Tool - Installing Clutch and Pressure Plate
SECTION4
GROUP
41
NO.
805
DATE
Aug. 1996
New tool for installing clutch driven plate and pressure plate
850
REFERENCE: TP 4101201, SECTION 4 (41, 43, 46) M56 MANUAL TRANSMISSION, INCL. CLUTCH AND DRIVESHAFTS; 850 1992-
New tool for installing clutch driven plate and pressure plate
Centering the clutch driven plate and pressure plate is very important to allow vibration free clutch engagement when starting and gear shifting. Vibrations can occur when the clutch is engaged at low engine speeds if the pressure plate is not correctly installed. Correct installation is difficult without special tools.
New tools have been developed that relieve the pressure on the pressure plate diaphragm spring when installing (or removing) it. The tools consist of a centering drift for the clutch driven plate and a press tool for the pressure plate diaphragm spring.
There are tools for all Volvo engine versions. The press tool is the same for all engine versions, only the centering drift varies with the engine version. This Service Bulletin describes how the tools are used for installing (or removing) the clutch driven plate and pressure plate.
Make a note in the following Service Manuals, Section 4 (41,43, 46) "M56 Manual gearbox incl. clutch and driveshafts" 850:
- TP 4101201, Page 20, operation A9 and
^ Cross out operations A9.
Write the following in operations A9: "See Service Bulletin 4-41-805"
New tools
Press tool, P/N 999 5662-5
Centering tool, P/N 999 5663-3
(The earlier clutch driven plate centering tool should no longer be used)
Removing clutch driven plate and pressure plate
See Service Manual Section 4 (41, 43, 46) "M56 Manual gearbox, incl. clutch and driveshafts".
Note:
If the pressure plate is to be reused, or is being removed and reinstalled when replacing a crankshaft seal for example, pressure on the diaphragm spring must be relieved with the relief tool before the pressure plate is removed.
Method:
Unscrew the center screw until the tool can easily be hooked under the edge of the clutch housing.
When the tool has been hooked into place, screw in the center screw so that it comes into contact with the diaphragm spring.
When the center screw is in contact with the diaphragm spring, note the position of the slotted handle and then screw it in two turns, but no more!
Remove pressure plate. Unscrew the center screw on the tool so that the diaphragm spring is not compressed for too long, max 24 hours.
Installing clutch driven plate and pressure plate
Unscrew cone from centering tool
Install centering tool as far as it will go into the center of the flywheel.
Use a wrench as a counterhold and tighten the outer nut until the tool expander is secure in the flywheel.
Install clutch driven plate on drift.
Screw on cone and secure clutch driven plate with it. Tighten cone by hand to center the clutch driven plate. Do not tighten too hard or with a tool, as the cone may damage the clutch driven plate and damping springs.
Unscrew the press tool center screw completely.
Position the press tool on the pressure plate diaphragm spring.
Push the press tool hooks between the diaphragm spring slots so that they grip under the edge of the clutch housing.
Screw down the center screw so that it comes into contact with the diaphragm spring:
- It the pressure plate is new, screw down the center screw four turns. One section of the handle has four slots. Note the position of this section of the handle and screw in four turns but no morel
- If the pressure plate is being reinstalled, only screw down the center screw two turns!
If the pressure plate is not flat against the flywheel, screw in the center screw another half turn and check. Turn the center screw a half turn at a time until the pressure plate is flat against the flywheel.
The pressure plate diaphragm spring may be damaged if it is pressed in too far!
Note:
The diaphragm spring should not be under pressure for tool long, max. 24 hours! Relieve pressure on the diaphragm spring as soon as possible.
Install pressure plate with press tool on the flywheel.
The center screw is hollow so the centering tool can be installed.
Check that the pressure plate is in contact with the flywheel all around its circumference.
Install pressure plate on flywheel.
First tighten the screws crosswise to contact. Then tighten screws crosswise to 25 Nm (18 ft.lbs).
Unscrew the press tool center screw and remove tool.
Unscrew the outer nut on the centering tool until it feels loose.
Tap the centering tool so that its expander is released. Remove centering tool.