1993 850 Clutch Not Disengaging

Jaydotscott96 · Post by **Jaydotscott96** » 07 Aug 2024, 18:40

I have a 1993 850 I bought with a non functioning transmission. Previous owner did something to cause a small piece inside the transmission to shear off and caused the car to not go into gear, when you tried to shift it just sprung back to the center. So I installed a donor transmission out of a 1994 850 along with a new friction disc and pressure plate. The problem I'm running into is:

The slave cylinder is not pushing the clutch fork far enough for the throw out bearing the disengage the friction disc from the flywheel. I can shift the transmission into gear no problem when the engine is off but if the engine is on I can not shift the transmission into gear. I have to force it and even then it does not go into gear, I don't want to push harder and break anything.

The slave cylinder doesn't appear to be leaking, the clutch fork does not slowly go back towards the slave when the clutch is depressed like it would if there was a leak in the hydraulic system.

I am stumped and any help is greatly appreciated.

Also, my coworker stuck a pry bar behind the clutch fork and with the motor on we were able to get it into gear and when he slowly let off the pry bar the clutch engaged and the car started to move.

Post by **foggydogg** » 07 Aug 2024, 19:23

Call Robert Spinner, of RobertDIY fame. His cell number is on his website. He ran into this same problem a few years ago, but I can't dig up that Y/T vid at the moment.

Post by **Goupil** » 08 Aug 2024, 09:54

There's a small plastic piece that clips onto the fork and sits between the fork and the ball it pivots onto, do you remember if it was there?
https://www.skandix.de/en/spare-parts/d ... k/1023076/
(the original factory one is white iirc)

Post by **scot850** » 08 Aug 2024, 10:28

Not sure of the P80 clutch forks, but if Goupil's suggestion to check is not the issue, check if the clutch forks are bent. Over the years I have seen this a few times.

Does the peddle travel and pressure feel normal?

Last think, I may be wrong, but in the early years Volvo refined stuff constantly. I think there was a clutch change early on due to an issue with bent forks.

Neil.

Jaydotscott96 · Post by **Jaydotscott96** » 08 Aug 2024, 16:49

scot850: I actually used the clutch fork from my donor trans that came out of the 94 wagon. This is the style fork where its one full cast piece as opposed to the one that came with my 1993 which is welded together. I think that's what you're thinking?
Clutch pedal feels a little soft but not spongey. When I press the clutch in the slave actuates the clutch fork properly, just not far enough.

Goupil: Yes! There was not one in my donor trans fork but I ordered one from Robert. He couldn't find the new ones he has stocked so he sent me a used one. Not sure if that would make a difference. Its a tan color as opposed to the Skandix black plastic color.

Foggydogg: I actually spoke to him recently and he said my clutch friction disc was installed backwards and that was my culprit...
I want to trust his wisdom as he works on these cars every day but I triple checked that I had the disc facing properly and I didnt have any problem tightening the pressure plate bolts to the flywheel. I feel if it was backwards there would be resistance when tightening those bolts. I dont know, that may be my problem... but galdarnit I know I had that disc in there properly. It took me literally months to get the old trans out because I had the vehicle at my friends house as I live in an apartment with only 1 parking spot. So I'm trying every option to see if there could be any other problem...

Post by **abscate** » 12 Aug 2024, 08:41

The clutch disc will go in either way, and only work one way. I almost screwed that up, you have to turn up the gain on the Situational Awareness Op Amp to maximum

Post by **scot850** » 12 Aug 2024, 15:35

Been a long time since I did a clutch replacement on a manual. Fortunately for me they usually had a clear instruction which face should be onto the flywheel thankfully!

Neil.

Post by **foggydogg** » 13 Aug 2024, 21:24

As I recall he had an issue once with putting the wrong juice in the master, and the used slave he installed just didn't like the stuff.
Once all the little things are eliminated, there could be a round trip coming. At least there won't be any frozen bolts. It always goes twice as fast the second time.
Just for the sake of information, try to get a really precise measurement of the travel as is, and ask for comparison numbers.