The continuing saga of Varts car.

Various, various and more various!
Vart
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Post by Vart » 12 Sep 2006 07:52 pm

i crashed it on the way home.

sorry

hehe

drives rather nicely now. more later.
1986 1.4DL - 147,000 - C746 VRT

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mac
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Post by mac » 12 Sep 2006 07:59 pm

Ok, all in all a good day. On road test new box and diff seem very quiet. Good shift quality and smooooth. Master Vart seems well chuffed (even if he did blanche somewhat at the cost of a new h/brake cable - £16 squid for genuine Volvo - Students!).

Next job was the door pins - now, oh joy, the doors close without having to lift them.
One thing left is final adjust of the new h/brake cable (give it a few days to settle/stretch).

4 to 5 completed, and my 1.6mm test gasket is now on the road !!

One strange thing we did find was some very odd damage to the diff. on the old 4 speed. It had obviously been done a long time - almost certainly long before Vart aquired the car. I can only assume that it's impact from something on the road (I will of course have it to pieces - can't really help myself).
Image

Mac.

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foggyjames
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Post by foggyjames » 12 Sep 2006 08:14 pm

Excellent work chaps, and a great photo-guide.

cheers

James
VOC 300-series Register Keeper
'89 740 Turbo Intercooler
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SteveP
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Post by SteveP » 12 Sep 2006 08:27 pm

Woah the old 4 speed is so small... I noticed today in a local scrapyard how much space there was to do a gearbox swap on a 340 - dead easy compared to a 360. I was going to nab the diff end plate as a spare since someone had already drained the oil, but it was all crusty and rusty :?
1989 - Volvo 360 GLT
1985 - Volvo 360 GLS
2008 - Volvo S60 SE Lux

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Cornholio
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Post by Cornholio » 13 Sep 2006 09:04 am

mac wrote:Next job was the door pins - now, oh joy, the doors close without having to lift them.
:shock: Need to get me some of that action. I'd assumed that the dropped doors were a design feature.

I've been meaning to get that job done for a long time. To compound the problem, the pin that keeps the drivers door open has disappeared as well. Is it an easy little task that an imbecile such as I could undertake? I seem to recall Mac mentioning a Door Pin Removal Tool - would I need such a device? Can the parts still be had from the stealers?

redline
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Post by redline » 13 Sep 2006 09:37 am

Vart wrote:i crashed it on the way home..
sorry are we missing some details here vart ?
Image

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mac
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Post by mac » 13 Sep 2006 10:12 am

I am assuming 'I crashed it on the way home' is what serves for student humour these days,

If not Master Vart, the car won't be the only thing in a crash (after the work I've put in over the last month or so).

hehe

Grumpy old fart.

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mac
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Post by mac » 13 Sep 2006 11:19 am

Mornin' Cornholio,

Door pins - generally very easy and very quick (about 3mins a side on Vart car) IF you have the Volvo tool (it is actually essential to have a pin remover - I have the Volvo one but there are 'generic' tools which should do the job just as well).

I will post a new thread detailing the proceedure.

Mac.

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Cornholio
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Post by Cornholio » 13 Sep 2006 11:20 am

Great! Thank you Mac.

Vart
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Post by Vart » 13 Sep 2006 11:28 am

gearbox very smooth much more so that the 4 speeder. 2nd is quite agricultural when shifting from 3rd but otherwise its very nice. much quieter cruising along now but it still needs 4th for 50ish to keep the go pedal in economy mode.

door wise i'd fully advise treating at least the drivers door to new pins should yours be haggard. dealers are 'major rip off merchants' as the pins are 55p each..... still the handbrake cable for £16 from brookhouse, not even solid gold and platinum i was expecting for the price.

macs door pin removal tool i fear would be essential in such an operation but i think even i could have perhaps managed it with only minimal assistance after a few goes.

certainly two changes i'd recommend to anyone with a 4 speeder and front doors that hang.

regards
1986 1.4DL - 147,000 - C746 VRT

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SteveP
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Post by SteveP » 13 Sep 2006 12:01 pm

Think I'll be getting hold of a set of door pins for the drivers door, drives me mad having to give it abit of a shove to shut properly :lol:

I'll leave the other side for now since the doors are going to be replaced anyway....
1989 - Volvo 360 GLT
1985 - Volvo 360 GLS
2008 - Volvo S60 SE Lux

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mac
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Post by mac » 13 Sep 2006 03:15 pm

Varts old box - been on my bench nearly 20hrs and I couldn't resist it any longer - had to have it apart to look at that strange damage.

Image
Image

Diff side bearing housing flange broken away. Diff casing unaffected !

Either - external impact, or someone with a lever (unlikely as main case ok), or just possibly corrosion swell. (crown wheel backlash is adjusted by moving whole crownwheel/planet gear assy. sideways to change mesh with pinion).
Backlash adjustment shims sit under bearing housing and are steel - housing is aluminium - if electrolitic corrosion took off (was evidence of this) it could produce enough pressure to crack bearing housing flange.

Who Knows ? (which way the wind blows).

Note Vart - new diff - nothing on magnetic drain plug, old diff - a veritable forest of metal particles.

Mac.

sven360
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Post by sven360 » 13 Sep 2006 04:53 pm

Nice work there boys.
What ratio was that 4 speed diff ?

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340GLT
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Post by 340GLT » 13 Sep 2006 05:24 pm

Yeh i did the door pins on the passenger side of mine when it was repainted. I have a Sykes tool which is top notch you wont do it with a punch, as you cant get one in there as the top pin has to come out downwards and the bottom pin has to go upwards!!! IIRC!!!
Adam
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jtbo
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Post by jtbo » 13 Sep 2006 05:33 pm

340GLT wrote:Yeh i did the door pins on the passenger side of mine when it was repainted. I have a Sykes tool which is top notch you wont do it with a punch, as you cant get one in there as the top pin has to come out downwards and the bottom pin has to go upwards!!! IIRC!!!
Adam
Hmm, I believe someone is multitasking sm14 sm46
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