Yesterday while setting at a stop light (clutch to the floor and in 1st gear) our 1996 Volvo 850 lunged forward. The clutch now sets against the floor. I have lost either the master/slave hydraulic cylinder or the line between the two has developed a leak. The only leak I can find is on the rubber portion of the line between the two cylinders. Has anyone had the line fail and NOT either of the cylinders? Quite a bit of brake fluid appears to have leaked out of the system but the brake fluid reservoir is almost full. Since the clutch hydraulic fluid comes from the same reservoir used for the brakes, it seems the fluid level would be quite low? Anyone with advice regarding this clutch failure would be greatly appreciated. Could not find any step-by-step repair instructions on the web yet (usually I can). I do have a Haynes repair manual which is somewhat helpful. I have replaced both the master and slave cylinders on a formally owned Jeep but it did not share the brake fluid reservoir (two independent systems). Bleeding the system on the Jeep was easy. Since the reservoir is shared on the 850, do I bleed the system (after replacing the defective part) as I did on the Jeep?

Thank Very Much in Advance for any Help!!
Regards, Ron

Update: I am 99% sure it is leaking out of the rubber portion of the line between the master and slave cylinder. It has been rubbing against a cable bundle that leads to the battery. It has rubbed a fair amount of rubber material off where it was rubbing. When I wipe the entire rubber portion clean I can see the fluid seeping out of the area where it has been rubbing. So I need to replace the entire line between the two cylinders. At the master cylinder end it has what the Haynes manual calls a spring clip. It is NOT OBVIOUS how one removes this clip? (just my luck I would have the version that can't be removed with a open end wrench)

The Haynes manual states this exactly in the last of section 4-4 on page 8-2: Where a snap-on coupling is used on the line fitting. Remove the spring clip and pull out the line. (NOTE: This spring clip is the one on the engine side located where the hydraulic line attaches to the clutch master cylinder and NOT the one on the push rod located under the dash board.

So the questions are: 1. How to remove the spring clip? & 2. Where to purchase the replacement hydraulic line that uses a spring clip on the master cylinder side?

I have some photos but it appears they are to large to post to the forum. I will try to post them to my web site and include a link later.

Photos are now on my web site please see link below 1206 and 1207 just show the other end. All the other pictures are of the end I am trying to remove.

http://rrolsbe.freeshell.org/pictures/volvo_clutch/

 

I have not taken one apart yet but I think the clip just pulls out and allow the line to be pulled out.
On the line not sure where to buy but the Dealer or used.
For the bleeding it should be the same as on the Jeep. But they can be a Pita to bleed at times.

 

That is what I originally though also, but there is metal showing on both sides and no slot in the clutch master cylinder housing to slide it up or down. It is in very tight spot, so it is very difficult to get my hands/tools positioned to try different options and I don't want to force it and break something.

Thanks Very Much for Your Reply
Regards, Ron

 

I wish I could help more on that part of it. I should have looked closely at mine when I did my manual swap.
But this might help. I found the part numbers for the lines. There is a chassis break through.
4D up to 71834 and 5D up to 1162 is part number 3520491
4D higher than including 71835 and 5D higher than including 1163 is part number 9181437

Hopefully that helps some.

 

Not sure if the part numbers match but this site lists it as a line. Maybe contact and double check.
http://www.volvowholesaleparts.com/p...layCatalogid=0

 

Maybe this link is better. See if it shows the part numbers and prices on your end. I am copying and pasting the part numbers and prices.
http://www.volvowholesaleparts.com/p...13784&items=10

 

Thanks for the info! I had found part number 9181437 and from the pictures that part number looks like it might be the correct part; however, the description did not state whether it was the clip type or threaded type. Now that you have found the other part number maybe I confirm it tomorrow. Where is the chassis number located? Maybe on the door plate under the hood?

Thanks Again for your help
Ron

 

The chassis number is the last 5/6 digits if the Vin number.

 

(SUCCESS!!!) Hope this helps other in the forum in the future.

I got the clip out without breaking anything!!!. Since I couldn't see the drivers side of the
clutch master cylinder, it looked the same as it did on the passenger side (but it could
not have been). Here is the trick
to removing the clip. I used the sharp point of one of the blades on my Leatherman tool to
get under the clip from the passenger side. I had earlier tried to get under the clip using
a small screwdriver and that did NOT work. Once you get under the clip is slides right out!
Note I had to remove the radiator fan assembly to get enough room to remove the clutch slave
cylinder end of the hydraulic cable. (It might be possible to do it without removing the fan
assembly but it is REAL tight quarters.)

The part number from the hydraulic cable stamped on the slave cylinder end of the
hydraulic info:

9143414 195
Part number 9143414 was superceded by part number 9181437. as per www.volvowholesaleparts.com
A5 40.08F Volvo
(or) Could be
A52 40.08F Volvo

The rubber portion has the following stamped on the line:
04/95 *** 02 026 >EPDM< >CR<

YV1 L S 55 4 2 T 2 2XXXXX <---VIN NUMBER FROM 1996 VOLVO 850GLT

YV1 = MANUFACTURER CODE

L = VEHICLE TYPE L=P80 Model 850

S = DOORS S=4 DOORS (Sedan (4-door) with Air Bag & 3-Point Safety Harness (Seat Belt))

55 = ENGINE TYPE 55= B5254FS (V70 FWD)

4 = EMISSIONS 4= ??? NOT DEFINED IN VIN DECODER (Double checked it is a 4 in the VIN)
I think this car was purchased by a US Military officer while living in Europe??
[1992-Present] Emission Control Equipment
* 0 = SULEV+ (Super Ultra Low Emissions Vehicle) / Engine Codes 39, 64, 72
* 2 = ULEV2 (Ultra Low Emissions Vehicle) / Engine Codes 38, 41, 51, 59, 61, 67, 68, 85, 98, 99
* 7 = LEV2 (Low Emissions Vehicle) / Engine Codes 52, 54,

2 = GEARBOX 2=M56, M59 MANUAL GEARBOX

T = MODEL YEAR T=1996

2 = FACTORY CODE

2XXXXX = CHASSIS NUMBER

There is a chassis break through.
4D up to 71834 and 5D up to 1162 is part number 3520491
4D higher than including 71835 and 5D higher than including 1163 is part number 9181437

Therefore since this 1996 Volvo 850GLT 4-Door Chassis number 2XXXXX is higher that 71835
the correct Volvo part number for the clutch hydraulic cable should be 9181437

The only part of the VIN # that was not defined on either of the decoders I found on the web was the emissions code of 4.

Thanks again so much for your help!!!!
Regards, Ron

 

Glad you got it all apart.