Soft Pedal Clutch Conversion

This is the same conversion carried out by the likes of BB Performance. It involves switching the standard clutch release lever/fork for a Volvo one along with some other bits.

Here are the Volvo main dealer part numbers for the longer clutch lever and other bits:

Fork V03455952
Bracket V03424195
Nylon Cap V03467278
Brass Bush V03455957
Flange lock Nut V00971098
Flange Bolt V00946329

Clutch Pedal Stop Plastic Block from Renault 6006 003 944 is £1.28 inc VAT.

Total parts cost is around £23.00.

The nylon bearing is fitted while the clutch is out. The arm is fitted to the gearbox when the new clutch goes in. The extension bracket is fitted to the bell housing mounting point where the large round clutch cable sheath end used to fit up to and through. The bush goes through this large hole to hold the bolt that clamps the bracket in place.

The extension of the release arm compared with the standard one is: Long lever; 62mm from tip of release bearing end to pivot and 225mm overall, Short lever; 60mm and 160mm overall. So the long lever is 65mm longer. The bracket is necessary to extend the sheath end to about the same distance so the cable can run straight into the sheath.

(For those who want to calculate the total leverage ratios the clutch pedal is 230mm from just beyond the centre of the rubber foot to the centre metal pivot, then about 50 to 55mm from the pivot to the top where cable runs through.)

The nylon cup is a replacement pivot bearing that the clutch release lever sits on inside the bell housing. The old one will probably have worn. The new one was quite a bit higher on mine. The old cap can (while the gearbox is out of the car) be easily removed by working the open end of an about 12 to 14mm spanner behind it and gently levering. The new one just pushes on.

The arm cannot be retro fitted from the outside afterwards as it's too big to go through the hole in the bell housing. So is the standard arm by the way.

In the car you will need to take off the 'clutch pedal stop' and hacksaw some off the height so the pedal sits higher and therefore starts to de-clutch sooner. Otherwise you will find that the pedal has to be pushed through the carpet to get the gears in. The pedals stops vary in height so you will have to experiment.