240 General: Driveshafts and Motor/Gearbox mounts

[Othen]

Originally Posted by Bob 1967

Cleaned all circlip /bearing recesses with wire brush bit in a drill

https://photos.google.com/photo/AF1QipN88AF9Jred4fNlfilG2ubbCVtR6-lJX_68a2li



This will make it easier to remove clip and bearing caps.
https://photos.google.com/photo/AF1QipNGFEOaQSOB5Ak7wq2D3YttyQCW2ORE4DxMhksN



Centre bearing removed ,both shafts were sanded treated Zinc primed and top coated with Black stone chip.
https://photos.google.com/photo/AF1QipNByy158egWUlTXeZGTwOXVYq77pCvzCiIkhYve


Exhaust cleaned with 60 grit on a strap made with duct tape ,then a coat of VHT black.




https://photos.google.com/photo/AF1QipMaSzJcegvMCfjKtkmEexGvwb3rQ-gOJIF2Aeqj

You can also see my gasket on the gearbox sump, made from cork sheet.
I just laid the pan on a sheet of cork gasket and drew around it .
I put white board marker on the mating face and used it to print the gasket on the sheet.

The links to those photos don't seem to work Bob (I don't know much about Google photos).

Ingenious about the cork gasket :-)

[Bob 1967]

Cleaned all circlip /bearing recesses with wire brush bit in a drill


This will make it easier to remove clip and bearing caps.


Centre bearing removed ,both shafts were sanded treated Zinc primed and top coated with Black stone chip.


Exhaust cleaned with 60 grit on a strap made with duct tape ,then a coat of VHT black.





You can also see my gasket on the gearbox sump, made from cork sheet.
I just laid the pan on a sheet of cork gasket and drew around it .
I put white board marker on the mating face and used it to print the gasket on the sheet.

[Othen]

Originally Posted by Bob 1967

Cleaned all circlip /bearing recesses with wire brush bit in a drill

This will make it easier to remove clip and bearing caps.

Centre bearing removed ,both shafts were sanded treated Zinc primed and top coated with Black stone chip.

Exhaust cleaned with 60 grit on a strap made with duct tape ,then a coat of VHT black.





You can also see my gasket on the gearbox sump, made from cork sheet.
I just laid the pan on a sheet of cork gasket and drew around it .
I put white board marker on the mating face and used it to print the gasket on the sheet.

Excellent Bob (photographs and work).

It looks very good (and was ingenious), but why did you make a cork gasket for the transmission pan? They are available off the shelf.

Good fortune,

Alan

[Bob 1967]

It looks very good (and was ingenious), but why did you make a cork gasket for the transmission pan? They are available off the shelf.


Hi Alan ,nothing is available off the shelf in Ireland.
Mail order can take weeks ,so make do and mend !
Also 1 sheet of cork can many gaskets make ,including engine sump and valve cover.
Bob

[Othen]

Originally Posted by Bob 1967

It looks very good (and was ingenious), but why did you make a cork gasket for the transmission pan? They are available off the shelf.


Hi Alan ,nothing is available off the shelf in Ireland.
Mail order can take weeks ,so make do and mend !
Also 1 sheet of cork can many gaskets make ,including engine sump and valve cover.
Bob

Hi Bob,
Thank you for the explanation. I suppose we take so much for granted here in England - not just with Volvo parts but everything.
I thought the sheet of cork was a really good idea for making gaskets, well done.
Alan

[Bob 1967]

Okay ,circlips
As much cleaning prior to commencement of work is recommended .
Circlips are finickity at the best of times and will "trip over a hair".
First one out...


Sometimes you will get a circlip that will only come out one side, using the side of the shaft for leverage you can pull the stubborn ones out of their groove.



In mine there are two sizes of clips , the larger were the more difficult to remove (smaller gap in circlip ring).These took a bit of twisting and pulling together.
One as can be seen snapped ,the method in pic 2 was used to remove this one.

Bob

[Bob 1967]

Firstly I used a large socket (27mm),to hit the coupling down onto the cross bearing( alternatively use a smaller drift on the outer face of the bearing cap.

The effect will be similar ,enough of the bearing cap will protrude to get a vise grips on.

And pull (it may need an outward tap on the vise grips to pull clear.[IMG]

Opposite side can be knocked out using a drift/socked against the shaft of the exposed cross. you are the able to remove the coupling.

I then used a 16mm plug spanner to knock the remaining caps out .

Bob

[Bob 1967]

Sorry to all about the sizes ,tried several times to edit and send correct link when posting .
I'm afraid it will have to suffice .
Bob
ps you may notice the red mark on the shaft in pic 4 ,there is a corresponding mark on the coupling to keep the aligned.
Also keep the shaft supported when doing step one !!

[Othen]

Originally Posted by Bob 1967

Sorry to all about the sizes ,tried several times to edit and send correct link when posting .
I'm afraid it will have to suffice .
Bob
ps you may notice the red mark on the shaft in pic 4 ,there is a corresponding mark on the coupling to keep the aligned.
Also keep the shaft supported when doing step one !!

Hi Bob,

Good work, well done.

I finds that with Imgur it is best to select the 'huge thumbnail' image size, rather than the actual size, this ends up fitting the page on this website well (bottom left of this screen shot, underlined in green):



Best wishes,

Alan

[Bob 1967]

Okay , so installation is reverse of assembly.
Clean everything especially the circlip grooves I gave the coupling a thorough cleaning before respraying.


Then with caps removed (my caps had been pre-greased so rollers stayed in caps snugly) put the cross (spider bearing ??) into the coupling .



Then press or tap ,I used the latter . Remember ,if tapping keep an eye on alignment of caps until flush ,then use a drift to pass circlip groove.. The caps go in easily enough, so not much effort is required to put them in.



Repeat for other side ,being careful with placement of cap over bearing surface of cross.

Place completed unit in driveshaft.



Insert caps as before and finish with circlips.



Bob