Clutch Propeller Shaft

Clutch

PropellerShaft Clutch Propellershaft 240.260 Repairsand 1976- Maintenance

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Group41: Clutch Specifications I SpecialTools 1 spar€ Pafts lllustlation. , , 2-3 ServlceProcedurcs: Replaclngclutch op€hting cable ...... 5 Replacingclulch pedal/bushing ...... 5 Removingclulch 5 Clulchtacing rgplacemenl 5 Servicingpilol bearing Clulchcafiior inspection , , 6 chltchinstallation,,.,,,,. 7 Additionalinfomalion 7 Group45: PropellerShaft Description...... 1 Spare Parts lllustrations 2 Servlce procedures Replacingsupport bearing 4 Propellershall 4-5 Re-buildingU-joinb ...... 6-7

NOTE:All referencesio Model2.40 in lhis manualalso apply to DL,GL and GT. NOTE:All referenceslo l\rodel260 in rlis manualalso apply to GLEand Coupe.

1P1140412 3000-3.80 o

www.myvolvolibrary.info Specifications

Group41

Clutch

Index Speciticat,ons ,I Special Tools ,I Spa.e Pans lllusvano. 2-3 Service Proceduresi Repracng clutch operatng cab|e 5 Replaong clurcf' pedal'bLshrT 5 Bemoving clurch 5 Clutchfaci.g replacement ...... 5 Servicingprlor bealnq ...... 6 Clutchcaff,er inspection ...... 6 Clurch Insrallalion 7 Additional information 7

Specifications 260 GLE& Coupe 240,DL, GL, GT Diessl Clutch,typ6...... Singledryplale,diaphlagmsping...... Singtedrydate,diaphragmspring Size ...... 9" ...... 8V2" Throw-oulyoke travel ,,..,,..,,.0 mm 0.00" , , , . . , , . , , , . , , . . . , , . . , . .3-5mm 0.12=O.2O"

SpecialTools

2824 Mandrel

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260

Group41 Clutch 3 www.myvolvolibrary.info Clutch operction

Replacing clutch assembly Two diflerenl designs ol pressureplates and release bearingsars cufiently used in productionol Modsl240 (DL,GL, GT and Di6s€l)and Modol260 {GLE and Coupe).

lrodel 240 (DL, GL, GT and Diesel) Thefingersofthe prassure plale are straightand must us6lhs corospondingrolease beafing, as shownon illusvation.The release bearing is ,$ mfi (1- 11/1 6") in lenglh. 240 ilod€l B€arlng No. 672122-9 Thispressure plale isiheonlyone currently slock€d by Prcrlurc Plaie No. 34124$2 ourSpare Parts Division-onlythe longer release bear ing is lo be used.See Fig. 1. Flg.r

itodel 260(GLE and Coupe) The fingerc ol lhs prsssur€ plate ars €ised approxi- mately7mm (9/32") al the c€nter.Consequently a shonerrsleas€ bea ng is 36.5mm(1-716") in length. When replacingths clrlch pressurc plate ass€lnbly, car€is to be takento use onlylhe matchingshorler bearing.See Fig. 2-

IMPORIAI'IT:Pressure plates and releasebearings musl ahrays be ol lhe coflect combinationand should neverbe interchanged.

260 flod€l Belrlng l'lo. 381213{ Pr$surc Pl.r€ No. 3812()7{ Flg.2

www.myvolvolibrary.info Clutch operaton

Replacing clutch operating cable 3. RemovereLease bearing. Disconneci cable fiom re easefork. Slackencable sheathfrom bracket.

I Purfronr eno o^ sra_ds.qFmove u_de-dash pa

2. Firstrer.ove ret!rn spr ng.Thendisconnectclutch cabe at cLrlchfork. Pullout cable. 3. RemovecLevis pin al cable upper efd. Pull cable olt of rubber grommet in fnew6 . 4. Push new cable into the rubber grommei in fi rewaLl.Re insraI clevis pin. 5. Fiiadjustmentdevice Lnthe b€llhousing. Connect cable to cluich fork. lnstall return spring.

4. Remove bolts. Remove flywheel housing. 5. Remove bolt for re ease fo.k bE Ltoint. Remove &ll and releasefork. 6. Removebolts holdingc utch to flywheel. Loosen 6. Adjusiclulch tork free pay to approx.3-5 mm them crosswisea coupe of turns at a time to (1/8',). preventwarping. Removeclutch and clulch plate.

Replacing clutch pedal/bushing The lnslructions below cover repacement of pedal o 1. Removeclevis pin securingcabe lo clutch pedal. Remove nui, pull out bot and remove pedal. 2. Remove tubular shaft. Dfive out bushingswilh

3. Pre-Lubrlcatenew bushingswith greaseand install them. lnstall tubular shaft. 4. Positionpedal and sttach bolt. lnstalland torque n!t. Reconnectcable and clevis pin.

Removing clutch Repaceclutch dsc (clutch) 1. Remove transmissionaccording to instruciions. 2. Remove upper bolt ior starler motor. Clutch facing replacement 1. Drillout vetswith a drillhavingsame diameteras vets,3.5 mm (9/9"). Removeod lacings.

Group41 Clutch 5

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Clutch carrier inspection As the clulch caftier cannot be disassembled,it nrust be replaced compete. Ch€ck the clurch carefully. Checkpressureplatefordamage by heat,cracks, scor ing or other damage pn the friction surface. Check the curvatureof the pressureplate with a sieel ruler, Hlb 5. which ls placeddiagonally across the friction surface 3, Spring of the pressurcplate. Then measurethe distancebe- tweenthe slraightedge of the ruler and the inner dia- 2. Checkclutch plate.The indentationson the ton meter oJ the pressureplate. This measurementmust gues should be even.The clutch plate must not not exceed0.03 mm (0.00012"). be warped. The clutch springsand rivets in hub should fit securely and not show any signs of looseness.Check to make sure that there are no

lf the clutch plate has any defects,ir should be

3. Rivet new facings (preferaby in a ivet presd. NOTE|the riversshould be insertedfrom the side o_ wl..h rhefac a9 liesaad |veled fro- rhc op positedireciion against the disc.Use every other ho e in thefacing.After riveting,thefacingsshould Cheking cuMluro of pressureplate be spacedfrom each other as determinedby the 1d.' raro-s on rl-e"lur.h d,sc. l-|srs mosr rr portantin orderto achievea smooth engagement when slarting and druing. The clltch facings must be absoluteLyfree from oil. Oil on the facingscan causeclutch grabbing. There musi be no "crown ng', i.e.cearance between the straight edge of the ru er and the outer diameter of the Dresslre plate.Check at severa points Check pilot Servicing clutch shalt bearing the pressurespdng carefully.lf il is crackedor darn- 1. Use puler hammerto removepilot bearing. agedin anyway, the€lutchshould be replaced. lf bearing, after ceaning and light oiling, ruis Chect rl-erelease bFaring bv rL r -9,r a fpw rre5 smoothlyand evenlyand has no noticeabeplay, under light pressureso ihat the balls rotate against r sroJld ba packedwrh ba I bed'irq S'F.se ._d ihe races.The bearingshould turn easilywithoLrtbind- ing at any point.The releasebearing should also slide No-t: hedres'sran q easpsl'ourd be used edsilyo_ th" g-,de sleevefro- rhe ,a.s-rssor.

Gtoup41 6 Clutch

www.myvolvolibrary.info Clutch installation Beforelnsrallaton, check thar clutch facingg flywheel ard pressureplate are completelyfree from oil. Wash rher wlll_ gasoli.e a.d wipe ort wilh a Llean p'ece

1. Set up rhe clutch plate khe longest side of the hubfac ng backwards) together w th clutch.lnsert centeringmandre 2484 as a guide in the pilot bearingin the flywhee. 2. Install six bolts which hold the clutch. Tighren them crosswisea couple of tlrns at a time. Re- move cenlerng manorer. 3. lnstall releaseyoke in flywheel housing. nstal upper bol for stalter motor in the housing and install rhe housing. Install bolts in the fo- 5. Insertcable shaft ln bracketand rear nut. Secure lowingorder: Fn* four upper(7/ 16 )bolts,and cable in releasefork. Install releasebearlng- then ower bohs for ihe srartermotor, and finaly 6. Installandtighten nul for the upperstarter motor two ower (3/8") bolts. The nu for rhe starter l.rlotorupper bot is installedafrer ihe cabe has 7. Insrdlrhp rrdrs- ssrolacco d,ng o as ruc ,on". L Adlust cutch pedal play.

AdditionalInformalion

It ispossibleto instalithe rubberwasher on clulchcable incorreclly. Such inslallalion willcause lhe rccessedpadot lhewasher lo Jacethe wrong direction. Thiswillprevenl lhe steelwasher from being located in its seat and willcause lhe rubberwasher to crackand eventuallv Jall ofl, Asaresultolthe incorrect installalion, lhe c utchwilldevelopanabnormalslipduingdeclulchingoperalion. Premature lailureol lhe clulchdisc may occur. o o

CORBECT INCORFECT

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www.myvolvolibrary.info I Desc ption

Group45

PropellerShaft

Index Description 1 SpareParrs lllusl ar,ons 2

Beplacirgsupporl bed'ing .. ...

Re-buildinsU-Joints 6

Description

2 4ab

Prop€llershaft with suppon be.ring

Flangeon transmision 7. Rear onive€l joint 5. Intemediate univeGaltoiil L Flange on rear axle Front seclion of propeler shaft 6.

The propellershaft is a divided,tubular type shaft, see Fig. above.The front section rear end is formed as a splined sleeve.The coffespondingsplined shaft cafties one of the intermediateuniversal joint yokes. The front sectionreaf end is supportedby a ball bear ing. The ball bearing is in turn installedin a rubber bearing housing,which is attached to the propeller shaft tunnelwith a cover,see Fig-,right. The propeller shaft has three universaljoinrs. Each joint coinsists of a cross with four trunnions which are carried in flange yokes by needle bea nss. A propellershaft is pairedand balancedasa unit. F ont and rearsections arc individuallymark€d with a yellow 8. Bearseclion oi propeler dot and an aiiow. The propellershaftmust be replaced 2, 3. 9. nubbefcover only as a pairedunit and the front and r€ar sectjons haveto be insr€lledso thar the aiiows (thedots) point 5. 11. Suspensonspring 6.

Group45

www.myvolvolibrary.info Sparc Pafts lllustrction

Propellershaftsand parts should be ordered according Th€ centerbearing used depends on typeof tribular to typeot transmissionand type 1140or 1310com- shaft.1140hasa tube diameterof /|4.5 mm = 1.7520" panionflange, and, to a certainextent, the diamete. and l3l0 a tube diameterof 50.8 mm = 2.m0".

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Ol \OL\O PAR]S 0. lala 12'7t1 OI

As a generalrule, all 4'cyl. modsls exceptstaton wa, All slaton wagonand 6 cyl. modelsare equippedwittl gonsare equipped with lhe lighlerpropeller shafl1140 lh€ h€avy-dutytype prcpellershatt 1310 witl50.8 mm with214.5 mm (1.753")ltibular shaft. (2.002")lubular shatt.

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@serrr

Group45

www.myvolvolibrary.info Renoval disassembly

ServiceProcedures

Replacing support bearing 3. Pre$ the old beainsout of the rubberhousing Installthe new bearing. Inslallsupporl bearing and olher pa(s in reverse put 1. Jack up the vehicleand it on stands Slacken oder 10femove, lf lhe splinedjoint appears dry, Bend the propellershaft from the rearaxleflange. lubicaleit with greasemixed wilh molybdenum removethe nut at the back the lock washer and disulphids(Molykote.) sliding joint. Pull our the propellershaft to the lvake sure that the aiiows point toward each other on propellershafts paired and balanced 2. Loosen the support bearing cover. Pull off the complete support oearrng.

PropellerShaft

Removal Disassembly Jack up the vehicle.Slacken the propellershaft from Propellershaf t disassembly rear axle flanges.For 245 use the transmissionand 1. Bend back the lock washer and remove the nut 2846 to loosen impact air wrench and specialsocket for the suppon bearing. Renrovethe propeller the support bearlngcover and take the bolts. Loosen shafl rea' seclron.Pull ofl the supoon bearng. down the complete propeller shaft. 2. Take the suopod bea'irg our of Lhe hoLsr.g. Fot 242 artl 244 use rool 2779 for the front flange bohs and tool 2846 for the rearflange bots, see Fig. Disassemblinguniversal joints I Removethe snap rings which secufethe needle bearings in the yokes, see Fig. below: o

Removingsnap ri.g

2. Seclre the shaft in a vise so that the universal tornrcom.s as nea as oossiblpto the vise raws. Rememberthat the propellershaft is tubular and can easily be deformed. 3. use a hammerand metalpunch to drivethe spidel as far as it wi go in one direction.The needle bearing will then come about half way out.

www.myvolvolibrary.info tnspecoon. assembly

Then drive th€ spider as far as h will Assembly opposrle direcrion,see Fig. Assemblins universaljoinls 1. li old needlebeanngs are installed, checkrhat they are fLlledwiih greaseand rhat the rubb€r s€als o e nor da-aged NFw bFainS\ -r ou d b- h"li f led wlth grease. I 2 .. rnFrorde.rh.fa Seyora.P."\r1ppd \ er n one direcl on so rhat the neede bearnq can be nstalled n the trunnion, see Fig. belowi '(

.ar\ *tu:=tac Removingspider, fn step _------:- # 5. Drive out one of the needlebearings whh a thin !l meta p!nch.Remove the spider. see Fig. beow: Driveolt the other neede bearing.

Then pressln ihe neede bearinglar enoughthat the snap ring can be insta ed. Use a dfift with a diameter sLightly ess than that of the f€edle

3. Insrallthe oth€r neede bearingand repearthe

Do the sam€on the remainingyoke-

lnstallation Insiallaiion s n r€verseorder to remov6.

Inspection ll is exlrerney mporlantlhal lhe propellershaft is slraighl.The inspecUonmusl be carelulsince even minordamage on lhe propeer shatlcan cause vibra- ton. The shatlshou d be set up betweencenlers and checkeda ongils entirelenglh wilh an indicatorgauge whilerl s olalr'lg.ll ir rsoJr-ol-true rorelha']0 25 nm (0.010")lhe shaflmust be replaced. NOTE|No artenrplshoud be madeto straightena damagedpropeller shafl: replace it. T\om re rl_esJpoofl bpalnq D.-ssrl e bp" i-9 ,ac.. aga nsl each other by hand and lurn them n opposte directions.The bearng shoucl run easiy without bind ,-g ar ar\ poi r l' I bi d5 - ao rl.eb.ar 19 J o .e.

Group 45 5 www.myvolvolibrary.info U-toints

Re-buildingU-joints

:::::::::::::: A:I B : 9995019::::::;::(: Instructions for press tool 999 5O18 and puller 999 5019

B. Arbor C. Rod D. Suppoft.Parr oi 9995018

Disassembling universal joint Removethe lock r ngs and positon the U joint in the press tool. Use the peda 10 move rhe spider.tf the power is not sufficient,use a h.mm€r on rhe rod.

Movethe U jo nt io the puller.Align rhe needlebearing between the jaws. Pressdown the handlewhich w ll remove the needle bearing.

Assemblinguniversal joint Locate the spider with seals n one of the coLrping I flanges.Locateone needle bear ng. Posltion the U-joint t n the presstool and pressin the needlebearing unti I the lock ring can be insralled.Turn the U-joint over and press in ihe other needlebearing. Inst.ll spider f, and neede bearingsn the sameway in the other co!- pling fLange. nstall the lock rings.

Gtoup 45 6 www.myvolvolibrary.info Replacingpress tool arbor Loosenlhe screwand remove the arbor.Position the other arborand tightenthe screw' NOTE:The largearbor has two recessesto be po- sitionedvertically-.For this reasonit is providedwith a hole correspondingwith the screw

Replacingpuller iaws Removethe O-ring and use a punchto pressout the

Jaws for sm8ll U-joints 9999 026 Jaws for large U-joints 9999 027

Lift the ring and bend

Holdthe leverin the upperposition and pressthe jaws into position. Positionthe ng with ths side marked "up" upwards.Installthe pins. Bendthsspring, which rctainsths lowerendsof theiaws, into position.Install the o-ring.

Gtoup 45 7

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