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Finally have all the parts to reassemble the 1990's tailshaft housing. Have consulted the FAQ about the orientation of the tailshaft bushing hole when pressing the new one in. Frankly, I'm not so sure that I believe the proper orientation of the bushing is with the hole at the top, especially NOT with the hole avoiding either hole in the tailshaft housing (see the last entry in the FAQ about the AW-71, by Patrick Patrella).
My old one was in there pretty much as shown in the photo in the FAQ section. BUT, mine was also worn to bits, and the hole was clogged up with metal particles that were packed in there tight. The bushing was so worn so badly that the grooves in it has disappeared The cylindrical part of the companion flange, the part that rides in the bushing, was worn down (asymmetrically) about 1/16 of an inch! The transmission was relatively new, having been replaced about 75,000 miles ago, in 2004 (by the PO) and the replacement was done by a Volvo dealer using a Volvo supplied transmission (I have the receipt=$$$$$$$).
My point is that given the damaged condition of my bushing and companion flange shaft, I can not just conclude that the hole was in the proper orientation. In fact, given the severe wear in just 75,000 miles, it seems safer to conclude that the bushing may have been in the wrong orientation.
More to come, but I'm typing this on a laptop, and the keyboard is driving me crazy. I'll remove this line when I finish up on my desktop. Meanwhile, feel free to comment anyway.
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1955 Human, Scott; 1991 745 Turbo, Thunderbolt; 1990 745GL, Posideon
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Sorry, was intending to put this in the above post, but right now, it won't let me edit it.
I'm pretty sure that I remember that the Mazda M-5 5-speed transmission has a similar bushing in the extension housing. I rebuilt one about 12 years ago. If I remember correctly, the hole in that bushing goes over a slot (similar to the one in the Volvo tailshaft/extension housing), or over an oil supply hole. I've gotten out my Mazda RX-7 factory workshop manual, but it only says to check the bushing, nothing about how to replace it. I do remember sawing the @$!#$%*!! thing out, though.
What I am thinking is that one of the slots in the tailshaft housing in our Volvo AW-71s is supposed to line up with the hole in the bushing so that the bushing has a supply of tranny fluid to lubricate it.
BTW, my tailshaft housing is somewhat different from the one in the photo on the FAQ page: mine has no speedo gear, and there is not a slot at roughly 12:00 (looking in to the housing from the front to the rear), like in the photo. Rather mine has two slots, one at about 4:00 and one at 9:00. The one in the photo looks like it only has one hole. Mine also has more webbing to strengthen the bushing area, there is a web just below the 9:00 groove that is not there in the photo.
I'll see if I can dig up the conversations on Mazspeed.com from 12 years ago, about the Mazda bushing (not likely, the site has changed ownership and I think all the old stuff has been lost.), go to the junkyard where I got the replacement companion flange to see how the bushing is installed in that car, and either call or drop in on Preston (head mechanic at Volvo dealer, he is a super master certified Volvo mechanic and knows just about everything there is to know about Volvos). Will post details by tomorrow evening.
Meanwhile, I'm not going to install the bushing, as was the plan for today, until I have some better information as to how it goes in.
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1955 Human, Scott; 1991 745 Turbo, Thunderbolt; 1990 745GL, Posideon
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Don Foster's photo in the FAQ shows an oil gallery, an oil hole, and the hole in the bushing all lined up. This is all moot, of course, for the later AW-70 series with oil seals, not bushings.
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See the 700/900 "FAQ" at the menu bar top screen left side.
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Let us know what you find out. I will edit the FAQ accordingly. All the information in there comes from contributors, btw.
Steve
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See the 700/900 "FAQ" at the menu bar top screen left side.
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So far today:
The old stuff at Mazspeed is lost, or only accessible by a certain few moderators, so no luck there.
Preston has retired from the Volvo dealer, and the guy that works on the older (200, and 700 series) cars is out today.
Edit to add: And it has been raining heavily for over 24 hours here in the Gainesville-Ocala area, so there is no way that I am going to crawl under a car at the junkyard to look at how its bushing is aligned.
But, I did call Continental Imports in Gainesville and spoke to Steve Brotherton. Steve is one of the owners of CI, and has been working with Volvos, Mercedes, and BMWs for a very long time. He said that they have done several of the tailshaft bushings, and that there is no particular way to align the bushing UNLESS THE BUSHING HAS A HOLE IN IT. If there is a hole in the bushing, then the hole should be positioned over the groove for the oil, or the bushing and tailshaft will get no oil.
I met Steve over 30 years ago, and take my car to CI when it needs something done that I can't do. Steve and Richard (Shop Foreman) know their stuff like they were born with car keys and a wrench in their hands, and read parts catalogs and factory repair manuals in kindergarten. CI is the only place I trust to work on my two Volvos.
That said, I'm going to install the bushing so that the hole in the bushing is aligned with the oil groove a 4:00 (looking from the inside of the tailshaft housing out the back end). The grooves are different sizes (width and depth), and the one at 4:00 is deeper and wider. Will also take care that the seam in the bushing is positioned at about 2:00. The bushing can be positioned two ways with the hole aligned with the oil groove, and I think that keeping the seam up higher, and against solid backing is the safest way.
The guys at CI have never let me down, and I have great faith in them. Now, onward and offward to my hydraulic press, then to get Posideon back in service. Will let you all know how it goes. But I'm hoping that it goes so well that there is nothing to post about this fix for years to come.
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1955 Human, Scott; 1991 745 Turbo, Thunderbolt; 1990 745GL, Posideon
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Great; I added your remarks to the FAQ for publishing at Christmas. Thanks for replying.
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See the 700/900 "FAQ" at the menu bar top screen left side.
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