The continuing saga of Varts car.
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).

Mac.
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).

Mac.
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- *** V3M DONOR ***
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Excellent work chaps, and a great photo-guide.
cheers
James
cheers
James
VOC 300-series Register Keeper
'89 740 Turbo Intercooler
'88 360 Turbo Intercooler
'85 360 GLT
'81 343 GLS R-Sport
'79 343 DL
'70 164
...and some modern FWD nonsense to get me to work...
'89 740 Turbo Intercooler
'88 360 Turbo Intercooler
'85 360 GLT
'81 343 GLS R-Sport
'79 343 DL
'70 164
...and some modern FWD nonsense to get me to work...
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
1985 - Volvo 360 GLS
2008 - Volvo S60 SE Lux
mac wrote:Next job was the door pins - now, oh joy, the doors close without having to lift them.

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?
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.
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.
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
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
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.


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.


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.
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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
Adam
F559 LFE - 340R 2.0 16v
C208 CTR - 340 1.8 16v
D300 LBO - 360 GLT 3 Door Turbo project!! (and restoration)
F706 RBX - 350R in process!!!
C208 CTR - 340 1.8 16v
D300 LBO - 360 GLT 3 Door Turbo project!! (and restoration)
F706 RBX - 350R in process!!!
Hmm, I believe someone is multitasking340GLT 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

