub from the schockabsorber and triangle and remove the frontdiscbrake caliper. I advice strongly not to remove the central locknut off the axle.
remove pin (5mm) from right axle
losen all bolts that hold the gearbox to the block an the enignemounts
Check if the rubber in your rearenginemount is not torn or sheared.
Take gearbox out to above.
Check rearcrankcase oilsealing and renew if suspected.
and mount clutch

asembly is vice versa.
This is in nutshell the works.
Good luck
Grerrsvolvo

Erics480 · Post by **Erics480** » Thu Apr 08, 2004 9:10 pm

How much do you charge for my 91 turbo change

You have done it 4 time's now, what about the 5th time on mine ??

Eric

kingrichy · Post by **kingrichy** » Fri Apr 09, 2004 6:57 am

When your at it, do mine to.
Yesterday i broke mine.

Erics480 · Post by **Erics480** » Fri Apr 09, 2004 8:32 am

Volvo Hooftman Waddinxveen â‚¬ 750,=
Volvo Schaap Lelystad â‚¬ 850,=
Non Volvo garage â‚¬440,=-â‚¬740,= depending on type of clutch.

Eric,

Turbo ZZZ · Post by **Turbo ZZZ** » Fri Apr 09, 2004 8:02 pm

could somebody made it clear for me...what is the gearbox input shaft bearing and clutch guide tube for? catalog nr?, my cluch is a little sticky and the realease fork is very loose...I have a feeling that i don't have this piece set in my gearbox

chris1roll · Post by **chris1roll** » Fri Apr 09, 2004 8:52 pm

I think i'm just gonna take the engine out if i do it, at least you can see what your doing.

(and i won't be attacked by a subframe)

Got the removal down to 2 hrs now.

pol · Post by **pol** » Fri Apr 09, 2004 8:57 pm

Well pretty much decided i'll be just dropping the sub-frame out (hopefully on my finger) and doing it that way. Just waiting for turbotwat to loan me his tool collection on sunday. Cheers turbotwat (I'll rope you into doing some of it somehow...twat)..

2 hours is a pretty good time... Just all the unfamiliar wires and hoses look scary at this point. Maybe engine out next time. When I need a new engine!

pol

chris1roll · Post by **chris1roll** » Fri Apr 09, 2004 9:02 pm

on an ES mind. not done a turbo yet
Thats 2 of us doing it.. putting it back in takes a little longer.

martinholmesuk · Post by **martinholmesuk** » Sat Apr 10, 2004 12:27 am

No help for the clutch, but....

Left ALT key, and 156 on the numeric keypad will give you a Â£ sign!

(I used to have a US keyboard on my old PC!)

And far too much time to play with. Learning ascii codes! eh...

pol · Post by **pol** » Sat Apr 10, 2004 6:50 pm

Spent most of this week taking stuff apart and cleaning to get more familiar with everything. Cleaned all my injectors, throttle body, idle speed reg, moved my FSE and replaced the hoses before I caught fire, sorted the power steering... Everythig is sweet except... The clutch... Tomorrow is the day....

Wish me luck!! I'll take pics of anything interesting I spy.

Quality time together with my turbo. I love it!

pol

kingrichy · Post by **kingrichy** » Sat Apr 10, 2004 7:05 pm

Good luck.

\

Bin there yesterday and today, it took me 12 hours.
But now she`s running fine again.

pol · Post by **pol** » Sun Apr 11, 2004 8:51 pm

End of day 1.... Started about 3 or 4pm... With a bit of a hangover... Didn't help much. It's the little thing that piss me off. Spent a couple of hours just trying to get the exhaust downpipe bolts off. Turbotwat turned up and helped lots... We've rounded a wishbone nut (going to grind it off I reckon.) Got dark so called it a day.....

Tomorrow...

pol

martinholmesuk · Post by **martinholmesuk** » Sun Apr 11, 2004 8:57 pm

Oops about the nut. Ha cars are fun eh?!

pol · Post by **pol** » Sun Apr 11, 2004 9:05 pm

Yep.... Great fun! Actually not got any cut knuckles and fingers today. Obviously wasn't working hard enough. Must try harder.

pol

MatBat · Post by **MatBat** » Sun Apr 11, 2004 9:07 pm

I hate wishbones ans spring compressors! They are evil!!!!!!

I have plenty of cuts on fingers

kingrichy · Post by **kingrichy** » Mon Apr 12, 2004 10:28 am

This is why mine stopped working.

bbf · Post by **bbf** » Mon Apr 12, 2004 11:59 am

kingrichy, bad.. this can't be renovated. renovating is waaay cheeper, i did a clutch repair on my old volvo for only 15 â‚¬ + my work (a day or so). the guys i gave them to renovate it changed the plates. actualy change one and add the other coz it wasn't there anymore. it 'exploded'...

pol · Post by **pol** » Mon Apr 12, 2004 10:38 pm

AAAAArrrrrrRRRRRggGGhhhhhhHHH!!!!!!!!!

Today I 'ave mostly been using..... Angle grinder...

pol

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