Here's the latest: The rear end was not the source of the noise. I did find that the front universal joint was shot, replaced all three as well as the center support bearing. The center support bearing was probably OK (two years old). Number one u-joint was definitely toast, so bad that one of the caps was turning freely under the retaining c-clip. Strange, I know. There definitely had been some hammerin' done, both on number one and on number three, which were both bunged up pretty good. The problem is this, I couldn't get number three in without some serious binding in the flexing of the joint. I'm worried that the piece which attaches to the rear end flange may be bent. (My latest theory: The binding in the joint or the bent attaching piece--the cause of binding--may be the long-standing source of the noise.) Any ideas? I'm thinking it may be time to hunt up a boneyard propeller shaft. If I do go for the boneyard propeller shaft, which models would work? If I find one, looks like I'll be starting over with new u-joints again--getting the old ones out, at least, does not a pretty picture make. Is it common for the shaft to get all beaten up with u-joint work?
Thanks in advance for all your help!

By the way, mine's a 1982 245 with an M46.

You can get a driveshaft from any 240 with an M46. The rear half is the same for all, but the front half is different between m46, m47 and AW-70. I have swapped just the front half without vibration problems but I was lucky. Best to get a balanced set and mark how they go together right away. It seems to me the last one I had come apart accidently on the floor had one large spline such that it would only go together one way (marking not necessary). I would not worry about redoing the u-joints unless they seem worn or seized. I don't find they fail very often.

Driveshafts / propeller shafts on a Volvo should not be beaten to snot during U-joint replacement. This can be done with a brass drift and hammer or a press. If someone has previously beaten the snot out of the assembly, give up on it as it will be out of balance and will create noise / vibrations.

I have a "free to a good home" driveshaft assembly with good used U-joints for a 92 240 with an M47 5 speed, but I don't know if it will fit your car that probably has an M46 trans. I suspect someone on the BB will respond with an answer.

One last thought, if the front and rear sections of the driveshaft are not lined up properly/in phase, vibration will result as well.

jorrell
--
92 245 245K miles, IPD'd to the hilt, 06 XC70, 00 Eclipse custom Turbo setup...currently in pieces

hi, i am interested in your 'free to a good home' driveshaft. i have a good home and need a driveshaft. could you e-mail me with more info at BOOSTEDVOLVOatGMAIL.COM


thanks!!
--
- '90 244dl m47, vx cam, new over axle exhaust, slowly upgrading creatur comforts, lots of vibrations and rattles

Thanks for your response! I put the shaft halves back in sync using marks left by a previous mechanic. Kept the other parts in their original relationships, too.