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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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Too tight 29 November 2009

Posted by elfringham in volvo.
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31st December 2007

I changed the oil seal on the OD output yesterday. Not too bad a job. The nut holding the flange in place is a castle nut with a split pin holding it in place so it was not torqued up too tightly and the flange just came off in my hand. I tapped the new seal in place using a couple of socket extensions through the propshaft tunnel. Lining the castle nut up to the holes was the hardest part of the whole job, I initially torqued it up too tight and could not get to the next slot and then had to undo it. The impact wrench had a bit of trouble then due to the slop in the extensions absorbing the energy but reordering them sorted that. I also tightened up the flange on the replacement diff, I don’t think I got to 200 ftlbs but it is certainly on tight!

Flange removed from differential

Flange replaced with new oil seal fitted

Out of line 29 November 2009

Posted by elfringham in volvo.
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5th November 2007

I drove the car a bit more over the summer which was good although it still sounds a bit rough and I noticed noise coming from the drivetrain as well. I now have the car up on jack stands. The new impact wrench undid the pinion flange with no bother at all. When I removed the old oil seal I felt that the pinion had a bit too much movement in it which I thought might be the cause of the drivetrain noise. So I now have a spare rear axle on hand and I will see what the movement of the pinion is like on that one. I also intend to replace all the universal joints and centre bearing and carrier on the propshaft so that came out as well. I undid the big nut on the propshaft before removing it but I had to remove the starter and jam a screwdriver into the ring gear to do it. The centre bearing carrier was rotten and had torn through almost half way round. The rubbber gaiter protecting the sliding joint was missing and to cap it all the sliding joint had been put back together 90 degrees out of line which may have been the cause of the drivetrain noise. Some serious rust found in the front chassis members which may well need sorting before the next MOT. Maybe I’ll save up for a MIG welder.

Plastic bowl 29 November 2009

Posted by elfringham in volvo.
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12th May 2007

The saga of the pinion oil seal continues. I ordered the new seal and was then a bit concerned as it did not look like the one that is currently installed but it turns out the design was updated so that is OK. A couple of weeks ago I made the counter hold lever from some angle iron and had a go at undoing the nut. I couldn’t shift it so I put a jack under the breaker bar. This then bent the angle iron and one of the bolts tore out of its hole. I tried again the next day with a bit more metal separating the bolt holes on the angle iron from the edge but it had the same result. I am now the owner of a new DeWalt cordless impact wrench and will try again at some point. Last weekend was a meeting in Basingstoke, primarily for Amazons but all Volvos were welcome and so we took the 1800 along. It was the only 1800 there which quite surprised me. Unfortunately the engine started to sound a bit rough during the trip there. It did however get us there and back OK. Oh well, something else to fix I guess. There was a missing clip on the passenger side headlight bowl which meant that there was no way to secure the chrome trim ring in place although it was reasonably firm fit. I did however decide it was time to fix it so I ordered a replacement plastic bowl from Amazon Cars and have just fitted it.

Dripping 29 November 2009

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24th March 2007

I had booked an MOT for 12:10pm today so at about 11:00am I headed out to the garage to start it up and get the battery charged. I used booster cables to hook up to my 240 to charge the battery for a while before I attempted to start it. I got the engine started on about the third attempt which was when I found that the clutch had seized again. I got the car out of the garage on the starter and let it warm up the engine while I had occasional attempts to unseize the clutch. It took quite a few tries before I finally broke it free and I did not have much time left before the MOT appointment. The MOT went fairly smoothly with just a headlight needing adjusting and an advisory for a seatblet beginning to fray. I did have a bit of a worry when I saw a liquid dripping from the car when it was up on the ramp but I eventually realised it was just the screen wash from the wipers test. So I now have a shiny new MOT certificate, the insurance and tax disc were also renewed last month so it is all road legal again. The pinion seal definitely needs replacing and sooner rather than later as there was quite a pool of oil from where it sat and dripped all winter. This is not an easy job as the torque required to undo the nut on the flange is quite high indeed, so you need a robust way to stop the flange rotating.

No leaks 29 November 2009

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18th October 2006

Well I finally got to finishing the brake lines off with the correct fittings this past weekend. It all went relatively smoothly and I could not induce any of the joints to leak even with booster pressure. I also tightened up all the suspension bushing bolts as I had left them loose until I got the car at normal ride height. Finally it was all done and we went for a short ride in it. It felt a lot better than previously and the annoying clunk had completely disappeared. Oh yes, I found that the diff had almost no oil in it so I filled it up. There is now a drip from the front of the diff suggesting that the pinion oil seal needs replacing. At least the engine started easily after its long rest.