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-   -   JJs Project Thread - 240 GL Estate (https://www.volvoforums.org.uk/showthread.php?t=322745)

Problemchild1976 Jan 29th, 2022 17:54

Put some cheapo mats in the car today

https://i.imgur.com/mrcFrARl.jpg

https://i.imgur.com/Oo9Rd45l.jpg

Not bad for £25


Also refitted the replacement chrome trim around the back with new clips

https://i.imgur.com/dwr9GVOl.jpg

Plus added 10bhp with this

https://i.imgur.com/snTgtJll.jpg


JJ

Othen Jan 29th, 2022 19:51

Quote:

Originally Posted by Problemchild1976 (Post 2803808)
Put some cheapo mats in the car today



Not bad for £25


Also refitted the replacement chrome trim around the back with new clips

Plus added 10bhp with this


JJ

Don't get too carried away spending money down at that car accessories store :-)

Alan

Problemchild1976 Jan 29th, 2022 19:58

Quote:

Originally Posted by Othen (Post 2803836)
Don't get too carried away spending money down at that car accessories store :-)

Alan

Damn that eBay :)

It’s a hobby right?

I have 30+ RC cars so I’m just changing where I spend my hobby fund ;)

JJ

Problemchild1976 Feb 7th, 2022 19:08

So with the clutch playing up and the master cylinder clearly leaking I ordered a new master cylinder from classic swede for about £60

So first thing was to take out the front seats to be able to get on my back

https://i.imgur.com/tnAh5pgl.jpg

Once out - on my back in the footwell and feet on the rear seats….

Can just about see the clutch master cylinder as it comes through the firewall

https://i.imgur.com/VIpcxCVl.jpg

Here you can just about see one of the nuts that hold the master cylinder though the firewall.

First thing is to remove the clip that holds the pin that joins the clutch pedal arm and the master cylinder (as seen in the image above)

It’s fiddly but once you see how it works then you can free it

https://i.imgur.com/0PzZJSrl.jpg

I used a 2 pronged trim removal tool to wedge in and remove

https://i.imgur.com/TGlf549l.jpg

Once it’s disconnected you can (with massive difficulty) remove the 2 x nuts

https://i.imgur.com/ImIjjqNl.jpg

And undoing the pipe from the end of the master cylinder under the bonnet allows the cylinder just to slip out

https://i.imgur.com/jfTPpmFl.jpg

leaving a nice hole

https://i.imgur.com/7REZoeRl.jpg

Here is a pic of the new one vs the old one - you can see how much leakage there is

https://i.imgur.com/Uf8Rc7Pl.jpg

Fitting the new one is the same as removal

You defo need someone to hold the master cylinder in place from outside the car while it’s screwed in from the inside

Then fill and bleed - I’ve not bled yet

I also got a slave cylinder delivered at the same time as it was only about £20

Good luck

JJ

foggyjames Feb 16th, 2022 11:13

Note the ovalled hole where the pedal attaches to the push-rod. I've welded a couple of those up before!

cheers

James

Problemchild1976 Feb 16th, 2022 22:17

Quote:

Originally Posted by foggyjames (Post 2808045)
Note the ovalled hole where the pedal attaches to the push-rod. I've welded a couple of those up before!

cheers

James

Thanks mate - yeah the pedal arm hole was elongated too so I have an inch of travel before actuation.

If I could fix with the pedal arm in situ I would

JJ

Bob Meadows Feb 17th, 2022 10:37

JJ:~
Out of interest do you think that the old unit is repairable?
Could be useful for other members with the same problem.
Regards Bob.

Problemchild1976 Feb 17th, 2022 20:20

Quote:

Originally Posted by Bob Meadows (Post 2808289)
JJ:~
Out of interest do you think that the old unit is repairable?
Could be useful for other members with the same problem.
Regards Bob.

Well if someone wants it for free……

JJ

Bob Meadows Feb 17th, 2022 20:37

I'd enjoy the tinkering:~ private mail sent.
Regards Bob.

Problemchild1976 Mar 2nd, 2022 00:23

Quote:

Originally Posted by Bob Meadows (Post 2808462)
I'd enjoy the tinkering:~ private mail sent.
Regards Bob.

Hi mate - sorry I’ve been trying to reply but I can’t

If you want it then it’s yours

JJ


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