nt

...on this one, Josh. I've had two aftermarket clutch cables shear off at the bellhousing on me. Wasn't pleasant the first time (I was in the middle of nowhere and got towed home); the second time happened while my wife was driving. I had to rescue her with a spare 'stock' cable and jackstands, etc. I've learned my lesson -- nothing but the original cable from Volvo. I got mine from George at TVK.

As Dave says, the stock cable will enable you to properly mount the metal plate and rubber block at the throw-out arm. Lubing the ball end of the cable will enable it to pass through the hole in the rubber block.

One last thought, and this is pretty rare from what I gather on the 'board, but it happened to me on my '83 and it took over a year to diagnose --> Check that black sheet metal plate on your firewall through which the clutch cable passes. On my '83 a crack formed between the hole for the cable and the edge of the plate. When I pressed the clutch pedal, the metal plate would deform. I adjusted the cable I don't know how many times until I finally figured out what was going on. Like you, I thought the throw-out arm was bending and ready to snap. The solution was to make a replacement plate out of 1/16" sheet metal and bolt it on. If you find you've got this problem, get back to me and I'll give you fabrication details.

Rob Kuhlman

From what I can get from your post. You are missing the retainer bracket and
the rubber buffer from the end of the clutch cable. They are supposed to
be there holding the clutch cable to the arm. You are probably using the
aftermarket clutch cable. If this has a threaded plastic section for the
adjustment then that is what you have. These cables do not work properly on
a 240. They don't have enough adjustment to install the rubber buffer and
the bracket on the clutch arm. So most people leave it off. Then you have
the problem that you describe. Get a Volvo clutch cable or an OEM one.
Then get the metal retainer and the rubber buffer. That will take care of
that part of the problem. It is possible that the clutch arm is bent.
You can watch the action of the cable with the car on ramps. Have a helper
move the clutch while you watch. You'll be able to see if the arm is bending.

In general aftermarket cables are of poor quality or don't provide enough
adjustment to work properly. All the control cables are best to keep
OEM and you will minimize the hassles. Hope this helps.

Dave 82 242ti 280k mi.