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  1. 1986-1993 Volvo 240 Clutch Replacement, Manual Transmission: step 1, image 1 of 2 1986-1993 Volvo 240 Clutch Replacement, Manual Transmission: step 1, image 2 of 2
    • Lift the bottom of the shift boot to expose the shifting socket.

    • Use snap ring pliers to remove the circlip securing the shifter to its socket.

  2. 1986-1993 Volvo 240 Clutch Replacement: step 2, image 1 of 2 1986-1993 Volvo 240 Clutch Replacement: step 2, image 2 of 2
    • Remove the set screw securing the shifter yoke pin. This assembly can be located on the underside of the car, above the transmission and directly below the shift lever.

    • Grab the head of the shifter yoke pin with your hands or pliers and pull it out.

    • If the pin won't readily come free, try jiggling the shifter while you pull the pin.

  3. 1986-1993 Volvo 240 Clutch Replacement: step 3, image 1 of 2 1986-1993 Volvo 240 Clutch Replacement: step 3, image 2 of 2
    • Remove the shift lever by pulling it straight up.

    • Remove the plastic bushing in the bottom of the shifter socket.

  4. 1986-1993 Volvo 240 Clutch Replacement: step 4, image 1 of 1
    • Remove the 6 nuts and bolts securing the drive shaft to the guibo and the back side of the transmission.

    • Only four nuts and bolts are visible and marked in the first picture. The others are hidden on the other side of the drive shaft.

    • Take note of how the bolts, washers and guibo are positioned. They are required to go back in the same way.

  5. 1986-1993 Volvo 240 Clutch Replacement: step 5, image 1 of 3 1986-1993 Volvo 240 Clutch Replacement: step 5, image 2 of 3 1986-1993 Volvo 240 Clutch Replacement: step 5, image 3 of 3
    • Support the drive shaft with a jack, jack stand, or other prop so it does not fall and get damaged or injure someone when the support is removed.

    • Remove the 4 bolts securing the drive shaft support.

    • Do not lose the washers on the 4 bolts or the spring and washer on the opposite side of the support.

    • Slowly lower the drive shaft and separate it from the transmission.

    • Remove the guibo and metal separator plate.

    • The separator may not come out with drive line and will be in the transmission.

  6. 1986-1993 Volvo 240 Clutch Replacement: step 6, image 1 of 3 1986-1993 Volvo 240 Clutch Replacement: step 6, image 2 of 3 1986-1993 Volvo 240 Clutch Replacement: step 6, image 3 of 3
    • Remove the bolts securing the transmission to the engine and to the starter.

    • Support the transmission so it doesn't fall when the final support is removed.

    • Generally, a jack is recommended for this.

    • Remove the four bolts securing the transmission support to the chassis.

    • Lower the transmission out of the car.

    • In many instances, the transmission may not come free from the engine once the bolts are removed. If this is the case, a pry bar is recommended to help separate the two.

  7. 1986-1993 Volvo 240 Clutch Replacement, Clutch: step 7, image 1 of 2 1986-1993 Volvo 240 Clutch Replacement, Clutch: step 7, image 2 of 2
    • Remove the 6 allen bolts securing the pressure plate to the flywheel.

    • Remove the pressure plate.

  8. 1986-1993 Volvo 240 Clutch Replacement: step 8, image 1 of 1
    • Remove the clutch by pulling it straight away from the flywheel.

    • When reinstalling, use a centering tool like the one shown here.

Conclusão

To reassemble your device, follow these instructions in reverse order.

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Phillip Takahashi

Membro desde: 22/08/2011

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