1977 244DL "Amy"

jamesinc · 2013-07-24T00:16:02+00:00

Love the bug-bomb holder you have there, James :)

timbo

Out of interest is the eccentric for the overdrive retained with a woodruff key or a ball?

jamesinc

timbo
Out of interest is the eccentric for the overdrive retained with a woodruff key or a ball?

Oh I missed this question, sorry Tim! It's retained with a woodruff key and a snap ring.

Ex850R

Kool posts, it's not something I would attempt but reading it is very satisfying,Thank you.

Philia_Bear

Srams so much easier to just run a m47..... though I did enjoy having a 10 speed gearbox in a 740 I owned long ago

Roinik

@timbo

I think I see my issue, thanks.

jamesinc

Okay while waiting for the new bearing I finished prep work. Everything has been cleaned and old gaskets removed. Here's three other seals I'm replacing, top to bottom they are the bushing that sits between the gear selector shaft and the gear shifter pivot arm, the input shaft seal, and the gear selector shaft seal.

The input shaft seal was easy to remove, you remove the circlip from the shaft sleeve (found inside the bellhousing), and then just whack it out rearwards with a rubber mallet. This pushes the seal out.

To get the gear selector shaft seal, I used a pilot bearing puller as you can't get in behind the seal due to a step. However, this seal is so small that you could probably just pry it out with a screwdriver.

jamesinc

Boom, bearing removed. New stuff turned up today, and I can confirm:

There's a seal at the rear of the gear selector shaft (part #947705) it should be included in the gasket set (part #271574).

This IS the case, the seal is included.

jamesinc

Ooh burn! There are two types of speedo drive housing. One has a (quite easy to replace) hat seal (part #380192), and the other has a seal that is between two pieces that are pressed together (part #380752).

The gasket and seal kit comes with the hat-style sealing ring but I gather this is only used by mid-80s-ish-onwards gearboxes. So I have to order the other one from GCP, it costs $6, and $40 shipping naturally. I might call the Volvo dealership tomorrow and see if they can beat $46.

jamesinc

Update: the early-style seal was in stock at Volvo Downunder Parts, and they are express posting it to me. I contacted Ashley there after reading that this seal was also used in the M40, which I imagine is the most common gearbox they see. Saves me a week of waiting and like $40 in postage ?

jamesinc

When I tore the box down, I noticed the cam on the gearbox output shaft that drives the oil pump for the overdrive was quite galled up on one face. Looking at the way this cam drives the pump, the face doesn't appear to require a precision fit. The critical surface is the cam's OD face, which spins inside a sleeve that in turn drives a piston. The cam's ID also had some burring, so I used a sanding cartridge on the Dremel to grind the burr away, and then I sanded the rough face back to something resembling flat. To do this sort of sanding I glue sandpaper to a flat backing surface (I use MDF).

This photo shows what the unworn side looks like, presumably how both sides looked originally:

And here is the worn side after cleanup:

jamesinc

finally, I replaced the output shaft seal. The speedo seal also arrived and I installed that back in and pressed the drive housing back together.

Next I just reassembled the housings and torqued everything down.

carnut222

Congrats! Maybe you’ll have a rare leak-free M46! :) I did all that on the M41 in my 1800ES last year and happy to report no leaks...however I was too lazy to pull the clutch and flywheel so didn’t replace the rear main, so that still drips a bit! :)

jamesinc

carnut222
Congrats! Maybe you’ll have a rare leak-free M46! :) I did all that on the M41 in my 1800ES last year and happy to report no leaks...however I was too lazy to pull the clutch and flywheel so didn’t replace the rear main, so that still drips a bit! :)

Well I'm playing with fire, because it was leak-free before I opened it up! The seals were definitely old though, the rubber was a lot less flexible than the new seals.

jamesinc

Aw the new wiring didn't arrive from Dave Barton in time for the long weekend ? it's pretty annoying to wire everything once the gearbox is in, so I suppose I'll have to leave it until next week.

jamesinc

Rebuilt the starter

I also modified the Supercheap press set I bought so that it fit the piston on my ebay press

jamesinc

Back again, small detail, didn't know these existed until I found some in a box - silver number plate lamp housings!

Before:

After:

Major Ledfoot

73 and 74 140s had silver ones. I'm going with black on my 142 build.

jamesinc

Painted the valve cover and polished the oil filler cap. I'll come back later and sand off tjethe VOLVO lettering, polish it, then clear coat the whole thing.

carnut222

Nice! I think that exhaust manifold would come up fine with the pot belly stove paint. George said it lasts OK but he said it goes a bit lighter colour with use. What did you paint the cam cover with? Debating about whether to paint mine or send it.

jamesinc

carnut222
Nice! I think that exhaust manifold would come up fine with the pot belly stove paint. George said it lasts OK but he said it goes a bit lighter colour with use. What did you paint the cam cover with? Debating about whether to paint mine or send it.

Just gloss black acrylic

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