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Old 10-20-2010, 05:50 PM
v8volvo v8volvo is offline
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Join Date: Jun 2009
Location: Montana, USA
Vehicle: '86 745, '83 764
Posts: 1,618
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Glad to hear you got it sorted out. It seems like the pilot bearing is one of the only weaker links in the D24T/M46 drivetrain. My first Volvo diesel, an '85 745 TD with an M46, had the same problem. I went around the loop adjusting the clutch, replacing the cable, worrying about a broken clutch fork, etc. Nothing helped, it still had intermittent disengagement issues. Finally pulled it apart and found a seized pilot bearing. At 200k the clutch itself still had plenty of life left. I think it would have made it to 300k or beyond if the pilot bearing hadn't given up first. Mine wasn't exploded yet, but all the grease had left the building and it was on its way there.

Luk is a good choice, their stuff is always good quality (except for those leaky PD TDI fuel pumps...). Did they provide a new pilot bearing with the kit? If not, what brand did you go with for that? Seems like a good one of those is hard to find.

They are indeed fantastic cars to drive, and under-appreciated. They got a bad rep from people who didn't know how to maintain them, but those of us who have them and understand how to take care of them know better...
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86 745 D24T/ZF 345k lifted 2.5"
83 764 D24T/M46 155k
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