I have parted out a 1992 245. I am putting the engine-automatic transmission into a 1989 sedan. I removed the engine-transmission, then separated them in order to replace the crankshaft seal and front transmission seal. I do not know how to properly orient the flex plate. Bentely manual is vague. Brickboard is vague. Volvo did not make this easy. Does anyone have a solid answer as to the placement of this flex plate. The penalty for me putting it on wrong is very high.

In case you were not previously familiar with John Sargent's qualifications, I can tell you his answer is the solid one you are looking for. I agree it would be (and has been) a costly mistake to get it wrong, and that the books are indeed vague.
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Art Benstein near Baltimore

I know a guy who's addicted to brake fluid, but he says he can stop any time.

What is the likely consequence of fitting the flex plate in the wrong position? Out of balance vibration at certain speeds?

Slightly of-topic but possibly relevant.
AW70 fitted as a replacement for a BW35 on an Amazon Wagon/Combi. All works fine except for passenger side rear wheel (LHD the one that basically does the driving) giving a bad vibration at certain speeds. Similar to an out of balance wheel, but wheels, shocks and even the axle, have been changed with no improvement. Investigation is travelling towards the gearbox. Propshaft which has a custom front section which is going to be checked and rebalanced again if needed before dropping the AW70. Has new centre bearing and mount.

derek uk wrote--"
Slightly of-topic but possibly relevant.
AW70 fitted as a replacement for a BW35 on an Amazon Wagon/Combi. All works fine except for passenger side rear wheel (LHD the one that basically does the driving) giving a bad vibration at certain speeds. Similar to an out of balance wheel, but wheels, shocks and even the axle, have been changed with no improvement. Investigation is travelling towards the gearbox. Propshaft which has a custom front section which is going to be checked and rebalanced again if needed before dropping the AW70. Has new centre bearing and mount."
Two things regarding the custom front driveshaft section -- 1. The front and rear sections must be balanced together. --- 2.The orientaton of the three u-joints must follow the original orientation (the same for all multi-section driveshafts). Here is the best way I can describe what is correct (short of providing a drawing)---If you set the front flange of the front section so the u-joint loops are parallel to the ground the rear most flange (connected to the differential) must be vertical to the ground--in other words if the rear flange and front flange were joined they would form one u-joint. This alignment has two "correct" solutions--but only one of those would be correct for the balance of the whole system provided the entire driveshaft has been balanced using the correct alignment. I know the Greenbooks and independent repair manuals have such a drawing. I've had two driveshafts made for 240 V8 conversions. -- Dave

Thanks Dave. I'm not the owner of this Wagon but he is very old Volvo savvy. He's had this car for 31 years and it would still grace any show field. He and me are clutching at straws on this. If he can't find an answer the BW35 will be going back in. I found the prop shaft out of phase on my wagon when I got it but frankly didn't notice any problems like that or after correcting it. No obvious difference, so the overall balance must have been very good. A new bearing and rubber mount did get rid of some annoying noise though.

Your vibration problem is probably unrelated to flexplate improper orientation, which would cause poor engine performance, or no start at all. The horror of misaligned flex plate orientation is you have to separate the trans from the engine to correct it. Stabbing a trans on a 240 is a horror. Trust me on this. The clearance makes it very difficult for a shade tree mechanic.

Removing a 240 transmission, if manual is not that bad.

However, I will concur with a slush-o-magic. A friend of mine, and yes, he's still my friend, spent a solid 8 hours putting one in a few years back. Not something I ever want to repeat ever again!

Matt

There are pics here, Haynes, Bentley, cleanflametrap.com,.....
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240 drivers / parts cars - JH, Ohio

Put the engine on #1 or #4 TDC. Install the flex plate with the two hole void in the starter opening.
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john

Thanks. It worked. By the way. If you think you have located a problem, methodically check other possibilities anyway. I have wasted many many hours by not doing this.