2004 XC70 Bread Clip Fix for an Aging AC Clutch

Post by **IdahoBob** » 21 Jun 2014, 23:34

The bread clip fix does work for newer Volvos.
Most of the posts on Matthews are for older series Volvos, so I wondered if it worked on newer Volvos.
I did this, this past weekend on my '04 XC70, and it works.
I suggest you look at YouTube. A guy in Texas ("TexasCoder"?) shows replacing the AC clutch on his '04 XC90. This will give you an idea of what the clutch looks like. Another guy shows installing the bread clips on his 850. The clutch looks the same: 850-XC70/S60-XC90. I also have an '02 S80 with the non-turbo 6 cylinder....same AC clutch.

What happens is that the clutch wears, and the gap between the clutch plate and the electro-magnet gets too wide. As the car & compressor gets hot, the electro-magnet's strength weakens (this is physics at work, not just your vehicle), and the magnet either can't pull the clutch plate to engage it, or it can't hold it engaged as it gets hotter. The gap is supposed to be .3-.5 mm. Both of mine (XC & S80) had worn to 1.0 mm.

Reach around through the wheel well (loosened and then pulled the splash guard out of the way, with car up on ramps) and insert a screwdriver between the spring and plate, twist the screwdriver and the gap between spring and plate opens, slide the solid end (not the bitey end) of a bread wrapper clip under each of the three round contacts (they're centered in each of the three loops). Use some gasket sealer to sorta glue them in place (let the glue dry before starting, or you'll sling it all over) and you're done. Look at the guy's video on doing this, this will all make sense.

If you don't have ramps, drive the right side up on a curb and slide under ( or "kerb" and left side, if that's your part of the world).

As an alternate, if you have all afternoon, and want to do some disassembly, remove the compressor from its mount (but, don't disconnect the gas lines!) and take the clutch off. You'll need a special tool ($30 bucks at the local parts place.) There are two .3 mm shims (look like washers) inside the shaft the clutch slides in on. If you remove the washers (one or both, the clutch plate will be that much closer to the electro-magnet.

Yes, this seems pretty 'shade tree mechanic'; but the dealer wanted $1200 to replace the entire compressor & recharge. I can get a replacement clutch, after-market on eBay for $100, or I can recycle three plastic bread clips, which may get me through another summer before spending $100 or 1200.

And, before someone tells me that this is going to destroy the compressor, please think about that. When your gear-shifting clutch gets worn, you adjust it. When you brake pads wear your rotors thinner, the calipers move the pads closer. I'm not seeing how 'adjusting' the clutch here is going to nuke my compressor. Enlighten me, please.

Happy Motoring!

Post by **abscate** » 22 Jun 2014, 03:22

I've never read here about anyone "running out of AC clutch lining" which is the only caveat to this fix. I currently have this fix on my 1999 and it is works great!

Post by **coflynn** » 22 Jun 2014, 05:16

Thanks for posting - was planning on shortly doing this to my '02 S60, and hadn't seen too many details on newer cars. It's rarely hot enough here that I've just kept putting it off

BTW here is a direct link to the YouTube video for anyone else:

Post by **chestermo** » 23 Jun 2014, 09:50

I did this on my 2001 S60 but I used zip ties. Worked like a charm. Still cold.

larrycrilley · Post by **larrycrilley** » 23 Jun 2014, 12:05

I used this theme on my 2001 V70XC. Instead of bread clips I used 3/8" washers. I cut them at 5 and 7 o'clock positions, held the clutch in place with spring clamp, installed the washers and crimped the opening insuring they would stay in place. the washers were the same thickness as the bread clips.
Now I am chillin'!

Post by **IdahoBob** » 13 Apr 2015, 19:21

It's that time of year again, even up here in NW Montana. Reached a scorching 49 degrees (F degrees), here today, so time to start saving bread clips. Thanks to Texas Coder for posting the YouTube! The clips on the '04 lasted all cooling season last year, including a drive to Florid and back. There's a guy on Swedespeed who has some photos showing how to remove the clutch and remove one of the shims inside the clutch. Same effect as bread clips, but not as embarrassing as when your paid mechanic asks about the bread clips.

Idaho Bob

Post by **abscate** » 14 Apr 2015, 07:07

AC in Montana, LOL!

Still have lots of friends in Bozeman from a stint I did there...