V40: !!! HELP!!! 960KG, GATOS.anyone with knowledge.. no clutch

[neanderthal]

!!!update!!!.. had to open the gearbox up as i could not get the left drive shaft back in due to object in the way(picture1)..i thought the centre shaft of the gearbox might be a problem to undo,but when i seperated the gearbox it just came out....removed outer lever pin,the lever itself was difficult to get off(rusty picture2). removed 18 bolts with a 12mm socket(picture3).carefully removed gearbox apart(picture4 showing guide pin)....this is what i found inside... at the centre of the largest cog(picture5)it stopped the central cogs from turning central to the driveshaft hole so i could not get the driveshafts in.i need another one of these(picture6)tried volvo dealers in york,but they don't do inner parts...is this called a collar ?....if anyone has one i would be grateful as i am stuck......i am not sure where it fits but can anyone tell me where it goes,could this be where it fits(picture7)...can anyone tell me where this goes in the gearbox,(picture8+9)as when i took it apart it was just loose....it is very magnetic with a dimple in it i have placed a pound coin at the side of it for size....please note this is a m56L2 1.9 turbo diesel 2003 gearbox...here are more pictures of the gearbox...apologies for some poor pictures....thanks yet again.....

[Dog_Book]

well done for getting all that lot off, at least now you can put new seals in it and sort that broken washer out

[960kg]

Congratulations doing what you have done to get that far, the only thing is you have now entered a different phase in a motor that the home mechanic can`t really go near because there are no breakdowns of gearboxes to see the parts unless you know where to look. Also you get gearbox specialist but will they sell the parts as they use them to recondition themselves.

i have done a couple of emails for you to my friend mechanics but i don`t think they will come up with anything apart from buying a second hand box or go to your local scrappy where you may see a damaged one, they are fairly common boxes. See if you have your own local gearbox specialist and chat him up to see what to do, use his brains?

myself i have only been inside RWD Ford boxes so i am no use to you with this one, all i keep trying to understand is how you come to bend that metal collar
what made the planet gear turn around so you could not get entry onto the splines ??

[neanderthal]

hi 960kg,when i rang my local volvo dealer he suggested the same thing, trying to find the part from a scrappy or buy another gearbox.....i noticed the other collar was in the planet gear,so i sat it in the base of the gear and it seemed to fit snug,and i noticed it kept the cogs in place better,because when i removed the collar,the cogs were moving around quite loose.and maybe thats why i lost the hole for the driveshaft. i hope i just need another collar and as dogbook says new seals.everything else looks okay.but i of course dont know this....if i have no luck on here,then i will check out a scrappy,or a specialist out.that has to be my last resort as always these days they need the work and money
....thanks for your effort in emailing friends much appreciated.

[mikealder]

The item in picture 6 looks like a shredded spherical shim, they fit behind the smaller cogs within the diff part of the gearbox, these might even be supplied in different thicknesses to adjust the pre-load on the cogs - Mike

[neanderthal]

hi mike,thanks for your reply,.... am i in the right area holding the shim against the base of the cog in picture 7.i know nothing about gearboxes and thanks for letting me know the name of the part and that there are different thicknesses....thanks

[mikealder]

Can you take a few more pictures of the item shown in picture 5 (The Diff Housing) I am interested in looking at that part from all sides as it looks like something (a cog) is missing from the pictures above.

I am not 100% that your diff will have different thickness shims, I know my 740 Diff had them when I took that to bits, the reason for me doing this was a smashed cog, the cogs are only supplied as a matched pair a cost a bloody fortune so I swapped the diff out. You are looking at a bigger job as the diff and gearbox are combined than what I had with the 740.

Have you had a good look around the inside of the gearbox for any loose items/ gear teeth etc - Mike

[neanderthal]

hi again mike,sorry about that....yes all 4 cogs are there,as thats the other cog in picture 7.it had fallen out,i believe when that shim came out and loosened the cogs.....i went to have a look at the gearbox not so long ago as you've said they fit on the smaller cogs....there are 2 smaller cogs in there permanently fixed and the shims are too big to fit in them,so i assume that they fit on the cogs in picture 7...thanks but if you want me to take pictures still, i will certainly do that.....

[neanderthal]

Originally Posted by neanderthal

hi again mike,sorry about that....yes all 4 cogs are there,as thats the other cog in picture 7.it had fallen out,i believe when that shim came out and loosened the cogs.....i went to have a look at the gearbox not so long ago as you've said they fit on the smaller cogs....there are 2 smaller cogs in there permanently fixed and the shims are too big to fit in them,so i assume that they fit on the cogs in picture 7...thanks but if you want me to take pictures still, i will certainly do that.....

mike or anyone,...is this the proper name of picture 6 at this website http://www.gardnerparts.co.uk/produc...sion/volvo.htm thrust washers in the differential thanks

[mikealder]

What holds the cog in place that has fallen, I appreciate it should have a drive shaft in it (assuming the center is splined) but how is it retained?

From memory thrust washers are used to shim the crown gear/ pinnion gear, I am not 100% as to whether the gears that have fallen out of your diff are shimmed - Mike