Clutch replacement and part number search

[Nevadan]

This is a new thread following up from my "snapped camshaft at idle" thread that wandered from the camshaft to the clutch job. Original thread is here: http://www.d24t.com/showthread.php?p=6867#post6867

The clutch disk I used was from the Sachs clutch kit pictured below, the same kit that v8volvo used but is now very difficult to find. It's in the AutohausAZ kit part number 271265 (Sachs kit number K70029-03) with a Sachs pressure plate number 3082 204 032. There may be a specific Sachs part number for the disk printed on the side of the box below the 3082 204 032 number. The number just below that is 1851 901 134 (I need to verify this number as correct since it's hard to tell from the picture) and there's a few other numbers below that but they're covered by the Autohaus sticker. I'll pull that sticker and get the other part numbers. I'm thinking there's one for the throw-out bearing and one for the pilot bearing (which is the wrong bearing). The complete kit was $215 plus shipping. If I recall correctly the kit was listed under the 1983 Volvo 760, not under the 1985 Volvo 745.



Here's a picture of the Sachs kit that shows all the part numbers of each item contained in the kit:



Here's a picture that shows the pressure plate part number in the above kit:



The disk that came in the kit is the one on the left in both of the following pictures. The disk on the right is from the O'Riely Power Torque kit mentioned below:




Here's pictures of the original pressure plate and the Sachs pressure plate that came in the kit:

[Nevadan]

Originally Posted by v8volvo

What is the Sachs part number for the friction disc? I haven't been able to find one from any of the suppliers I have tried.... I used to be able to get the complete Sachs kit, part # 271265, but can't get it anymore.

About your findings performing your power-brake test -- did you have someone watching both rear wheels? Volvos use a very heavy brake bias towards the front and a dual-circuit hydraulic system where each rear break is on a separate circuit, which depending on the condition of everything can lead to a little more application force on one wheel than on the other -- plus you have the open differential which, in my cars at least, always seems to have a noticeable bias towards the right side rear wheel. I wonder if the scraping sound you heard was one rear wheel still spinning?

See my reference to the AutohausAZ kit above. I don't know what the separate part number for the disk is yet.

Then, about the clutch test. I did not have anyone watching both rear wheels and I didn't push the brake pedal REAL hard so it may just have been that I wasn't putting enough pressure on the pedal to fully stop the rear axle from turning. Your description sounds like that's what was happening. When I drove my 30 mile test it all seemed fine but I'll do a more thorough test drive this weekend.

[Nevadan]

Originally Posted by 745 TurboGreasel

I'd be worried if I couldn't stall the car in every gear using the brakes.

I know Volvo uses some flywheels with a flat surface, and some have a dished grind. If you use the wrong parts, or a machine shop has ground your dished flywheel flat, there isn't enough surface area, and it slips.
To me, this disc looks burnt to hell in one ring, and new in the rest?
I think I have a Sachs disc I can still read the numbers on, I'll dig that up later.

Where was the red powdered metal coming from?

I'll re-do my test and have someone watch both rear wheels so I know exactly what's happening.

You can see the clutch kit above that I used so I'm thinking it's just an incorrect test I performed.

That burnt clutch disk was the one I took out of my "new" 1983 745 which had 203,000 miles on it and the used car store I bought it from had purchased it from a guy in San Francisco. Based on my pictures of the throw-out bearing and wear on the original pressure plate spring contact point I would say that clutch got used a lot.

About the red powered metal....I'm not sure. I think it's just a mixture of clutch disk dust and flywheel/pressure plate dust combined with the Bay Area moisture.

[Nevadan]

Before finally ending up with the AutohausAZ kit 271265 (Sachs kit K70029-03) I ordered several different kits that probably would have worked but didn't have the same clutch disk with the extra spring set.

Autozone kit number NU31153 would have worked. They also had a kit number NU31153-1 that looked like it had the correct disk but I had already received the AutohausAZ kit by that time. I would definitely try Autozone for this kit. It's a Duralast product. If you look at a picture of this disk here: http://www.autozone.com/autozone/par...er=245009_0_0_ it looks like it will fit around the two flywheel pins shown below. The Sachs pressure plate had to be ground a little to fit around the pins.



O'Riely has a kit K70029-02 that also would have worked but it had the disk without the extra spring set. It was a PTQ, Power Torque kit with the AP pressure plate and the PHC Valeo disk. I didn't check to see if they had the K70029-03 kit with the proper disk. Here's a picture of that kit:


Rock Auto has 2 remaining K70029-03 kits available right now.

There's also a few of the K70029-03 kits on eBay right now.

None of these kits have the correct pilot bearing but look at the linked thread in the first post here for that discussion and part number.

It would also be helpful to have a part number for the sleeve that goes over the transmission shaft that then fits into the pilot bearing, pictured here:


The bottom line is that the original clutch disk with the extra spring set was hard to find. With the above known kit numbers it should be a lot easier. I will get the part number from underneath the AutohausAZ sticker to see if there's a separate part number for the disk only.

[745 TurboGreasel]

Originally Posted by Nevadan

That burnt clutch disk was the one I took out of my "new" 1983 745 which had 203,000 miles on it and the used car store I bought it from had purchased it from a guy in San Francisco. Based on my pictures of the throw-out bearing and wear on the original pressure plate spring contact point I would say that clutch got used a lot.

About the red powered metal....I'm not sure. I think it's just a mixture of clutch disk dust and flywheel/pressure plate dust combined with the Bay Area moisture.

Clutch materiel is black.
That red is usually unlubed wear, like if you run a CV 2 years after the boot breaks.

I think that shop was probably doing terrible work.

[verdigo]

If you want to call me Monday I will get your part numbers and possibly get you the right parts. I own and operate a shop in Clarksville TN. We also sell parts.

I'm Dennis. My cell# is (931) 801-2596

[v8volvo]

Thanks for the extensive info.

Looks like all of them come with the wrong pilot brg.... The gasser type bearing is pictured, and it was what I also found in the last 271265 Sachs kit I got. Too bad about that. Looks like the Sachs kit has the right disc but the cover looks quite different from the original -- the fact that it had to be modified to fit over the dowels on the flywheel makes me wonder if it is a gasser cover that they throw into the diesel kit, like with the pilot. Were there any other fitment or operation issues putting it in?

The Sachs number on the OE disc I took out of the car I'm working on (also an '85 wagon) is 18.1861 901 104, similar to but slightly different from the 1851 901 134 you pictured on the 271265 kit box, maybe they updated the disc or the linings slightly, in either case I suspect you are right that that is a good number for the disc. However, using this number, or using any of the *three* Volvo part numbers I have for the disc alone (1220942, 1377326, 3549535), I'm not able to find the disc available by itself. Might just get this one re-lined since the cover and TO bearing are in good shape.

[Nevadan]

Here's a link to what should be the correct "non-Sachs" kit NU31153-1.

http://www.ebay.com/itm/390515507291...84.m1423.l2649

[ngoma]

Getting ready here for my big summer (Volvo) project: Replacing the clutch/pressure plate, etc. Ordered the Sachs K70029-03, same P/N as described above. Will finally be happy to be rid of the stuttering on takeoff!

Nevadan, other than modifying the PP to accommodate the two flywheel dowels, did you have to make any other modifications? I watched someone renew their clutch/PP (not sure of brand or where purchased) on their D24T and they simply ground off the dowels from the flywheel. The other problem he had was that the new throwout bearing did not fit correctly in the clutch fork and he had to mod it. End result was that the clutch does not release until near the end of pedal travel. Did the throwout brg. in the K70029-03 kit fit correctly?

I do have a correct replacement pilot brg., NIB.

And a pair of new plastic shifter linkage bushings.

[Nevadan]

Other than modifying the pressure plate to fit around those dowels I didn't need to do anything else. I'm guessing those dowels are there to hold the pressure plate in position while you get the first few bolts in place and probably could be ground off.

As I recall the throw-out bearing from that kit worked good. I'm not sure which part number on the Sachs box is for the bearing but you could do a search by part number.

Good work on finding the pilot bearing, I just had to use the old one since it was in better condition and had the seal whereas the "National" bearing I purchased looked weaker and didn't have the seal. There's a picture somewhere of both of the bearings, probably on my original "broken crankshaft" thread.