Bushing, Clutch Pedal, Replacing
Bushing, clutch pedal, replacingRemoval
Remove the soundproofing panel and the pedal position sensor
Remove:
- the driver's side soundproofing panel.
Bushing, brake pedal, replacing
- the pedal position sensor from the clutch pedal
- clip that locks clutch cylinder push rod.
Unhook the push rod from the pedal.
Unhook auxiliary spring
Press down the pedal. Unhook the auxiliary spring.
Remove torx screw (upper arrow).
Unscrew pedal bearing screw
Unscrew the screw approximately 30 mm. Remove bracket and pedal.
Replacing bushings or pedal assembly
Remove the pedal from the bracket shaft. Replace the bushings or pedal assembly. Lubricate the bushings using grease; P/N 1161241-3.
Install the pedal on the bracket shaft.
Installation
Install the bracket with the pedal
Install the bracket with the pedal.
Loosely install the screw holding the pedal shafts together and the torx screw on the bracket.
Tighten the screw for the pedal shafts. Then tighten the torx screw for the bracket.
Install clutch cylinder push rod
Pull up the clutch pedal. Install the clutch cylinder push rod on the pedal with the retaining clip.
Press the pedal down. Install the auxiliary spring.
Install the pedal position sensor on the pedal and the body.
Install the soundproofing panel.
Clutch cable, replacing
Note: The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.
Preparatory work
Disconnecting the battery lead
Remove the battery lead. See: Note when disconnecting/connecting the battery lead.
Removal
Removing Components
Remove:
- the torque rod.
- the air cleaner (ACL) housing.
- the cover on the side of the air cleaner (ACL) housing. Only applies to cars with B5454T4 and B5244T5 engines.
Disconnect the integrated relay/fusebox, put to one side.
Preparation
Note: Unscrew the bleed screw until drops start to form. The version uses a rubber gasket instead of a cone.
Open the bleed screw.
Install the bleeding equipment hose on the bleed screw. Alternatively place paper wipes or rags underneath. Slowly press the clutch pedal all the way down. Lock the pedal. Use a pedal jack.
Removing the clutch line
Remove the cable from the clip on the left-hand frame member.
At the clutch cylinder, pull up the striker plate. Pull out the clutch line. Wrap the end of the pipe in paper to prevent spillage.
At the master cylinder, pull up the striker plate. Pull out the clutch line. Be prepared with paper to prevent spillage. Remove the clutch cable.
Installation
Installing components
Note: The new clutch cable has plastic protection on the ends. Keep these until the cable is in position in the engine compartment. Place the clutch cable in position in the engine compartment.
Press in the master cylinder. Lock using the striker plate.
Press the cable into the clutch cylinder. Lock using the striker plate.
Press the cable into the clip on the left-hand frame member.
Bleeding the clutch
Note: Unscrew the bleed screw until drops start to form. The version uses a rubber gasket instead of a cone.
Bleed the clutch.
Installing components, continued
Install
- integrated relay and fusebox.
- the cover on the side of the air cleaner (ACL) housing.
- the air cleaner (ACL) housing.
- the torque rod.
Finishing
Installing the battery lead
Install the battery lead.
Final check
Check the brake fluid level. Use only Volvo Genuine parts brake fluid (Volvo DOT 4+) when topping up. Start the engine. Check that the clutch disengages when the gears are selected. Bleed the clutch if necessary.