hi all, i have a volvo 460 1990 model that has broken the clutch cable three times. i put a heavy duty cable thinking it will do the job but to no avail. i replaced the clutch and pressure plate and also replaced the release bearing but it has made no difference. am at a total loss.. when the car warms up the pedal becomes very stiff and hard to press. does anybody out there know what to do????

I have only had one 440 that had similar problems, a very heavy clutch - got so bad I broke the pedal. Check the routing of the clutch cable, if it stiffens when it gets hot, check where it is routed past the exhaust manifold, two things could be possible, if it is not an OEM cable it may not have the correct heat shielding where it goes near the exhaust manifold. also check there are no sharp kinks in the cables, I am pretty sure it must be one or other of these, the metal cable is sheathed in plastic (or nylon) and if it gets too hot it will be able to bind and make clutch operation difficult.
Grendel

Hi everybody!

I'm still having a similar problem with 440 TD :huh: For that reason I had to change twice the whole clutch kit but the problem persists...

Regarding the grendel1960's suggestion about pre-heating of the clutch cable: yes, that one I used is some made in Italy but I didn't notice for a contact with any so heavily heated parts? If it is like that, what I'm supposed to do? Probably disassembling the clutch cable and covering all along the shield with an extra heat-protection like insulating tape?

I'd like to ask about one more thing: take a look to the image and tell me what's the application of the bushes numbered 11 & 12? And what if they are missing? (for example: in my car..)