Greg's 79 245GL Barn Find

carnut222 · 2018-07-29T03:42:39+00:00

After cleaning it up, it sat in mum's shed until July 2018, when I finally got it shipped down to Daylesford where we live.

carnut222

@jamesinc thanks I went thru your thread again. Helpful. It looks like you only removed the input shaft to replace the bearing, not the main shaft? I think you have to have a special bearing puller to do the main shaft. Hmm.

jamesinc

carnut222
@jamesinc thanks I went thru your thread again. Helpful. It looks like you only removed the input shaft to replace the bearing, not the main shaft? I think you have to have a special bearing puller to do the main shaft. Hmm.

Yeah that's right, you need a Volvo special tool, but in reality I think any bearing puller with a long reach will do it. I kind of regret not going to the effort to get the rear bearing while I was in there.

You could also modify a normal bearing puller like this:

carnut222

jamesinc
https://ozvolvo.org/discussion/comment/176959#Comment_176959
Yeah that's right, you need a Volvo special tool, but in reality I think any bearing puller with a long reach will do it. I kind of regret not going to the effort to get the rear bearing while I was in there.
You could also modify a normal bearing puller like this:
https://cdn.ozvolvo.org/uploads/086/MR5J7EL8NRSO.png

I forgot I recently bought one of those bearing splitter/puller sets...I see now how I could possibly do something like that...thanks for the idea! :) I love this forum.

Ex850R

Just some lengths of allthread to make it work?

carnut222

Why is it that every time I've removed a tow bar off a 240 I've had to lever, pry, pull, swear etc? Well, today I removed the last bolt from the one on the silver 92 wagon and thought "I'd better be careful just in case..." and it fell off and smacked me in the head. Ouch! #@&**. Lesson learned - listen to your inner thoughts! :)

buddyglitch

Ouch..! Yesterday I dropped a shiny piston fresh out of ultrasonic cleaner onto concrete shed floor. Put a nice little ding in the crown. That among other setbacks with my engine build. Nice to know I'm not the only one with Volvo woes atm.. ?

jamesinc

buddyglitch
Ouch..! Yesterday I dropped a shiny piston fresh out of ultrasonic cleaner onto concrete shed floor. Put a nice little ding in the crown. That among other setbacks with my engine build. Nice to know I'm not the only one with Volvo woes atm.. ?

Oh I did that once, worst feeling 0/10 would not recommend

carnut222

Maybe today will be my lucky day?

carnut222

Had a bit of success today. Pulled the OD from an 86 240 I bought years ago and the one-way clutch in that is fine...so I'll use the rear housing etc from that, combined with some of the other giblets from the Wangaratta transmission, and possibly the gearbox from the 86. A bit of mix and match as the friction surface on the 86 OD was a bit chewed up and had some bits missing. Once I get this one back together, I reckon I can make another complete good M46 from the bits I have left over and a new one-way clutch. Fingers crossed it all goes together OK. Just waiting on an order for some Type F ATF as I want to smear that on everything as I put it back together. I've learned a lot, but I really didn't want to know! My shed looks like a transmission factory exploded inside. LOL!

carnut222

Also, does anyone know for certain which set of holes are used in the chassis rail for the crossmember attachment with manual gearbox on a 240? The rearmost 2 holes were for the auto...I'm assuming the middle 2 holes are for the M46? Reason I ask is I want to run a tap in the holes to clean out the underbody deadener spray, and I couldn't be asked to crawl under my 245L as it's surrounded by spare parts and the EV would require removal of the belly pan to see. Thanks in advance!

Roinik

If it's anything like the 140 series, the first 2 holes are the manual mount and the second 2 holes are the auto mount. Since you're under there it probably isn't a big deal to do all of them.

carnut222

Roinik
If it's anything like the 140 series, the first 2 holes are the manual mount and the second 2 holes are the auto mount. Since you're under there it probably isn't a big deal to do all of them.

Makes sense Ian - I think the very front 2 of the 6 are probably for the V6 as it was mounted so far forward.

carnut222

OK, FINALLY got the overdrive unit assembled today as I got sick of procrastinating. Now need to clean up the gearbox, replace gearbox seals, cut out the spot in the bellhousing for the crank sensor, etc.

Ex850R

Nice look8ng unit.

carnut222

Finally got the transmission back together today. Only thing missing from the seal/gasket kit was the output shaft seal so I had to place a quick RockAuto order. They have the SKF seals for $8.xx each so I grabbed 3 of them for a couple spares. Might need a puller to get the old seal out or will just use the drill holes/self tapper/slide hammer trick. I sure hope this gearbox works OK. It felt a bit funny turning the input shaft counterclockwise...before I installed the OD, so maybe it's just the friction in the syncros or something? No oil in it at the moment so that probably doesn't help...or it's stuffed...time will tell. I have enough bits to make up another M46 I believe (if I order a new OD 1-way clutch)...so might do that for spare. Should do it now while everything's fresh in my mind and before the bits get scattered to the wind, but I'm really sick of gearboxes at the moment. :)

Ex850R

"I'm really sick of gearboxes at the moment. :)"

I cant imagine doing what you do , wether its age or life or what its the reason i love your inspiration here!

carnut222

FINALLY got back on the bleeping gearboxes. Pulled #1 back apart...had a worn 3-4 synchro ring, so I swapped in a good one. Still no good...binding input to output shaft in neutral. So I said #&@$ it and built up #2...seems ok but I couldn't be arsed to check the bearing free play so just used existing shims. Hope it works! Then spent a bit of time cleaning up and putting tools away.

Yesterday we cut up some wood from a large old tree that fell in our back paddock last year. Used the paddock basher Mk II to haul it back up to the house. Had to swap some old rally tyres onto the back as I couldn't get traction in the paddock. All good now. I think I'll cut the roof off and make it into a ute some day. ?

We've had nice sunny weather for quite a while but this week it's supposed to turn cold and possibly snowy? We'll have to fire up the wood stove I reckon. Stay warm, stay safe, STAY HOME!

carnut222

Worked on organising the "storage" shed today...my "mother-in-law" is moving house soon, so we've been shifting a lot of stuff down to our place, plus I bought that huge lot of bits from Steve in Kyabram...plus we have a trailer to store too once the move is complete. Krikey I need more storage space. The workshop is full including one car parked under the hoist, so getting that out is necessary if I ever want to get this yellow beast done! Preparing for snow tomorrow!

Roinik

I'm about to start a M46 refresh myself. I'm dubious of the condition because the oil smells burnt in the first OD. Maybe 1oo2 might be ok.

carnut222

Made some more progress today - gorgeous weather. Wattles nearly in full bloom and it felt like spring.

Installed new pilot bearing and clip, flywheel, clutch, crank sensor and transmission. Wayne helped me remove the bonnet. Will make it easier to get the engine in and I want to put a sound insulation pad on it from the 93 sedan, so need to drill some holes for attachments. Will do some rustproofing on the underside while it's off.

Engine and trans now about ready to go in.

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