Clutch won't disengage after new install - Ideas?

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ttermyna
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Year and Model: 1999 V70
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Clutch won't disengage after new install - Ideas?

Postby ttermyna » Tue Jan 26, 2010 12:21 am

I'm stumped. New clutch, pressure plate, throwout/slave installed this past weekend in my 1999 V70. Flywheel was resurfaced, machinist told me he took off close to 20,000ths of an inch. Everything went back together fine, initially I was worried when I couldn't get any clutch pedal feel but after some reading here >>> http://www.jimrothe.com/volvo/clutch_bl ... html#volvo
and the purchase of a motive bleeder, that problem has been solved.
After the hydraulic line was pressure bled, I attempted to put the car in gear. The synchos engaged slightly and the car tugged forward, but not nearly enough to really move it. The VADIS software shows some models with a self adjusting clutch mechanism which appear to need compression, but the clutch which was installed/replaced on the car was not this type. My mechanic friend and I are at a loss but have these ideas:
1) The machinist seemed to indicate 20,000ths of an inch on the flywheel is a good deal of metal. Apparently the flywheel was "cupped" which he said is typical due to heating for thinner dual mass flywheels. Does this amount seem unusual? Should spacers be used behind the flywheel?
2) Is there any sort of adjustment on the pressure plate which we may have missed?
I would like to get an idea of what this might be before we resort to tearing everything out again. Thanks in advance>>>Troy

vegasjetskier
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Re: Clutch won't disengage after new install - Ideas?

Postby vegasjetskier » Tue Jan 26, 2010 1:24 am

Are you sure you have all of the air out of the hydraulic line?
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Re: Clutch won't disengage after new install - Ideas?

Postby Ozark Lee » Tue Jan 26, 2010 1:51 am

Are you sure the clutch disc was installed back in the proper orientation? There is a front and back side.

The reason I ask is that I once put a new clutch into a 740 backwards and it behaved very much as you describe.

...Lee
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Re: Clutch won't disengage after new install - Ideas?

Postby FCPEURO » Tue Jan 26, 2010 1:54 am

+1

It sounds like the clutch disc it backwards or the line has a lot of air in it. I would try and bleed the line first and see if that helps the issue. If it doesn't, you will need to pull the transmission out and check the clutch itself.

ttermyna
Posts: 56
Joined: Thu Dec 10, 2009 10:35 pm
Year and Model: 1999 V70
Location: PA

Re: Clutch won't disengage after new install - Ideas?

Postby ttermyna » Tue Jan 26, 2010 2:39 am

Thanks for the responses all. Will try to bleed a few more times before we go back in. Will post what I find. I had hoped to make a "how to" out of this little project but at this point it's more like "how not to".

ttermyna
Posts: 56
Joined: Thu Dec 10, 2009 10:35 pm
Year and Model: 1999 V70
Location: PA

Re: Clutch won't disengage after new install - Ideas?

Postby ttermyna » Thu Jan 28, 2010 12:06 am

Update:
Clutch was bled again, still no dice. Dropped transmission, clutch disc is installed correctly. Has anyone here ever needed to shim the flywheel after resurfacing? Does anyone know how much travel the throwout bearing should have?

cattledog
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Re: Clutch won't disengage after new install - Ideas?

Postby cattledog » Thu Jan 28, 2010 12:14 am

Does the pedal "feel" normal.
Never heard of shimming a flywheel, nor would I recommend, if it's that bad, replace.
We used to back bleed saab clutch slave cylinders off of the front brake caliper.

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Re: Clutch won't disengage after new install - Ideas?

Postby larryh » Thu Jan 28, 2010 12:26 am

is the cluch fork ok? i had a cracked/bent fork in a truck of mine. acted similar

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Re: Clutch won't disengage after new install - Ideas?

Postby vegasjetskier » Thu Jan 28, 2010 12:38 am

ttermyna wrote:Update:
Clutch was bled again, still no dice. Dropped transmission, clutch disc is installed correctly. Has anyone here ever needed to shim the flywheel after resurfacing? Does anyone know how much travel the throwout bearing should have?


You shouldn't have to shim it. They took 20 thousandths off of the entire flywheel surface, right?

I helped my stepson put a new clutch in his Ford pickup and it took forever to get it to work. The master cylinder was mounted at an angle and an air bubble got stuck at the top. We bled it for 4 straight hours and couldn't get it to work. Finally I had to take the piston out of the cylinder (from inside the car) and fill it with fluid to eliminate the air bubble. Then it worked. I don't know if the Volvo design is similar or not.

If you're sure there's no air in the line, then I suspect that the new clutch disk is too thick or you have the wrong pressure plate.
.

SOLD - 2001 Volvo S80 T6: Mobil 1 Oil & Synthetic ATF, Brake Performance drilled and slotted front rotors, Akebono Euro Ceramic pads and Yokohama Avid V4S tires, 91K miles.

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ttermyna
Posts: 56
Joined: Thu Dec 10, 2009 10:35 pm
Year and Model: 1999 V70
Location: PA

Re: Clutch won't disengage after new install - Ideas?

Postby ttermyna » Thu Jan 28, 2010 12:52 am

Pedal feel is normal, or what i suppose is normal (bought the car with the clutch on the way out and it was really stiff.) It feels more resistant than the wife's S40, but less than it was. As far as bleeding off the brakes, isn't the system separate from the clutch (two part reservoir?) Thanks for the responses.


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