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Pelican Technical Article:

Clutch Replacement

Jared Fenton

Time:

7 hours7 hrs

Tab:

$500

Talent:

*****

Tools:

T40 Torx socket, clutch alignment tool, 10mm XZN driver,

Applicable Models:

Volvo C30 T5 (2008-13)
Volvo C30 T5 R-Design (2008-13)

Parts Required:

Clutch kit, flywheel bolts, flywheel

Hot Tip:

Follow the directions completely

Performance Gain:

Proper gear shifting

Complementary Modification:

Replace transmission fluid

One of the most common repair procedures for the C30 is the replacement of the clutch assembly. Unfortunately, it is a rather big process involving the removal of the transmission and other items. The good news is that it's really not a super-difficult job if you have some information and a few hints and tips. Disconnect the battery before you begin, as we will be working around the starter.

Before beginning, please see our articles on the following items. Most of these items will need to be removed to gain access to the clutch.

Jacking up your C30

Battery Replacement

Airbox Removal

Battery Box Removal

Transmission Removal

Axle Assembly Replacement

Front Subframe Removal

Engine and Transmission Mount Removal

Timing Belt Replacement

Starter Replacement

MAF Replacement

Rotate the engine to TDC and install the crankshaft lock.
Figure 1

Rotate the engine to TDC and install the crankshaft lock. This is to keep the clutch assembly and flywheel locked when removing and installing the new clutch. See out article on Timing Belt Replacement for more information.

Shown here are the components supplied with a typical clutch kit: the clutch disc (green arrow), the pressure plate (blue arrow), the combination release bearing and slave cylinder (purple arrow) and finally the clutch alignment tool (yellow arrow).
Figure 2

Shown here are the components supplied with a typical clutch kit: the clutch disc (green arrow), the pressure plate (blue arrow), the combination release bearing and slave cylinder (purple arrow) and finally the clutch alignment tool (yellow arrow).

Once the transmission is removed, use a T40 Torx socket or driver to remove the six bolts (green arrows) holding the pressure plate to the flywheel.
Figure 3

Once the transmission is removed, use a T40 Torx socket or driver to remove the six bolts (green arrows) holding the pressure plate to the flywheel. The clutch disc is sandwiched between these two components. Don't be surprised if a lot of clutch material pours out as dust. Remove the old pressure plate and clutch disc. 

Shown here is the flywheel.
Figure 4

Shown here is the flywheel. Note the glazing (purple arrow) along the surface of the flywheel. This is due to heat and/or abuse of the clutch. You'll likely find the same sort of glazing on the surface of the pressure plate. You'll need the flywheel to have a clean surface for the new clutch disc. This is called resurfacing. The flywheel is setup on a milling machine or lathe that machines down the old flywheel to remove the glazing. Often times, a flywheel is too far worn to be machined. In this case, you'll need to purchase a new one. Use a 10mm XZN socket to loosen and remove the ten (green arrows) holding the flywheel to the crankshaft. Then replace the flywheel using new bolts. Be sure to torque them to 45 Nm (33 ft/lbs).in a criss-cross pattern. Then turn each bolt an additional 65 degrees.

Fit the clutch alignment tool into the new clutch disc(green arrow), taking note of the writing on the clutch disc (purple arrow).
Figure 5

Fit the clutch alignment tool into the new clutch disc(green arrow), taking note of the writing on the clutch disc (purple arrow). Typically, there will be a label saying "gearbox side". This side must face the transmission. Now fit the clutch disc onto the flywheel. The tool will center the disc while you install the new pressure plate.

Now leave the tool in place and install the pressure plate.
Figure 6

Now leave the tool in place and install the pressure plate. Install the six T40 bolts (green arrows) and torque them in a criss-cross pattern to 27 Nm (20 ft/lbs.).  

Pull the clutch alignment tool out of the clutch disc and lightly lubricate the inside of the clutch disc splines with moly grease.
Figure 7

Pull the clutch alignment tool out of the clutch disc and lightly lubricate the inside of the clutch disc splines with moly grease.    

Fit the new combination release bearing/slave cylinder inside the transmission and secure it in place with the 8mm bolt (green arrow).
Figure 8

Fit the new combination release bearing/slave cylinder inside the transmission and secure it in place with the 8mm bolt (green arrow). Also lightly lubricate the splines of the transmission input shaft (purple arrow) with moly grease. This will make it easier to slide it into the clutch disc. At this point, you are ready to re-install the transmission and put the whole car back together. 

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