New Member seeks help with diff on 1990 240GL Saloon

[Ben W]

Hi guys, I've recently purchased my first Volvo

Its a 1990 240GL Saloon, and I noticed the diff was seeping a little bit, more after it had been on a drive.

Took it to a specialist, and he says its corroded enough to let fluid through the flaky rusty bitties.

I've done an exhaustive search, and can't come up with even one at a breakers yard!


Anyone know where to get a diff. cover and gasket? Would be super appreciated, as its all my car (hopefully) needs to be a real Volvo right now



many thanks for reading,

Ben W

[mikealder]

Where is it leaking from if it's the rear cover plate that is far easier to change than swapping out the whole diff, the main structure of the diff housing is made from thick steel so I doubt thats totted through to the point it's become porous??

Make sure you get the same unit though as there are different ratio diffs about so you need to be a little more selective than just any old 240 diff - Mike

[classicswede]

They are still available from the dealer. The cover on 740 axles is also the same irrc

[Ben W]

Originally Posted by mikealder

Where is it leaking from if it's the rear cover plate that is far easier to change than swapping out the whole diff, the main structure of the diff housing is made from thick steel so I doubt thats totted through to the point it's become porous??

Make sure you get the same unit though as there are different ratio diffs about so you need to be a little more selective than just any old 240 diff - Mike

Thats why i said 'Diff. COVER'

I am in no capacity ready to jack her up and replace the diff, lol. Well appreciative of your info though, mike - cheers

[Ben W]

Originally Posted by classicswede

They are still available from the dealer. The cover on 740 axles is also the same irrc

My local specialist said they weren't available..? Been a bugger even finding info, but i'll have a look into who my local official dealer is and go check them out, as the seeping is just worrying me.


I'll try and keep it topped up, as i have a squeezy bottle and some ATF 85W 90 that'll probably be okay to use?

Thanks for the help!

[mikealder]

One other idea, drain the diff and remove the end plate, give it a very good clean up then use liquid metal filler to plug any holes from the outside, the metal filler is a two pack epoxy that you mix, it can be worked in to place before it will set, once set it is as hard as metal.

For a new gasket try giving FRF a ring at Swansea, if they can't help get a sheet of gasket paper and make your own new gasket by drawing around the old cover and careful use of a knife.

Re-fit and fill the diff with the correct grade oil, unless yours is fitted with a limitted slip diff I would expect Hypoid SAE 90 EP would be the fluid to use, not too sure about using ATF though - Mike

[migrator]

If the correct cover plate is no longer available from the dealers can you not get a local garage to make one for you? Use the existing plate as a template and do the same for the gasket. There is not a truly high pressure inside the diff - it is the way the oil is thrown about within the diff. The thin cover plate is where the damage will be seen. Many years ago I had this problem on my 265 but back then the Volvo parts were available.

[Ben W]

Originally Posted by mikealder

One other idea, drain the diff and remove the end plate, give it a very good clean up then use liquid metal filler to plug any holes from the outside, the metal filler is a two pack epoxy that you mix, it can be worked in to place before it will set, once set it is as hard as metal.

For a new gasket try giving FRF a ring at Swansea, if they can't help get a sheet of gasket paper and make your own new gasket by drawing around the old cover and careful use of a knife.

Re-fit and fill the diff with the correct grade oil, unless yours is fitted with a limitted slip diff I would expect Hypoid SAE 90 EP would be the fluid to use, not too sure about using ATF though - Mike

Hmm. we were thinking of playing about with repairing it. Might also be the cheapest road to go down :/

[Ben W]

Originally Posted by migrator

If the correct cover plate is no longer available from the dealers can you not get a local garage to make one for you? Use the existing plate as a template and do the same for the gasket. There is not a truly high pressure inside the diff - it is the way the oil is thrown about within the diff. The thin cover plate is where the damage will be seen. Many years ago I had this problem on my 265 but back then the Volvo parts were available.

I've still to get in contact with the main dealers, and as for making one - that'll probably prove costly i'd imagine..?

I'm probably going to just try and work out a nice easy repair .. He said hopefully!

[mikealder]

I would look at using something like This to cover the area where its worn thin, just make sure the surface is spotlessly clean before you start. It would be better done off the car otherwise the diff oil will leach through and prevent the filler from bonding to the metal work, the repair paste must ONLY be applied to the outer surface, don't put anything on the inside face of the diff cover plate.

As for gasket paper try a search on the "bay" and you can get some sheets larger than you need for about £5 so it's not that costly, otherwise make your own gasket out of a cereal box see Here - Mike