240 General: Master and Slave clutch cylinders

[Johnny64]

Hi, i dont know if anyone can help; my K reg Torslanda (107,000) estate has a clutch problem which i am fairly sure is hydraulic. I have been told that it needs a new clutch but there are none of the usual symptoms of a worn or slipping clutch. The problem is worse when the weather is very hot or cold and really bad in town or in slow traffic; the travel of the pedal becomes stiffer, 'scrunchy'/ notchy feeling and there is a distinct squeak which is hard to say where it comes from. during mild and slightly damp weather it operates at its best but is definitely getting worse. I have been told by one independent volvo specialist that they cant get replacement master and slave cylinders and that a repair kit is pointless (as are second hand spares).. Is this right? They said there are cheaper rubbish chinese ones but basically good luck in tracking down the bits you need. Anybody got any suggestions, advice, links to where i might get the parts etc?? i love my old beast and i'd be very grateful for any help

[classicswede]

Sounds like they just dont want to the very easy job more than anything else

slave is the same for all https://www.classicswede.org/shop/lu...=6060e5072a385

The master should be fed from the brake master cylinder bottle and will be this one https://www.classicswede.org/shop/cl...=6060e5072a385

It is an odd issue. I would try the slave/master first before pulling the gearbox

[Juular]

Pretty sure it's somewhere round about the slave as ClassicSwede says.

My first port of call would be the release arm itself, which might just be covered in corrosion and muck. Get someone to slowly pump the clutch while you stick your head in through the engine bay and see what the release arm is doing. It might just need a clean and some lube.

Squeaking / creaking is fairly normal on these. The gritty feeling isn't.

The good thing about these cars is the majority of the hydraulic system is extremely accessible, so you can go round the various components while someone pumps the clutch pedal. Stick your ear up to the master cylinder as well while you're there.

[Johnny64]

Thanks Classicswede and Juular, that all sounds like what i instinctively felt to be the case.. I intend to check out those things and have always felt that the sensible thing was to check linkages and hydraulics first. My 240 is hands-down the best, most reliable car ive ever owned and i get fed up with doom-mongers telling me that i wont be able to get parts etc and its not worth pursuing!

[Big 240]

Another thing to check, something that I found on mine the other day. Get your head under the drivers side and check where the clutch/brake assembly mounts to the body. I spotted a missing bolt on mine. This was making the frame of the assembly flex when the clutch pedal was pressed, causing me to lose full travel and the pedal always very weird. Fitted a bolt and it fixed the issue.

Just an easy check to do bud.

https://www.volvoforums.org.uk/showthread.php?t=329854

[Johnny64]

Thanks Big 240! Thats where i'll start looking, cheers for the tip!

[Johnny64]

Had a good look through the clutch pedal mountings and although no bolts missing, the mechanism was very dry and stiff so some lubrication helped. Then looked at the release arm and also rather dry so a clean and lubrication there also helped. An initial drive showed the operation to be improved but will see how it goes over the next week or so and report back! Thanks again everyone for your advice and support its really appreciated!

[Big 240]

That's a great start chap. Another thing I noticed recently after some more investigation was that there was a lot of movement on the pedal before the clutch started to engage etc. It appears that a nylon or rubber bush has worn away where the pedal links to the master cylinder.

I have circled on the pic where the link is, there's a pin that goes through and has a locking clip on the end. I've sourced some brass bushes and will try them out when they arrive. If you need one let me know and I'll post one.

[Johnny64]

Originally Posted by Big 240

That's a great start chap. Another thing I noticed recently after some more investigation was that there was a lot of movement on the pedal before the clutch started to engage etc. It appears that a nylon or rubber bush has worn away where the pedal links to the master cylinder.

I have circled on the pic where the link is, there's a pin that goes through and has a locking clip on the end. I've sourced some brass bushes and will try them out when they arrive. If you need one let me know and I'll post one.

Thanks! thats very kind, i'm going to have another, closer look when this awful wet weather stops (got nowhere under cover at present).. After the floods and muck on the roads of late its no surprise linkages etc get mucky and dried out- i guess its page one of (any) car care but checking, cleaning and lubricating throughout is essential!

[Big 240]

Agreed on the weather front, I'm getting most of my little jobs done over the weekends as I can dodge the rain. Even though I do have a double garage!!

These arrived yesterday and fit perfectly, really good tolerance. I am yet to try them in the pedal mech, but all looks good to me. I will update when fitted.