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

Roinik
I recently changed the heater 'spacer' on a k-ket. You've got acres of space with efi!

Guess I shouldn't be complaining. I know with the K-jet B21/23/230 having that octopus under the manifold was no picnic! :)

carnut222

Got the inlet manifold and injectors installed today Once I had the injectors and fuel rail in place, I discovered (as others have) that the white injectors could slide down about 2-3 mm, which might cause a leak at the fuel rail, so I pulled the rail and injectors and put an extra O-ring at the bottom of each injector hole in the inlet manifold. Everything is tight now so should be OK. Also got the new cap and rotor installed. The rotor was extremely stuck to the distributor shaft. Had to use much force and it broke in several pieces. Used a small wire brush on the Dremel to clean up the distributor shaft and applied a little anti-seize grease before installing the new rotor. Had a minor panic running around the shed(s) looking everywhere for the rear lift eye that bolts on the rear intake runner. Of course after searching high and low for it, I finally found it where I thought it should have been, the 3rd time I looked there. Yay! Coffee time! Oh, I probably ought to pull the fuel pressure regulator and replace the short hose and O-ring...must remember!

carnut222

Still plugging along. Discovered I do have a transmission gasket kit (except rear seal) in my stash, so will replace the front seal and gasket for sure and check the OD filter. Still sorting through misc bits that haven’t be categorised yet. I do need to reduce my hoard! How many license plate lamps, interior lights, ignition switches etc does a person need? Hundreds of switches and relays yet to go through. Yikes! ;)

Roinik

I can relieve you of a couple of number plate lamps when the time comes.

jamesinc

Is it an M45? I think I have a rear seal for one

carnut222

jamesinc
Is it an M45? I think I have a rear seal for one

M46 James...so J-type OD.

carnut222

Still sorting thru relays, switches, etc. as a bit of a distraction (see my "for sale" posts).

OK, so you know that obscure "Volvo special tool" you wondered whether you would ever use? Hmm, this one looks like it will be handy! It's a holder for M45/M46 transmission. Maybe I'll get another engine stand and make it even more useful...wait for them to go half price at SuperCheap. Just need Wayne to help me lift the box in place then I can have at it. Decided I'll pull the OD and replace all the seals and O-rings. I think I have everything I need except the output shaft seal.

Our friends from down the road asked whether I knew anything about clothes dryers, so I had a slight distraction this afternoon. Fisher & Paykel dryer - motor just hums but won't start. Tried manually rotating drum while humming, and still no run and it smells like burning...thought it might just be the capacitor but I guess bad motor...so now it's up to them whether they want to proceed with new motor, capacitor and belt (and probably drum bearing while it's apart!) or get a new or used one...all in a day's work!

carnut222

More distractions...looking for a new house for Wayne’s mum, so did a bit of a loop down through Ballan and Ballarat...then to Stawell to pick up the eBay “bargain” 1992 240 wagon. Made it home with no dramas. Didn’t check the tyre pressure but feels like it must have had 80 psi in the tyres LOL! Kick down cable was stuck pretty far out so unable to get into OD. Steering is a bit funny (seems like it’s super boosted and almost turns by itself? WTF?) Anyway, watch the “for sale” section as I’ll be parting it out when I get around to it. Beautiful day for a drive in beautiful countryside! Our driveway is starting to look like my child-hood dream career - Volvo salvage yard owner...

carnut222

Also, made a big GCP order yesterday (manual trans seal kit, gear knob, OD switch & number surround, etc, etc). I decided to bite the bullet and ordered another set of the bits to make up the OE “turbo” exhaust system...same as what I ordered for the gold wagon (but haven’t yet fitted). Will be interesting how it sounds on a non-turbo car. I was looking at for example the ipd sport kits (shipping too dear) and Simons sport kit from CVI...but the OE turbo set-up from GCP is significantly cheaper with their more reasonable shipping.

carnut222

Been a while since the last update. The GCP bits arrived. Been helping find a new home for my partner's mum so a bit too busy!

Got the M46 mounted in the Volvo special tool holder and started disassembly. Plan is just to replace the main gaskets and have a quick look at the overdrive. Gears in transmission all look great so hopefully the OD is good and will be OK to go with some new gaskets and O-rings. Too bloody cold in the shed today so had to come in as my hands were getting cold!

carnut222

OK, minor update on the M46. I had a very hard time pulling the OD unit off the trans. End of splines on trans output shaft look pretty bad. :( Then looked into OD unit and saw a roller floating around. Double :(. Turns out the one-way clutch is shattered. Can buy new ones, but the output shaft might be too damaged. I have another gearbox without the OD that has a good shaft, but could I be F'd to pull everything apart? Plus it looks like you need special pullers to get the bearings off the main shaft etc to get it out of the trans (anyone had experience with this?) Hmm, I think I'll just use one of the M46s I bought recently in the lot...then can build up a good one for my L in due time. And it goes on, and on. My excuse for not getting this car on the road in 2020 is COVID19. :)

jamesinc

Golly that is quite a bit of carnage! I recently did a partial M46 rebuild, I can answer your questions probably. Have a look at my thread from this post first: https://ozvolvo.org/discussion/comment/170221/#Comment_170221

Major Ledfoot

The bright side of the equasion is how you've found this now, instead of after installing the box.

Is damage like this consistent with the OD being engaged and then being placed in reverse?

carnut222

Major Ledfoot
The bright side of the equasion is how you've found this now, instead of after installing the box.
Is damage like this consistent with the OD being engaged and then being placed in reverse?

Yes, probably better to find it now rather than later! :) Possibly reverse engagement issue? not sure how they typically fail if they're allowed to operate in reverse...for some reason I'm thinking this might be the failure mode, but not sure. The rest of the trans and OD looks fine so I doubt it was an oiling issue @jamesinc but who knows? Will have a look at your rebuild thread - thanks! Fun and games!

jamesinc

I'd say more likely the clutch has been dropped on it a few times. Who knows though. Could have been something as simple as an oiling issue.

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! :)

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