Clutch change help needed

robkendall · Post by **robkendall** » Thu Apr 15, 2004 4:00 pm

HI all,
am hoping that at least some of you are near to me!
I need hep to change my clutch.
Have got the three piece kit (Â£60 new), have started stripping out the engine bay, but i dont have the confidence to do it myself.
Ive also not got any lifting gear.
Would anyone be willing to come and 'supervise'?
I would do all the grunt work,just need someone whos done it before to tell me what to do.
I think ive got the one where the subframe has to come out...the hose from the rad to the block goes OVER the subframe.

Im in south yorkshire....i think dragon is near me (hint!)

let me know?
email me at robkend@aol.com
ring me 07977 218428

thanks in advance

martinholmesuk · Post by **martinholmesuk** » Thu Apr 15, 2004 4:01 pm

At least your willing to give it ago! Everyone respects you for that

dragon · Post by **dragon** » Thu Apr 15, 2004 6:46 pm

I wouldn't have a clue about a clutch I'm afraid - happy to come and watch you do it though

robkendall · Post by **robkendall** » Thu Apr 15, 2004 6:54 pm

thanks for the offer Gaz....you're welcome to come over and ave a

.
drop me a mail....i can give you directions if you really want to come over.

dragon · Post by **dragon** » Thu Apr 15, 2004 7:03 pm

When are you planning on doing it, and where in Yorkshire are you (roughly)

robkendall · Post by **robkendall** » Fri Apr 16, 2004 9:19 am

Hi Gaz
have already started stripping some of the engine parts out....have got as far as the starter motor, with the help of my trust hayes manual.....the manual

yeah right......
I want to do it all this weekend,sat and sun.
Im only in rotherham....dont know if you know rotherham much?(know you said you worked here for a while) im about 1/2 mile away from the Asda.
like i say....i will have a go at anything,its just that my mechanical knowledge of the 480 could be written on a very small postage stamp

let me know,and i will pm you my address....
cheers
rob

dragon · Post by **dragon** » Fri Apr 16, 2004 10:23 am

I might be able to pop over on Sat morning, or maybe Sunday for an hour or so...

gerrsvolvo · Post by **gerrsvolvo** » Fri Apr 16, 2004 11:23 am

I think that I live to far away In the Netherlands, to come and watch you.
But remember it is a straight forward job. At least on the ES.
You do not have to remove the radiator.
After removing the batterytray and takening the gearbox lose from the block you can tilt it out in vertical direction.
Youi only have to loosen teh subframe to give the gearbox some extra movement to tilt it out. But beware it is heavy (at least for me)
One special point is that you normally need to remove the starter engine because there is a 15 mm. nut hidden by this startermotor.
And have to drain the gearboxoil in the early stages of the proces before you take the left axle out of the gearbox.
And for the left axle you can take it out after removing the brake caliper
and take loose the mounting (2 bolts) to the strut and the 2 bolts mounting it to the triangle(wishbone?).
The other things should show for itself.
Goodluck
gerrsvolvo

pol · Post by **pol** » Fri Apr 16, 2004 4:07 pm

I found the starter bolts were some of the trickyiest to get to. If you have that off already then you're doing well. Not much to it, i was a bit unlucky with seized bolts and damaged threads. Nothing a new angle grinder and a tap couldnt fix. You do really need someone or 2 people to help you remove the box (i had a foam thing to drop it onto too) and some ropes and help to get it back on. Look out for akward to reach heat shield screws.

pol

doug_480_turbo · Post by **doug_480_turbo** » Fri Apr 16, 2004 5:36 pm

taking the starter motor off is a challenge and a half on the turbo dont now about the es. but they are probaly the same.

robkendall · Post by **robkendall** » Fri Apr 16, 2004 6:38 pm

pol wrote:I found the starter bolts were some of the trickyiest to get to. If you have that off already then you're doing well. Not much to it, i was a bit unlucky with seized bolts and damaged threads. Nothing a new angle grinder and a tap couldnt fix. You do really need someone or 2 people to help you remove the box (i had a foam thing to drop it onto too) and some ropes and help to get it back on. Look out for akward to reach heat shield screws.

pol

heat shield screws......

took me all day to get them off. the starter tookabout five minutes!
have got the battery and air box off.
thinki only need to loosen the studs holding on the box, and take out the drive shafts, but its the driveshaft bits that are worrying me.
spoke to a guy today, whos going to come and have alook...hes got lifting gear in his garage, so might end u taking it to his house to do it.
thanksfor all the advice....keep itcoming!!
rgrds
rob

pol · Post by **pol** » Fri Apr 16, 2004 6:48 pm

Driveshafts are the easy bit. Apart from I had to grind 3 of the 4 wishbone bolts out but took no time at all with a nice angle grinder.

Use something like an old drill bit to drive out the roll pin on the driver side driveshaft. Drain the gear oil befor removing the other one.

You'll need a puller to get the shaft out once you have removed the stub axle to strut bolts, a balljoint separator for the tie rod ends (dont use a hammer, you'll fu@k them up). Stick a screwdriver in the brakes when undoing the driveshaft nut...

I've still got it all pretty fresh in my head so give us a shout if u need any more tips...

pol

dragon · Post by **dragon** » Fri Apr 16, 2004 7:00 pm

I have a puller and a tie rod seperator if you need em

robkendall · Post by **robkendall** » Fri Apr 16, 2004 8:47 pm

thanks guys...
me mate is coming over tomorrow to have a look and see what we will need.
hes pretty tooled up, but doesnt have everything, so i may be taking you up on the offer gaz...willpmyou tomorrow if i need the tools.
mainly though....thanks for the support and advice...its nice to know people would put themselves out if needed.
really appreciate it

wish me luck...tomorrows the big day.
rgrds
rob

pol · Post by **pol** » Sat Apr 17, 2004 2:44 am

I know the feeling!! It's not so bad really... (maybe...) I would help if i was nearer... it is an arse of a job, but it has to be done at some point and quite satisfying when done. Pullers and separators are quite cheap if neaded anyway.... I would have spent hours with a grind stone on me drill if i hadn't bought an angle grinder. Biggest help of all...

Good luck.

pol

martinholmesuk · Post by **martinholmesuk** » Sat Apr 17, 2004 9:40 am

How is the work going?

robkendall · Post by **robkendall** » Fri Apr 23, 2004 4:26 pm

changed mi clutch today

easier than i thought it was gonna be.
didnt hit any probs,dropped the box, even the sub frame jumped off at us.
clutch didnt look too bad, but we put the new one on anyway
put it all back together, but it looks like the original problem was the cable!!!
when we put it back on, the cable needed to be taken all the way up again.
does the cable stretch that much?
also, does anyone know the a part code for a replacement, and where to get one from, other than volvo dealers?
dealer near me is quoting 46 quid...seems a bit steep to me.

let me know?
rob

chris1roll · Post by **chris1roll** » Fri Apr 23, 2004 8:07 pm

even the sub frame jumped off at us.

I know that feeling!!

robkendall · Post by **robkendall** » Sat Apr 24, 2004 9:35 pm

have sorted it.....
where the outer cable goes through the bulkhead, it had literally gone through the bulkhead.
the rubber grommet had gone into the cabin of the car.
I pulled it back through, which took up about 1.5 inch of slack.
trouble is that when i engage the clutch, it pulled back through.
I got a small piece of aluminium, and drilledit in the centre, and cut a groove to it from the edge, kind of like a keyhole.
slipped it over the cable, sat the outer back on to it,and hey presto,10 mins, and a piece of scrap ali was all it needed, not a 60 quid clutch!!

regards
rob