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  #1  
Old 04-02-2007, 12:12 PM
 
Join Date: Apr 2007
Posts: 9
Default Clutch adjustment

I bought a 740 wagon Volvo with a bad clutch(or so I was told). I replaced the clutch cable, clutch plate, preasure plate, and throw out bearing. The actual problem was the spring on the outside of the shift "fork" (I guess you could call it for lack of a better term). The spring had fallen off and the "fork" was flopping around. I reshaped the spring and the fork snuggly popped back on the pivot point. The problem now is the pedal is very close to the floor. I have adjusted the adjustment at the end of the clutch cable almost to the maximum.

Is their another adjustment? Can the pivot point be adjusted? Could the Fork be bent?

Thanks Steve
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  #2  
Old 04-02-2007, 04:35 PM
Super Moderator
 
Join Date: Jan 2006
Location: Durham, England
Posts: 981
Default RE: Clutch adjustment

There is no other adjustment. The fork (yes, it is called that)may be bent but that is unlikely unless it has been bent by a previous owner in an attempt to adjust it.

I have posted two pictures, both courtesy of Volvo cars, showing what the fork should look like (1) and the adjustment specs (2).

Two other things spring to mind: the cable is mis-routed or it is too short.



[IMG]local://upfiles/4491/3785BE6B994648AF90F1B54D843096B0.jpg[/IMG]

[IMG]local://upfiles/4491/E874B2ECF3AB4F08BD9AAB003E16B672.jpg[/IMG]
__________________
Work was good - retirement is better.

1996 850GLT 2.5 20v Estate Manual.
1995 Peugeot Boxer 2.5Tdi Autosleeper.

Previously:
1984 244DL, Manual.
1987 744GLE, Manual.
1991 960 3.0 24v, Auto.
1994 940T Wentworth, Auto.
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  #3  
Old 04-02-2007, 05:07 PM
 
Join Date: Apr 2007
Posts: 9
Default RE: Clutch adjustment

Thanks for your reply, although it makes me wanna cry...

If memory serves the fork I had was much more curved than the one in the picture. I'll have to get a new one and compare through the boot hole. More than likely I'll have to take apart the whole thing again. I doubt it can be bent back while in place.
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  #4  
Old 04-02-2007, 06:49 PM
 
Join Date: Apr 2007
Posts: 9
Default RE: Clutch adjustment

You scared me, but upon further review my fork should (and does) look like this

Click the image to open in full size.
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  #5  
Old 04-19-2007, 11:50 PM
 
Join Date: Apr 2007
Posts: 9
Default RE: Clutch adjustment

I just found something in the back seat. Since the cable was out when I bought the car, I didn't have the advantage of disassembly. I think I found the missing puzzle piece, but don't know where it goes.
Click the image to open in full size.

This is how I found it with the cable end in this heavy metal piece. The notch doesn't fit over the top cable attach point of the pedal.It measures 2.75" X 1.75" x 1.75" or metrically 7cm X 4.5cm X 4.5cm

I found this picture on the web.
Click the image to open in full size.
Is that it on the lower right part of the picture? Does it fit over the fork?

What the heck is it?
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  #6  
Old 04-21-2007, 04:00 PM
Super Moderator
 
Join Date: Jan 2006
Location: Durham, England
Posts: 981
Default RE: Clutch adjustment

The only thing I can see on the VADIS diagram that resembles this is part #13 which is listed as an oscillation damper. associated with that is part #12 which is listed as a rubber block. I have attached a complete picture of the clutch mechanism. The cable does go through 12 & 13 and it would appear that the fork sits inside them.

It is a long time since I did a 740 clutch andI can't remember how it went. The picture you found does look like the damper.

[IMG]local://upfiles/4491/C86D683FA9D04DBD83556245CEBCA2E3.jpg[/IMG]
__________________
Work was good - retirement is better.

1996 850GLT 2.5 20v Estate Manual.
1995 Peugeot Boxer 2.5Tdi Autosleeper.

Previously:
1984 244DL, Manual.
1987 744GLE, Manual.
1991 960 3.0 24v, Auto.
1994 940T Wentworth, Auto.
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  #7  
Old 04-21-2007, 05:44 PM
 
Join Date: Apr 2007
Posts: 9
Default RE: Clutch adjustment

Thanks. I did get in touch with the previous owner and he stated that this fell on the ground after the cable broke. So it must go there on the shift fork. Now you state that a rubber piece goes in there too. I'm gonna have to hit a junk yard to find that.

With these two items taking up space on the cable, I think it will solve the low pedal problem.

Thanks again
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  #8  
Old 04-21-2007, 06:00 PM
 
Join Date: Apr 2007
Posts: 9
Default RE: Clutch adjustment

Using the info you gave me on the oscillation damper did a search and found this

http://forums.turbobricks.com/archiv...p/t-33483.html

Looks like they are rare. At least I have the metal piece, maybe can get by without the rubber piece.
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  #9  
Old 04-21-2007, 07:40 PM
Super Moderator
 
Join Date: Jan 2006
Location: Durham, England
Posts: 981
Default RE: Clutch adjustment

If you want to try a dealer for the rubber block the part number is 1329785. I know they sometimes have obscure parts in stock but often don't have everyday stuff.
__________________
Work was good - retirement is better.

1996 850GLT 2.5 20v Estate Manual.
1995 Peugeot Boxer 2.5Tdi Autosleeper.

Previously:
1984 244DL, Manual.
1987 744GLE, Manual.
1991 960 3.0 24v, Auto.
1994 940T Wentworth, Auto.
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Old 04-21-2007, 07:40 PM
 
 
 
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Tags
1984, 240, adjust, adjustment, bent, cable, clutch, damper, fork, oscillation, shift, stiff, suspension, turbobricks, volvo, xc70


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