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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.

Zerk fitting 29 November 2009

Posted by elfringham in volvo.
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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.

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.

No heat 29 November 2009

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1st August 2006

I am going over some of the rear suspension at the moment prompted by the need to fix those bushings. So far I have managed to remove the panhard rod and one torque arm, the other torque arm is being held by the bolt at the body end which has corroded into its sleeve and will not come out. So I am going to have to cut that bolt out which I am not looking forward to. I cannot get heat to it as the sleeve is in the middle of a bushing and hitting it with a hammer was doing nothing. I have sanded and painted the panhard rod and fitted new poly bushes to it. I will clean up and paint the mounting point on the body as well before I refit. The torque arms will also get a clean up and paint as well as the new bushings before going back. I found that the bolts in the flange for the differential were not tight so that may have been the cause of the thump but I also need to check the gearbox mount as the prop shaft seems very close to the tunnel just behind the overdrive.

Rubbing 29 November 2009

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17th July 2006

I gave the car a wash today, it was a bit grimy but there were some patches that never got washed after all the welding so it was good to get rid of them. I fitted the new rubber straps in the rear seat frame as well. I also found the passenger side seat belt hanger while I was poking around inside the car, I don’t know how I missed it before. I had a little look under the car to see if I could work out where the thump that I sometimes get is coming from. I don’t think it is suspension so that leaves either the exhaust or the propeller shaft. The exhaust seems to be held fairly solidly. The centre support bearing is a bit loose in the frame but I am not sure if it is that loose. I’ll have to jack the back of the car up sometime and see if I can check it all out a bit better. While under the car I did notice that the torque arms seem to have the incorrect bushings in them and they are both rubbing the inside of the mountings, possibly because the bushings are not holding them in place correctly. Fortunately I did recently buy a pair of NOS bushings on eBay.

The rear seat frame

Clunk 23 November 2009

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17th June 2006

Went for a ride in the car today. Noticed a clunk coming from under the car on rare occasions. I will have to check out the centre support bearing carrier as I think it is the prop-shaft hitting the floor but I can’t be sure yet. I applied a heat gun to the glued on window winder this morning and managed to remove it without doing any obvious damage to the winder nor the door panel which is a big relief. I still have to remove the rest of the glue from the inside of the winder before I can refit it but that should not be too hard. I spent some of my birthday money on a new cordless drill that has three batteries and I put it to good use this afternoon cleaning out the channel round the boot opening but I still only managed three out of the four sides, there was a lot of rust and bodyfiller to remove. I think I may actually have to remove the boot lid to get at the top edge. I have now bought or ordered top and bottom ball joints and polyurethane bushings all round to give the front suspension a complete going over. The rear will be done later although I did win a new pair of trailing arm bushes (the big ones) cheaply on eBay the other day. They are over £40 each in polyurethane so I’ll stick with these rubber ones. Noticed that the passenger seatbelt storage hook has fallen off and I can’t find it which is a pain.