Jackson
Hi guys, just wondering if anyone out there has had the same issues as me or knows a bit about the M56.
First issue: Jumps out of 2nd gear unless I am VERY conscious of shifting the stick ALL the way to within the very last 1mm of travel, and if I'm going around a corner, holding it there. I suspect I have a worn shift fork or detent. I am going to replace the torque mounts first, in the desperate hope that it will make a difference, but I suspect the box is just worn inside. The shifter cables seem to be fine, in that they move freely, and more than far enough. Has anyone had the same problem?
Second issue: When I am decelerating, select a lower gear, and engage the clutch (take my foot off the pedal), I get a loud buzz. I guess it happens when the input shaft / clutch is spinning faster than the flywheel. Do some clutches chatter like this, when they're slipping in the opposite direction, or is it some other noise? Honestly, I'm worried that it's vibration inside the box.
Oh, and I've got a synthetic 75W-85 oil in it.
I will try to get some video over the weekend.
Vee_Que
Second one I'd go for the throwout bearing before the clutcg itself.
first one, unless it happens in 4th also, I'd say worn internals too.
Anthony
I would suspect worn syncro rings. The M56 has double syncros on all gears. 2nd gear syncros cops it most especially in changing down forces as most of us don't match the revs.
Its a box out and dismantle job.
Second issue sounds like the small pivot bearing in the flywheel, or the clutch release bearing.
How many kms on the gearbox out of interest?
You could enquire if Volvo have an exchange service on the M56H.
Jackson
Damn. I bought this gearbox as part of a manual swap. I have no idea how many kms are on it. I'm pretty sure it was swapped into the previous car as well. It would have at least 200,000 km on it.
In regards to the second issue. I read that I did not need a pilot bearing. In fact, I don't think the input shaft would even butt up to it if I had put one in. I did put a brand new throwout/release bearing in though.
brock
My 4th gear is dodgy, synchros are very slow and I have to make sure it's fully in otherwise it will pop out, it doesn't jump out otherwise thankfully.
Mine also sounds like it has a lot of slack inside, I'm just waiting for it to die :| I suspect mine has a lot of kms on it, it was also bought as part of a conversion but kms weren't listed.
There's definitely no pilot bearing, the input shaft doesn't reach the crank.
Jackson
@brock: I've heard that the single mass flywheels result in a fair bit of noise. Like a constant dull rattle. Mine does that too...
timbo
i wouldn't rule out the engine mounts, if the right hand and front mounts are soft/sagged/torn like the majority of p80's i see, it could cause issues with movement of the engine. We use an 80w gl4 from hi-tech oils when we do single mass conversions to reduce the increased gearbox noise
Jackson
Thanks for the tip, tim. Does the 80W oil help with worn synchros? The noise doesn't bother me, but if there are other reasons to use it, I will give it a go. The engine is sitting on brand new mounts by the way, but the torque mounts are all a bit worn.
Ex850R
My R started to jump 2nd at times , hadn't done more than 160k , new clutch had been installed , I don't know if that had any bearing on the problem.
Jackson
Video of buzzing noise
Video of it popping out of gear
Might end up trying to rebuild this box eventually... Oh, and if you anyone's selling a Volvo shifter and boot, I'm chasing one. :)
brock
I understand the constant rattle at idle, my S70 had the same thing. At slow speeds, such as driving through a car park, it feels like there is a lot of wear in the box, it is really quite hard to describe. I know the ARD tune designed for an auto isn't helping, it is reduced when using a stock manual ECU.
timbo
good luck with rebuilding the box you can't get any parts from volvo unless you want a complete exchange gearbox. I have not seen any rebuild kits for them
nickm
At best go through a timken catalogue and replace the bearings you can.
I think the synchros are unique. and would present the biggest issue. But the box is a getrag so something may match.
There also seems to be a issue with the shift forks....local machine shop to build them up and machine? Or mill out some brass to replace the plastic...
That being all the cogs are still good.
not a cheap exercise.
nickm
Jackson
Thanks Nick, I was thinking the same things. I've heard all the synchros are the same between gears, so maybe I could just swap the 4th and 5th gear ones onto 2nd and 3rd. I think my main problem is one of the shift forks, which, like you said, could be built back up.
