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Clunk 13 December 2009

Posted by elfringham in volvo.
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1st October 2009

Well I fitted the rear wheels as intended but as I rotated them back and forth I noticed a significant clunk each time I reversed the direction of the wheel I was working with at the time. Thinking that the replacement axle was in fact junk I started to strip it all out again and was intending to refit the original axle. I was pretty upset about this and wasn’t really thinking it through. I also went off and ordered a new pinion oil seal to fit in the old axle. Anyway after I got a good way through the removal process I realised that the clunk was actually coming from the gear box and not the axle. So I had to tighten everything back up again. I adjusted the brake shoes so they are close to the drums. The car is now sitting on all four wheels again, something it has not done in over a year. Things still left to do include, tightening propshaft bolts to gear box flange, centre carrier bolts tightening, starter motor bolts, new exhaust, finish alternator conversion and associated rewiring and then refit the manifold. Doesn’t sound too much when you say it quickly now does it? Trying to ignore the drip from the gear box where I replaced the oil seal on the output shaft, ho hum.

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Bleeding brakes 13 December 2009

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26th July 2009

I fitted the rear brake backing plates with the new gaskets. I just cleaned up the seal carriers and used them as is for the moment. I then connected up the brake pipe to the rear brakes and removed the clamp that had been on the flexible pipe for about 18 months. I left the joints loose for a week and found brake fluid oozing out when I went back to it today. For good measure I bled the rear brakes out with fresh fluid so they should be good to go now. Unfortunately the dripping brake fluid has taken some of the paint off so I’ll have to touch that up soon but otherwise I am about ready to refit the rear wheels at least long enough to tighten the castle nut on the axle end and then adjust the brake shoes so that they will be close to the inside of the drum as they should be. When disassembling the axle one of the torque rod bolts was very stuck and I used a blow torch on it. This slightly burned the rubber piece that locates the lower spring mount. I bought a pair of these rubber pieces on eBay and replaced the burned one today as well. I jacked the axle up and then put spring clamps on the spring, then lowering the axle again took the pressure off the mount enough to change it over. This was all a bit nerve wracking as I don’t like working with suspension springs under tension but went OK in the end.

Shims 13 December 2009

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10th April 2009

I have cleaned up the shims that set the end play on the rear axle. There are some either side and they fit behind the brake backing plates. I also cleaned up the spacers that go in front of the backing plates but in the process of removing the gaskets that sit either side of these spacers I damaged the paint on the backing plates. So I touched that up but now I need to get new gaskets. I also need to decide what to do about the seal carrier as they are a bit rusty, I’m just not sure what the best way of finishing them will be. Last week I continued on removing the insulating tape and then the braided cloth covering as well from the wiring loom that went to the generator. This loom runs from the generator, through the front bulkhead and along above the radiator before passing back through the bulkhead and back along the nearside wing, past the fuse box and on round to the starter motor. Curiously enough I found some disconnected wires in amongst the others. A couple of these could well have been to drive the second horn which seems to have been rewired at some point using additional wires. I’ll join those horn wires into the harness to make it a bit neater there. I think I’ll use cable ties to keep it tight around the points where wires join/leave and then the spiral binding to keep it neat.

Grit in my eye 12 December 2009

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31st December 2008

Progress has been slow as usual but it has been happening. The rear axle is back under the car and the trailing arms and torque rods are connected. While doing this I decided to redo the paint on the panhard rod mount on the body. I only managed to get one coat of hammerite on it before I got some grit in my eye. By the time that was sorted out it was too late to put a second coat on immediately and I have to wait six weeks for the first coat to cure properly. With the cold weather I am probably going to give it a bit longer as well. I had given up on getting an alternator bracket from Scandcar so I bought an IPD version from eBay, whereupon Scandcar got back in touch and sent another bracket which has now arrived. So I now have two alternator brackets to choose from. The IPD version is the nicer of the two so I’ll probably go with that one.

Freeze plug 12 December 2009

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24th August 2008

I should have mentioned that while cleaning up the manifold gasket surface that I noticed the freeze plug on #2 cylinder does not look particularly secure. It is at an angle with one edge practically coming out of the boss. I prepped and painted the axle tunnel over the last couple of days which is a great relief. All that exposed metal was making me quite anxious.

Insecure freeze plug

Sheared off 12 December 2009

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16th August 2008

I got the rear nut off with a nut splitter and then removed the manifold from the engine so that I could work on replacing the studs. I sheered off the last remaining stud even after freezing it and applying heat and oil. So I had to drill out the studs. I bought a set of left handed drill bits in the hope that while drilling the studs out the left handed action would encourage the studs to unscrew but no luck there. Two of the holes were rescued by running a tap down but the third suffered from having too large a drill bit used on it and needed a thread insert.While I had good access I replaced the braided oil pressure gauge line, the old one was in quite a poor state as the braiding had frayed at one end. I then noticed that one of the rings that locates the inlet manifold to the head was missing so I’ll have to source one of those before the manifold is replaced. I moved the exhaust out of the way and found that it separated from the down pipe quite easily. I then managed to disconnect the front box from the middle pipe again with surprising ease. The back box was so rotten that it would have disintegrated before coming off so I cut it free with a hacksaw, keeping the middle pipe intact. I removed all the studs from the head with no incident and cleaned up the mating surface where some of the old gasket had stuck. I should now be able to get back to sorting out the rear axle tunnel.

Rust flakes 12 December 2009

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14th March 2008

Since my last update of these pages I have removed the old axle and painted the new axle and lower spring mounting cups. I have bought a set of new springs which will be fitted on reassembly. I also started to attack the rusty top spring mounts. While under the car I could not help but notice all the rusty bits that have crept under the under seal. So while the axle is out of the way I resolved to tackle that as well, at least the bit of it that will be difficult to reach once the axle is refitted. So far all I have managed to do though is to shower myself in rust flakes that went down my arms and neck. This is going to be quite a job, I just hope I can get it done before next winter rolls around again.

Zerk fitting 29 November 2009

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20th December 2007

The replacement axle feels better to me so I fitted the new pinion seal to it. Now I just have to do the swap! I have also done the universal joints in the prop shaft. These caused me quite a bit of concern as they seem very tight when put back together. However the two ones I did first have eased up nicely and I assume the last one will as well. The first time I put the first UJ together it was tight and I undid it to check it which meant cleaning it all out and regreasing it. It went back together just the same but eased while I did the second. I ended up doing the third one twice as well due to getting it 90 degrees wrong which meant that the zerk fitting was fouling the arm on the prop shaft. The new centre support bearing and carrier is in place, that all went easily having undone the big nut while the prop shaft was in the car. I just need to put some fresh molybdenum sulphide grease on the sliding joint and fit the new protective bellows and the prop shaft will be all set to refit. However before that goes back in I’ll need to do the axle swap and also change the oil seal on the output of the overdrive as that is also leaking. The OD flange should not be as hard as the differential except for the fact that you can’t get tools on it directly as there is not enough room before the prop shaft tunnel starts.

Double flares 29 November 2009

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26th September 2006

I painted the brake drums with high heat paint which turned out to be a very matt black, I had expected it to be gloss but never mind. I disconnected the shock absorbers again and dropped the axle until the prop shaft was resting on the bottom of the tunnel in an attempt to remove the springs and seats but that was not enough. I gave the axle a going over with a wire brush until I got bored, which did not take too long, and then slapped some Hammerite over it. Having reconnected the shock abosrbers I just need to reassemble the brakes and hubs etc and tighten up all the bushings bolts and I could be driving the car again. Of course that also includes replacing the hard brake lines which will mean learning how to do double flares which could be interesting. It looks like an old repair failed to replace the captive nut for the axle limiting strap on the off side which is why they were missing from my car. So it looks like a quick trip to the welder may be on the cards to get that sorted.

Cleaning up 29 November 2009

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16th September 2006

OK the rear brake fitting kit includes the correct number of those caps, it was just that my car was missing the ones from the inner ends of the springs. The support arms got painted last weekend and the new bushings fitted. I spent half the day today cleaning up the rear brake backing plates etc and then painting them. I also painted the axle end mounting points for the support arms. The body end mouting points just got a spray of undercoat. I bought a pair of genuine Volvo rear shock absorbers which I will fit once the support arms are back in place and can hold the axle in check. I think new springs may be on the cards but not yet although I will clean and paint the lower supports when I change the shock absorbers.