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S60 AC Clutch Shim Fix

Help, Advice, Owners' Discussion and DIY Tutorials on Volvo's stylish, distinctive "P2" platform cars.

2001 - 2007 V70
2004 - 2007 V70 R
2001 - 2007 XC-70
2001 - 2009 S60
2003 - 2007 S60 R

fazool
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Year and Model: S60, 2007
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S60 AC Clutch Shim Fix

Post by fazool » Sat Aug 27, 2011 10:22 am

By now most everyone has heard of the "bread tag" AC clutch fix. This worked for my 2001 S60 AC so I am sharing the details which are particular to the S60.

Some introductory comments, first:

My 2001 exhibited the classic symptoms: AC runs cold for 10 minutes then blows hot air. Checking under the hood, the clutch was disengaged. I tried tapping with a broom but with no effect.

The electro-magnetic clutch plate is extremely sensitive to setup. It has to be spaced with a gap (see below) between 0.3-0.6mm or about .012-.024 inches

The spacing is determined by TWO factors: 1) the metal shims on the inside and 2) the rubber bumpers which stop the clutch plate from moving OUTWARD. Its a stack-up. Simply think of it as spring-->bumber-->plate-->shim-->clutch

The shims wear and get thinner. Other parts wear as well. The shim removal process describes removing a shim to bring the plate closer to the clutch. That's one way. I've read some people claim the bread clip is wrong. Technically it is wrong but the rubber bumbers (nder heat and vibration and pressure) are just as likely to lose some height as the metal shims. So I would contend that replacing the rubber bumpers would help fix the gap problem too. The bread clip is a quick fix to the bumpers. That suggests that it is a perfectly reasonable fix. People's success with it (for years of healthy operation) support that suggestion.

OK, on to the S60 details:

[email protected]'s nicely detailed post describes the procedure for an 850-series car
http://www.matthewsvolvosite.com/forums ... 0&start=28


Some differences exist from the 850, however. I tried removing and accessing through the passenger wheel well. That doesn't work on the S60 since the compressor is too far forward.

If you don't have foglights, you can use the foglight opening as a nice access point to get a screwdriver in to the clutch.

OK, first thing you need is a cheap feeler gauge (at Harbor Freight Tools for $2.99).

Looking down from above the compressor I labeled the important points with colored arrows in the photo below.

Image


The yellow arrow shows where to measure the gap. If it is greater than 0.6 mm (0.24") then it is out of spec and needs to be corrected.

To do this, you will slip a shim under each of the three bumpers. Two of the three bumper locations can be seen by the green arrows in the photo.

The easiest wat to do this will be to place a flat bladed screwdriver in the space shown by the blue arrow. Then you can turn the screwdriver which will push the plate inward. While doing this you can slip a shim under the rubber bumper.


Calculate your gap size and determine your needed shim thickness. I needed a .4-.5mm shim. I found a plastic No Trespassing sign that was just the right thickness. That was my raw shim material.


Image


After examining the shape and cutting 1 or 2 trial shims, I came up with a good size and shape shown below. This is a good size so it won't slip out. The kidney-shape is to clear a rivet you will see when placing it.

Image


To access the clutch, jack your front passenger wheel. Block the tires and place a jackstand under the frame for safety.

Crawl under the lifted bumber and remove one bolt holding the splash/stone guard, allowing it to hang down. Pull the overflow tube off its holder on the fram and let it hang to the side. Remove the foglight hole insert. This whole process only requires one bolt removal so its super easy.

Image

Using the technique described above, slitp a shim under a rubber bumper, then rotate the clutch by hand and repeat for the other two.

Image

2007 S60 2.5T AWD (Daily Driver)
2001 S60 2.4T (Daughter's Car)
2003 S80 2.9 (Son's Car)
1995 850 2.4 (Daughter's Car - sold off)
2005 S40 2.4i (Bought new - since sold)
1986 740GLE 2.3(First Volvo - sold off)

DGM
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Year and Model: V70 2.4i 2005
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Re: S60 AC Clutch Shim Fix

Post by DGM » Sat Aug 27, 2011 12:01 pm

It is a clever idea and more elegant than the bread clip fix.

Your write up is easy to follow and understand.

Thanks for sharing it.
V70 2005 2.4i 195,000km, sold
S70 1998 T5 355,000km, sold
960 1994 80,000km, sold
760 1990 Turbo 265,000km, sold

fazool
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Year and Model: S60, 2007
Location: buffalo, NY
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fazool

Re: S60 AC Clutch Shim Fix

Post by fazool » Sat Aug 27, 2011 3:55 pm

Quick update:

I took the vehicle on a 30 mile test drive and everything was fine. AC worked perfectly. Wife took the car shopping and came back with the AC off. Upon inspection I saw 2 of the plastic shims dislodged and fell out. I replaced all three with metal shim material. I made them a little longer and smothered them in crazy glue.

So far so good

2007 S60 2.5T AWD (Daily Driver)
2001 S60 2.4T (Daughter's Car)
2003 S80 2.9 (Son's Car)
1995 850 2.4 (Daughter's Car - sold off)
2005 S40 2.4i (Bought new - since sold)
1986 740GLE 2.3(First Volvo - sold off)

fazool
Posts: 747
Joined: Sat Feb 06, 2010 1:17 pm
Year and Model: S60, 2007
Location: buffalo, NY
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fazool

Re: S60 AC Clutch Shim Fix

Post by fazool » Sun Aug 28, 2011 9:05 pm

Update:

The metal shims are holding in place nicely. Everything looks good so far and the AC is working fine.

2007 S60 2.5T AWD (Daily Driver)
2001 S60 2.4T (Daughter's Car)
2003 S80 2.9 (Son's Car)
1995 850 2.4 (Daughter's Car - sold off)
2005 S40 2.4i (Bought new - since sold)
1986 740GLE 2.3(First Volvo - sold off)

toyznstuff
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Joined: Sun Jun 10, 2012 10:19 pm
Year and Model: V40 2000
Location: California
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toyznstuff

Re: S60/V40 AC Clutch Shim Fix

Post by toyznstuff » Mon Jun 11, 2012 3:24 pm

2000 V40 w/ NO Air Conditioning. Tried this, denada, neien, niet, nothing. the AC clutch still does not turn... used different space shims & zilch. Any suggestions about tracing this down??? Would a clutch shim removing the clutch be the next step? Not so certain on how "smart" these Volvo engineers/designers are w/their "safety" B.S.? Might be a safe car but a LOT of design flaws, especially a decent console w/a coffee cup holders, 2 NOT just one goofy one. For someone who never changed a design in years, the late '90's & early 2000's are very, very different...

toyznstuff
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Re: S60 AC Clutch Shim Fix

Post by toyznstuff » Mon Jun 11, 2012 3:26 pm

This is a very good submission (S60 clutch shim), just didn't work for me...

LionelHutz
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Re: S60 AC Clutch Shim Fix

Post by LionelHutz » Sun Jul 08, 2012 5:53 pm

I am trying this on my 99 S70 and noticed that the rubber bumpers are worn, one is almost entirely gone and the other two are decent.

Should this affect the size of my shim? Or can I use the same one all the way around?

Is it possible to narrow the gap TOO much?

JimBee
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Re: S60 AC Clutch Shim Fix

Post by JimBee » Sun Jul 08, 2012 8:42 pm


db130
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db130

Re: S60 AC Clutch Shim Fix

Post by db130 » Fri May 15, 2015 7:18 pm

I just wanted to thank the OP for the great pictures. I had previously tried the bread clip fix on my departed S70 with success and I was hoping for similar success with my NA V70.

I tried this tonight My thickest feeler gauge which is .024" easily slipped through the gap. I used 3 e-clips from Dorman kit 13325(probably the 3/16" ones mentioned here

and the gap was .018-.019" afterwards which is within spec.
2002 V70 T5 169k
2002 V70 NA 249k
2006 Mini Cooper S 90k

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