1(5) New tool for installing clutch driven plate and pressure plate. Special tools: 999 5662-5, 999 5663-3 It is very important to center the clutch driven plate and pressure plate is very important when they are installed in order to provide 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 tool 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. 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.) These tools will be sent out on subscription in May 1996. They can also be ordered from Volvo Car Corporation, Aftersales. Removing clutch driven plate and pressure plate See also Clutch driven plate and pressure plate, replacement and checking 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:
2(5) Unscrew the center screw until the tool can easily be hooked under the edge of the clutch housing. (See also Position the press tool on the pressure plate diaphragm spring. ). 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 the centering tools. 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 centering tool. 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 tighten with a tool, as the cone may damage the clutch driven plate and damping springs. Unscrew the press tool center screw completely.
3(5) 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: - - If 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 more! 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 a turn and check. Turn the center screw a half turn at a time until the pressure plate is flat against the flywheel. Caution! 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 too long, max. 24 hours! Relieve pressure on the diaphragm spring as soon as possible. Install pressure plate with press tool on the flywheel
4(5) 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. 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. Checking and removing throwout bearing and throwout fork. Remove throwout bearing Remove throwout bearing from the guide sleeve and throwout fork. Remove throwout fork and dust cover. Check guide sleeve for damage. Replace guide sleeve if it is worn or burred.
5(5) Clean components Check throwout bearing. Lightly turn bearing. bearing should rotate freely and silently. Check the throwout fork for cracking and wear. Check that the throwout fork ball joint is intact. If the throwout fork has a plastic ball joint replace the ball joint. Check that the dust cover is intact.