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broken clutch cable 700 1989

The clutch pedal on my 89 volvo 740 wagon dropped to the floor and I saw something bouncing across the road. Yup, the clutch cable failed and there is a frayed end visible. I found what dropped off the car onto the road...not sure what it is called but it is quite a heavy thick piece of metal (cast iron?) which appears to hold the cable end. Unfortunately, that piece also broke. I can find the cable through ipd but any suggestions of a source for that washer thingy and its rubber damper block? Also, this is the first time the clutch cable has failed. Should I order a spare or is this something that rarely happens?
Also, any tips and advice for this repair? Is this something that should be done by professionals? That said, I haven't had much luck finding quality mechanics for this volvo.








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    broken clutch cable 700 1989

    If you can't find a replacement clutch cable end weight ( I don't know what else to call it) and have all the parts, it can be brazed or welded back together.

    Greg








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    broken clutch cable 700 1989

    Try these guys. They would have the clutch cable too.
    they're in Atlanta.

    http://www.voluparts.com/








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      broken clutch cable 700 1989

      Thank you, CB
      I contacted Voluparts in Atlanta and the cable, rubber block and metal keyhole block thingy are on their way. This is a great resource for older volvo needs.








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        broken clutch cable 700 1989

        hi raven- good to hear you had a successful experience with voluparts. a few years ago i ordered a center plastic console which covers the hand brake and has a cubby holder from them for my 92 245. original console was shattered in the war. good service from mel at volup and didnt get soaked. dealer tried to shyster me. one question what brand cable did you get. brickers here advise to only get gemmo clutch cables for the volvo. havent had to replace one of them yet. let us know your installation experience. thanks tons oldduke








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        broken clutch cable 700 1989

        Once upon a time in 120/140/240/740/940 legend

        RPR - Rusty, Albany CA the Ultimate Volvoarian..retired...parts catalogue---Priceless
        IPD- Volvo/SAAB - Wash State...got bought out

        Current: In Atlanta - the sunny south Voluparts

        Cheers








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          broken clutch cable 700 1989

          thank you everyone for your thoughts and suggestions. As suggested, Voluparts in Atlanta came through with everything, including the heavy casted metal end piece. They had initially not sent it even though i requested it, because "noone has ever broken this piece." Well, when it hit the road, it fractured, so maybe this is a first.
          It took a friend and me about 2 hours to replace the cable. I am absolutely not mechanically intuitive, but i would like to be. (just like people who would love to draw, paint, or play a musical instrument but it is simply not that easy). Definitely a two person task, imo. That heavy end piece is weird how it sort of just hangs there with the right tension.
          I think that my clutch cable had some additional wear and tear because, a few years ago, the only recognized volvo repair facility in Alaska really messed up when they replaced the transmission. Looks as if i am going to need some driveshaft center bearing work, too. While not happy about this, i am happy that this volvo is still driveable.
          The cable that arrived looks exactly like what the ipd folks sell. It fit and appeared at least as durable as the original cable. But, while removing the clutch pedal cable end, i found a piece of duct tape wrapped over the connection. Is that something that volvo applies in Sweden? For the record, i applied another piece, just because it seemed like a good idea.
          I'm going for bigger things now....perhaps a timing belt change. Egads. Life skills 101. (p.s. raven 42 is a female animal doctor who struggles to understand other things because there seems to be a lack of quality work in many professions. As i said to one plumber..."If this was a dog, it would have died!")








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            broken clutch cable 700 1989

            Raven42 I think we are all glad you were able to complete the task. To answer your question regarding the duct tape--no, Volvo does not use duct tape to secure a clutch cable. Someone used what he/she had on hand. There should be a flat headed pin through the cable end with a small cotter pin inserted into a hole in the pin - or a split washer like clip that fits into a slot at the end of the pin (I'm not absolutely sure since I didn't even realize a 740 could be had with a clutch cable rather than a hydraulic system with a master and slave cylinder as I've seen in any standard shift 740 I've come across). Curiosity led me to take a look at the Rock Auto catalog and at least for 1989 they list both type systems. WHICH LEADS ME TO THIS NOTE -- one of the two cables listed had an excellent suggestion - to check that the motor had a proper ground cable attached to the body. The reason being that in the absents of a good ground the clutch cable can act as a ground itself and become brittle leading to failure. That happened to me with a Fiat -- after replacing a cable, failure followed shortly after. That led me to look further and I found no motor to body ground. With one installed the 2nd new cable lasted as expected.
            BTW--according to the "Hitch Hikers Guide To The Universe" 42 is the answer to "life, the universe and everything". -- Dave








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              broken clutch cable :any recent updates on available cables available? 700 1989

              hi raven, cb other 240 sages- inquired years ago about these cables and was told by more than one only to use gemmo cables which i think was the oe on 240s. have used the clutch a billion times since i got the 92 245 in 2011 and the original cable hasnt busted. due to warnings i bought a spare (pioneer brand)on a close out sale at a parts store and its been under the seat for years in case i get stranded on that dark desert highway at 4am with the clutch pedal on the floor. even bought another one (proparts of sweden)which i was later told is nfg. it hangs in my garage waiting to be drafted if needed. do you folks still perceive gemmo as the only way to go? incidentally i cant find gemmo anywhere except a dealer which requires a short term 2d mortgage. have times and perceptions changed on this one? thanks tons oldduke








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    broken clutch cable 700 1989

    I cannot believe that end broke. Yeah, it did bounce along the street but still surprised.
    Getting the cable off the Clutch pedal is not fun, not hard but just no room to work.
    The adjustment is fairly easy... there should be about 1/8" of slop before the clutch engages. That is; you should be able to push the Clutch Fork an 1/8", by hand, before it stops.
    No, these cables do not usually fail. No spare necessary. In fact usually they give you plenty of warning . They fray and the pedal gets stiff.

    Not sure where to get that end. Junk.. probably not. Maybe VOLVOFROMHECK (Dave)will chime in and have one.


    --
    '75 Jeep CJ5 345Hp ChevyPwrd, two motorcycles, '85 Pickup: The '89 Volvo is the newest vehicle I own. it wasn't Volvos safety , it was Longevity that sold me http://home.lyse.net/brox/TonyPage4.html http://cleanflametrap.com/tony/








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      broken clutch cable 700 1989

      Hi Tony--and thanks for the "endorsement". I do not have one of those heavy cast iron pieces. I think they were used as a "damper" of sorts. If the original poster can't locate one perhaps he can make up a distance piece to compensate for the extra length of the cable. 140, 160, and early 240 cars did not use any rubber cushion or weighted damper so the clutch fork will still function fine without the extras. I've never changed out a cable on a 740 but by removing the dash cluster on a 240 you gain better access - should be about the same for a 740. -- Dave








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        broken clutch cable 700 1989

        I'll have to remember the Cluster idea. A few Summers ago I worked myself into a lather trying to unhook, Grease and reinstall the cable, at the pedal. I had a slight squeak when depressing the clutch and it drove me nuts.
        It didn't help that my son would get in the car and rib me about it. " Hmm, hey dad, nice squeak you got there. Pretty embarrassing" I reminded him that the car is older then he is and if I stepped down on him I could make him squeak too. All in good fun
        --
        '75 Jeep CJ5 345Hp ChevyPwrd, two motorcycles, '85 Pickup: The '89 Volvo is the newest vehicle I own. it wasn't Volvos safety , it was Longevity that sold me http://home.lyse.net/brox/TonyPage4.html http://cleanflametrap.com/tony/







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