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92 240 5spd manual- disconnecting floor shifter before pulling manual trans 200

posted by  someone claiming to be oldduke on  Sun Feb 9 06:36 CST 2014 [RELATED]

hi sages- bet there are a number of you who have done this and know all the tricks. anticipating a clutch job at some point and dont want to pay a shyster $2000. only tricky part seems disconnecting/removing the shifter mechanism. could you give me the steps and warnings thereto? no electric wires to fool with since no electric overdrive. also is there a kit of bushings, pins etc to tighten up a lose shifter? thanks tons oldduke








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    92 240 5spd manual- disconnecting floor shifter before pulling manual trans 200

    posted by  Adirondack Blues on  Sun Feb 9 09:12 CST 2014
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    last visit: Mon Sep 8 12:11 CST 2014
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    Oh, and a clutch job from a good indie shop on a '92 should only run you about $800-$1000. At least that is the going rate here in upstate NY.








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      92 240 5spd manual- disconnecting floor shifter before pulling manual trans 200

      posted by  someone claiming to be oldduke on  Sun Feb 9 16:06 CST 2014 [RELATED]

      hi sages- thank you for the excellent responses. a couple questions: what would be a reasonable parts price and a good brand name be for a clutch disk, pressure plate throwout bearing and pilot bearing on this job? on an american car(dodge) it was about $100. also how hellacious is replacement of the rear main bearing seal once the trans is out(behind the flywheel?). rear main bearing seal replacement was moderately hellacious on an american tank. thanks tons oldduke








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        92 240 5spd manual- disconnecting floor shifter before pulling manual trans 200

        posted by  trichard on  Sun Feb 9 17:12 CST 2014
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        last visit: Fri Oct 24 05:52 CST 2014
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        r and r'ing the main seal is easy. you are at eye level with it as you tap it in.

        mark the flywheel and a unique block mark for proper re install position.

        i think there are only a handful of clutch makers in the world for these clutches maybe even all clutches. so many brands will be made by the same factory and have different names and prices

        sachs clutches are good but there are other clutches as good or better.

        i would not worry too much about it.

        if this was for a competition or heavy power/torque application i would go with a spec clutch out of florida.








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          92 240 5spd manual- disconnecting floor shifter before pulling manual trans 200

          posted by  Volvo From Heck on  Sun Feb 9 21:13 CST 2014
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          last visit: Mon Oct 13 20:56 CST 2014
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          Be sure to also order the crankshaft mounted pilot bearing--it will not likely be part of any kit. Do not remove the rear seal housing unless there is good reason to--the seal is a full circle--pry the old one out. Fill the void on the back of the new seal (faces to front of car) with grease to keep the spring from popping out--be sure the seal lip doesn't fold under when installing. -- Dave








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        92 240 5spd manual- disconnecting floor shifter before pulling manual trans 200

        posted by  Volvodad on  Sun Feb 9 16:30 CST 2014
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        last visit: Thu Oct 23 16:18 CST 2014
        [RELATED]

        Try FCP Groton and make sure they quote you for an OE clutch kit - a Sachs. This will come with new pressure plate, clutch disk, release bearing and maybe an alignment tool. Should be under $200. When you pull the flywheel to R&R the rear crankshaft oil seal, consider getting the flywheel resurfaced for a like-new clutch feel.
        --
        Bob: Son's XC70, my 83 240, 89 745 (V8) and S90. Also '77 MGB and some old motorcycles








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    92 240 5spd manual- disconnecting floor shifter before pulling manual trans 200

    posted by  trichard on  Sun Feb 9 07:41 CST 2014
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    last visit: Fri Oct 24 05:52 CST 2014
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    1. disconnect the back up light switch to the right of the right knee UNDER the carpet and snake it through and push it under the rubber boot so it comes out with the trans

    2. disconnect the front half of the driveshaft from the guibo and move it out of the way. (i like to remove the entire drivehaft as one piece but thats your call)from under the car use a star bit (forgot the size) to remove the set screw which holds the pin in place to keep the shifter from pulling out of the linkage frame on the trans. USE A SNUG FITTING star bit for this job. if you round out the inside of the set screw you're in trouble

    3. push out the pin once set screw is removed

    4. lift up and away from inside the car the shifter after removing the snap ring, remove the bushings on the trans linkage rod and keep them safe for reinstall of the shifter

    5. place a block of wood behind the engine valve cover so as it falls backwards the engine won't move as the wood takes up the space between it and firewall

    6. remove the bellhousing bolts including the starter 2. (the battery ought to be already disconnected) pull starter out of the way with wires attached

    7. remove the trans mount nut from the inside the crossmember

    8. disconnect the clutch cable from fork and and slide it through the bellhousing loop so it hangs free

    9.place a floor jack under the trans and jack up so the trans remains stationary as you remove the trans crossmember.

    10 have someone lower the jack SLOWLY as you rotate the trans to clear the tunnel at the starter hump and pull it back. DO NOT LET INPUT shaft hold the weight of the trans by itself. it sets inside the pilot bearing, disc and pressure plate. get that shaft out of the way and free quickly and smoothly as you drop the trans to the ground. (it is possible the trans will appear stuck because of a snug fit between the bellhousing and the 2 locating dowels on the back of the block. use a pry bar on the bottom of the bellhousing and the block to push the bellhousing out a bit to clear the dowels if necessary)

    removal is easier than install since gravity is your friend on this part of the job.

    on reinstall you will need to lift the box with a jack before rotating it to clear the tunnel and set it in the pilot bearing smoothly or have very very strong upper body strength.

    replace the rear main seal once you get the box out. you're a fool if you don't.







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      92 240 5spd manual- disconnecting floor shifter before pulling manual trans 200

      posted by  Adirondack Blues on  Sun Feb 9 09:10 CST 2014
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      last visit: Mon Sep 8 12:11 CST 2014
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      Use a good quality 6mm (I believe this is the size) hex bit (this is what Trichard refers to as the star bit) to remove the shifter linkage setscrew. Lots of penetrating oil if rusted, or you will be drilling it out (takes forever, ask me how I know). Clean out the set screw with a pick, and tap the bit all the way in to ensure full engagement. It should come out with a little persuasion -- just work carefully and you should have no problems unless very rusty. Anti-seize on the reinstall will do wonders.

      As I recall, you also need snap ring pliers to dismantle the shifter from above. Nylon bushing kits are available and cheap and will remove the slop from the shifter.

      The block of wood at the firewall to support the engine as described is very useful. Also, I have used a racheting web strap run through the shifter hole and tied to steering wheel to help support the transmission if removing by yourself.

      Definitely replace the RMS while you have it all apart.








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        92 240 5spd manual- disconnecting floor shifter before pulling manual trans 200

        posted by  Volvo From Heck on  Sun Feb 9 10:03 CST 2014
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        last visit: Mon Oct 13 20:56 CST 2014
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        Adirondack blues wrote--"Use a good quality 6mm (I believe this is the size) hex bit (this is what Trichard refers to as the star bit) to remove the shifter linkage setscrew."
        I'm pretty sure the set screw size is a 3mm allen (hex shape). While I've never removed an M47 3mm is the size for the M46 and there just wouldn't be enough room for a screw with a 6mm drive. It may be possible very late models use a Torx type screw (the star shape) since Volvo started using that sort of fastener in various places--but I don't know for certain one way or the other on a '92. -- Dave








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          92 240 5spd manual- disconnecting floor shifter before pulling manual trans 200

          posted by  Adirondack Blues on  Sun Feb 9 10:16 CST 2014
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          last visit: Mon Sep 8 12:11 CST 2014
          [RELATED]

          On my old '92 wagon, and on an '88 sedan, it was definitely a hex key. I am pretty sure it is a hex key on my '93 240 wagon as well. I am not exactly sure of the size.








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      92 240 5spd manual- disconnecting floor shifter before pulling manual trans 200

      posted by  Rolandp on  Sun Feb 9 09:03 CST 2014
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      last visit: Wed Oct 15 17:36 CST 2014
      [RELATED]

      Since my 240 1982 went thru a M-46 clutch job lately may I mention a few things that made it fail.

      1- Lubricate the fork ball joint at the far end inside the bell housing

      2- Make sure the recall spring does its work which is: pull the cable to bring back the clutch pedal.

      In my case the combination of these two ruined the pressure plate fingers, and fork ball joint wore through where it is clipped. Clutch kit was less than 75k miles.







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