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Re: Chronic clutch cable stretch? 200 83

I had similar clutch cable problems on my 144, although my cable would always break before it stretched beyond further adjustment.

First, check and clean the ground strap connections from the chassis to the block. If the ground is bad then the clutch cable gets used as the ground path which can hasten the cable getting brittle.

Second, make sure you're using a genuine Volvo cable. Others may be a slightly different length or of a lesser quality.

Next, you really need to examine a broken cable. If the cable is breaking near the ends then likely the cable isn't routed correctly so it is aligned properly with the cable attachment points. Similarly, the clutch pedal and yoke travel must be in alignment with the cable attachment points. If the cable is breaking near the middle then the cable might be routed with too sharp a bend. Neither situation was obvious in my case, but cable routing turned out to be my problem.

If you don't have a broken cable yet, you should still unhook the cable ends and check it. Pull the cable wire fully in both directions and check for any signs of fraying. If there is any resistance when doing this then the internal cable sheath may have worn through and you likely have some rust starting to bind it. This could well be a sign of incorrect routing. If you turn the cable over 180 degrees so that the cable strands bear against a fresh surface you may be able to get a little more life out of it. I always lubed the heck out a new cable before installing it, if nothing else to keep moisture out.

Hopefully that will give you some ideas.






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