Community Forums:

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.