I have had to adjust the clutch on the 245 twice in the last month. The cable is in good shape it appears. But the clutch fork seems a bit loose in the transmission. I see that in the IPD catalog they offer replacement forks due to cracking??? How common is this and what are the symptoms ?? Any help is apprectiated.

Mike

The clutch fork can indeed crack. Mine did around 260k.

I got new one with complete clutch kit and had it installed.

But now two years later I still have to adjust the cable every so often as it does seem to back itself off.

I can't answer your question, but I can tell you that I have the same problem with my '86 244 DL. I only have to adjust mine once every 6 to 8 weeks, however, so I should consider myself lucky.

The original clutch cable in this car was replaced at 154K miles when I had a clutch job done due to a noisy pilot bearing. I've gone through two cables in the intervening 80K miles and have had adjustment issues with all three, including the VOLVO branded cable installed w/new clutch by a reputable indy Volvo garage. Both cables failed at the little "ball" (for lack of proper terminology) where the cable connects to the clutch pedal, not at the fork end.

I haven't been aware of cracked clutch forks, but they can be bent. Not an uncommon thing for the cable to back itself off, too. When my 245 was new sometime in the last century, the dealer service department put a hose clamp on it to try to hold it. They wound up replacing the cable, but told me that they clamp a lot of them.

I would buy that explanation. Its kinda of a cheesy plastic adjuster. Maybe I could put a witness mark or paint mark on the cable and see if thats what is happening. Thanks.