New Clutch - Pedal Goes to Floor

Asked by 93Volvo850_GA Dec 10, 2017 at 12:54 AM about the 1993 Volvo 850 GLT

Question type: Maintenance & Repair

I replaced the clutch in my 1993 Volvo 850 (non-turbo) and cannot get the
clutch to bleed. I replaced the clutch master slave cylinder and the clutch
master cylinder. I have tried bleeding by having someone press the pedal,
opening and closing the bleed valve, and repeating. I have also tried using a
gravity bleed method. After many hours, I still have a pedal that drops
straight to the floor. I am starting to think I messed up the clutch fork when I
put it together. Is there a fairly easy way to verify this without taking it all
apart, again? I am a DIY mechanic with moderate skills/ability and did this in
my driveway, so I am not 100% confident.

45,155

jamnblues answered 6 years ago

right- assume first, that you did the mechanical part right- it is too hard to take it apart again- I hate bleeding these things- worse than brakes- keep trying to get air out- I would even tow it to a mechanic before I take that thing apart again-

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93Volvo850_GA answered 6 years ago

The system seems to be properly bled now and the pedal returns as it should. However, the pedal only goes down about 3 inches, instead of the usual 9 or so. It feels like maybe the fork isn't properly engaged with the throwout bearing. When running, the car won't go into gear, so the clutch is not engaging. Is it possible to get the fork repositioned with the throwout bearing without taking the engine and transmission apart? I removed the snap ring from the slave cylinder and moved that back a bit and the fork seems to move around way too much. Shouldn't it feel secure?

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