I searched for advice about this but the posts arent very specific. My clutch cable snapped so I bought a replacement from a local volvo garage. It's a "Pex" version, I asked why they didn't carry OEM and they said this is just as good. Anyway I got down to replacing it and it is very very hard to get the ball end into the clutch fork when the pedal end is already connected. I figure the only way to get it on is to fully depress the fork, which takes considerable effort with a pry bar. Does this sound normal to have so little play to work with? If I do manage to get it on this way will it even engage properly?

Thanks for the reply. I know exactly what you're saying but the thing is the "sheath" (plastic part with threading) doesnt want to fit into the grommet. Is the grommet threaded already or is it just a matter of jamming it in? Don't want to force it as the piece looks fragile as it is.

I have to admit it's been a very long time since changing a 240 clutch cable. My recollection is that the early cars had a threaded end cap and a locking nut on the far side. Later cars had only the adjusting collar on the forward side which moved the sheath back and forth. Sounds like you need to remove the part you called the grommet from the bellhousing bracket and fit it directly onto the cable before inserting the cable through the bracket (does the new cable already have this grommet???). -- Dave

FIXED! Thanks man, no wonder. The part I described was leftovers from the old cable that had become so thoroughly wedged into the bracket that I thought it belonged in there. Punched it out with a hammer and screwdriver. New one is in and adjusted. The volvo is back!

the "grommet" i refer to is inside the bracket that the cable is supposed to slip through in front of the clutch fork. A thick rubber bushing type piece that sits inside. the "sheath" part doesnt want to slip through the hole in the center. Maybe I have to drill out some of the material to make it fit, I dunno. I'm tired of having my Volvo sitting around.

This is not normal---unless you aren't installing the cable properly. If you adjust the sheath so all, or the majority of the adjustment range is inserted into the bracket there should be no problem attaching the cable end to the fork. After attachment, you back off the adjustment till the proper free play is attained. -- Dave

replied to the wrong message.