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"I need to replace a clutch cable on an 1987 240(230K miles). Can anyone tell how difficult this is? Any tricks?"
I went through this not long ago. Removing/installing the clutch cable is easy unless the new cable doesn't open up far enough for it to stretch over the "big metal thing" it attaches to behind the release arm. On the original (Volvo) cable the adjuster nut can ride all the way down the cable so there's no question of having enough slack to work with. My replacement was a Sachs cable and it has limited adjustment, not enough to fit over that big heavy metal thing behind the release arm when the release arm is in the clutch-engaged position.
Someone else said he had the same problem. I think he used a clamp to pull the release arm toward the front of the car, giving enough slack to put it in place. He said it was a real pain. I just put the old cable back on; I'll deal with it later.
Here's a picture of my old and new cables so you can see what I'm babbling about:
On the original the adjusting nut spirals down the cable housing. It can go all the way to the other end of the cable.
You can see on the new cable the adjuster runs up and down a length of nylon threads. It can only go so far.
Bottom line:
- if you get a cable just like the original it is really easy to replace.
- if the new cable has a limited amount of adjustability it might be difficult. I'm not saying it will be a pain, but it was for me and at least one other person.
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