Major Ledfoot Yes I posted it back and they said they will send a new one. I said "open the box and make sure the needle is somewhere near zero" and they said "will do"…LOL
Greg's Gold 1991 240GLE wagon B230FT-M46
OK I ended up ordering a generic steering shaft from Ian Boettcher race parts in QLD. I went with the Sweet 12-inch one, which may work if I stick to a short and a long U-joint. I found a slimmer cast steel long lower U-joint in the shed (I was wrong about my existing one being steel/iron - it is in fact aluminium). The aluminium ones are a lot bulkier at the ends (squared off) and have bolt and nut set-up with a clip, which protrudes a lot more from the body of the U-joint. The steel ones just a bolt that's screwed into a tapped bit on the U-joint, with only a small protrusion for a hairpin clip. Once the shaft arrives, I can play around and see whether I can put the long U-joint on top, and short on bottom. Ultimately, I may have to go with 2 short U-joints, in which case I'll have to order a longer 18 inch shaft from Coleman in the USA.
My waterproof fuse holders arrived so I need to get cracking on my driving light relay wiring and tidy up the air hor wiring. I should also be working on the baffling for the airbox while waiting for the steering shaft.
I checked the throttle position switch terminal 3 is definitely going from open circuit to earth at full throttle, so the Turbo+ kit should be getting that. I guess I need to check the solenoid valve function, and run through the rest of the potential wiring issues. Not a high priority at the moment.
Why didn't somebody pick up on my mistake with the steering shaft U-joints? Can you see it? The steering U-joints have a different design at each end of the joint. On the steering rack/steering column end, they are designed such that the bolt slides into a groove in the shaft, preventing the U-joint from moving (much) on the spline as long as the bolt is in position. On the steering shaft end of the joints, there's a tang on the shaft and a machined-out notch in the corresponding U-joint casting…the tang prevents the U-joint from sliding off the shaft as long as the bolt is in position, but allows the U-joint to be positioned along the shaft before tightening the bolt (the bolt is completely clear of the splined area). Sooo, if U look at the pic below, you'll see that I can't do anything meaningful to the angle or position of the shaft by swapping the U-joints from bottom to top, as the long portion of the one shaft is on the shaft side, not the rack/column side. The only other option is, with this new aftermarket shaft, I might be able to flip the long U-joint 180 degrees and put the "wrong" end on the steering column side, since the new shaft has a groove machined in it, which would be similar to the Volvo's rack/column ends. Hmmm, a lot of words that translate to BUGGER! It's possible that with the new shaft, and the short U-joint used at the bottom, that will give me enough clearance to the turbo drain pipe even though it won't actually reposition the shaft as such…it will move the U-joint end fitting farther down the shaft, which would probably give me 15 mm more clearance than I have now (about 10 mm). Also. getting rid of the 2-piece rubber isolated "fat" shaft will also give me about another 10-15 mm clearance at the downpipe. If I can get 25 mm clearance all around I'll be happy. Wait and see!
- Edited
I know I encountered that same issue when I was doing my 242. Pretty sure I just cut the tab off the shaft, enabling me to flip the U joint.
By doing so removed the intended method of failsafe to prevent the shaft coming out. That said, in any case you would have to have multiple loose joints to allow the shaft to slide enough to come out. Even then on my 242 I don't think I can get it out without unbolting the rack.
VolvoHordz Yeah, in theory with the new aftermarket shaft with no tabs, I should be able to flip the U-joints…I want to make sure it's pretty fail-safe though! 
While waiting for the steering shafts I ordered, I've been working around the edges. I did take the car for a test drive yesterday and all good with the clutch thankfully.
Started building my air inlet box. Pretty far along including mounting the small washer bottle to the one wall of the baffle. Next step will be to cut the large hole for the inlet pipe to poke through the rear wall, then I'll tidy it up (maybe paint) and make up a top cover plate. I've made it out of stainless steel off one of the doors of our old BBQ that went to the scrap metal. Nice that I kept the doors thinking "I might be able to use that stainless steel one day…"
Airbox is coming along well…a few more attachments, and a couple holes & grommets for the windscreen washer hoses. I made the mistake of using some silicone grease on the large grommet (ex fuel filler pipe grommet!) to insert the air inlet hose, so I'm thinking now I may just clean up the stainless steel and call it good instead of painting it black. Knowing my luck with painting, it would be full of fish-eyes from silicone grease fingerprint residue LOL! I'm going to make a top cover out of black plastic so it pretty much will all be hidden anyway.
The original length (12-inch) steering shaft arrived from QLD yesterday and I've painted it. Debating about whether to install it or wait for the longer (18-inch) one from the USA. Guess I can tinker along on the various other bits and pieces and wait for it, but I'd really like to do a bit more test driving/road time before taking the car down to Melbourne and back in May.
Finished up the airbox cover today and stuck on a bit of bling. My windscreen washer diverter valve arrived today so I'll get that mounted and wired up (will need a diode to prevent the front washer circuit from energising the diverter valve, which will just be used to divert flow to the tailgate when the rear washer circuit is energised). Everything seems to be fitting in OK. Going into Ballarat tomorrow to pick up the Megane E Tech so will stop at Bunnings to pick up some foam weatherstrip. I want to fill the gaps between the intercooler and radiator for more efficient cooling. No update on the wiring and E-fan relay from eBay USA…says it arrived at the eBay gloal shipping depot about a week ago…hmmm
Did some work on the battery & relay cover today. Pretty much done other than the fastening strategy. Should be fairly simple with a couple fabbed-up L-brackets at the right height.
Didn't spend too much time on the project as there was an emergency warning for an out-of-control bushfire about 1 km from our house…we're right on the edge of the Hepburn Regional park, where they had started a controlled burn on Thursday. Well, I guess it got away from them in a big way. We had water bombers doing non-stop runs basically straight over our house all day. Hopefully it won't flare up tonight.
Scary stuff, stay vigilant.
Thankfully the fire has subsided, so we've gotten back to our normal business. Did anyone see me with my VOLVO cap on the TV news stories about the Daylesford fire?
Today Wayne helped me wire up the washer diverter valve. Got that tested and installed, then reinstalled the air filter.
Also got the intercooler reinstalled after putting some self-stick D-shaped rubber extrusion seals along the sides and top to close out the gap between the radiator and intercooler. I suppose that might help the cooling efficiency a little bit.
My 2-speed fan relay and wiring arrived today from eBay USA…so Wayne and I are going to take a run down to Geelong in his new car tomorrow so I can see if the 850 at Jolly's still has the fan wiring intact. I need the harness from the relay to the fan. Worst case I'll see if Voldat has it as @DCW242 hasn't gotten back to me as yet.
Once I get the fan wiring completed, I'll get stuck into the steering shaft issue. The longer shaft I ordered from the USA is on the way via FedEx, so should be here next week. I also have to get the Rolling Australia magazine layout for May/June done and to the printers, so I'll be keeping busy!
Bonus pic of Wayne's new car next to the (dirty) XC40.
My long steering shaft arrived from the USA today, so I now have all options available. I probably will just use the long one with two short U-joints, as that will maximise the clearance between the shaft and both the turbo oil drain pipe and the exhaust downpipe. Also, the Febi diesel engine mount for LH side arrived from the UK, so I can fit that if necessary.
The 850 wagon at Jolly's in Geelong was picked over and out the front ready to be scrapped. Sadly somebody had already cut off the cooling fan wiring and relay, so no luck there yesterday.
