1
- Lift the bottom of the shift boot to expose the shifting socket.
- Use snap ring pliers to remove the circlip securing the shifter to its socket.
1986-1993 Volvo 240 Clutch Replacement
Step-by-step instructions
1
- Remove the 6 allen bolts securing the pressure plate to the flywheel.
- Remove the pressure plate.
2
- Remove the set screw securing the shifter yoke pin. This assembly can be located on the underside of the car, above the transmission and directly below the shift lever.
- Grab the head of the shifter yoke pin with your hands or pliers and pull it out.
- If the pin won't readily come free, try jiggling the shifter while you pull the pin.
2
- Remove the clutch by pulling it straight away from the flywheel.
- When reinstalling, use a centering tool like the one shown here.
3
- Remove the shift lever by pulling it straight up.
- Remove the plastic bushing in the bottom of the shifter socket.
4
- Remove the 6 nuts and bolts securing the drive shaft to the guibo and the back side of the transmission.
- Only four nuts and bolts are visible and marked in the first picture. The others are hidden on the other side of the drive shaft.
- Take note of how the bolts, washers and guibo are positioned. They are required to go back in the same way.
5
- Support the drive shaft with a jack, jack stand, or other prop so it does not fall and get damaged or injure someone when the support is removed.
- Remove the 4 bolts securing the drive shaft support.
- Do not lose the washers on the 4 bolts or the spring and washer on the opposite side of the support.
- Slowly lower the drive shaft and separate it from the transmission.
- Remove the guibo and metal separator plate.
- The separator may not come out with drive line and will be in the transmission.
6
- Remove the bolts securing the transmission to the engine and to the starter.
- Support the transmission so it doesn't fall when the final support is removed.
- Generally, a jack is recommended for this.
- Remove the four bolts securing the transmission support to the chassis.
- Lower the transmission out of the car.
- In many instances, the transmission may not come free from the engine once the bolts are removed. If this is the case, a pry bar is recommended to help separate the two.
Conclusion
To reassemble your device, follow these instructions in reverse order.
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