Elliott,

could you please mail the reply I posted to me (bram@fangorn.xs4all.nl)? I can't find it back unfortunately, and I want to put it up on my webpage to save me some typing if it's asked again - as someone already does in another thread...

Bram

The pilot bearing is the little bearing located in the tail end of the crankshaft. The tip of the tranny input shaft sits in it. Yes, you'ld have to pull the tranny again. The you'll have to get the bearing out. The official tool is a small internal puller (ie. the type that grips inside the bearing). Since I don't have one of those, I use an old mechanics trick: pack the space behind the bearing with "chewing gum" (although you need relatively a lot of it, so most sensible people use bodykit or similar kit that stays soft and mallable), pack it down with a reasonably well fitting dowel (I found a 1/4" extension bar to be about the right size), fill it up some more, repeat until you've driven out the bearing. I've seen the same trick described in vclassics magazine using a better fitting dowel and wetted toilet paper, or even with grease although I've never had much luck with grease as you'll need an extremely well fitting dowel. An old input shaft from a tranny you parted out would probably work if the grease seals are still intact on the bearing.

Carefully drive in the new bearing by its outer race, preferably using something softer that the bearing (ie a copper pipe or wooden block the right size or whatever) although I'll admit I usually use either the old bearing or a socket.

These are standard bearings, if you quote 6202 to your local bearing emporium they'll know what you want. Shouldn't be much over $10, probably less. This bearing was used from the B18 to the last B230.

Preaching to the choir: I don't know why they're so often overlooked. As previously stated my local parts place initially forgot to order one when I order a complete kit (even though I said I wanted it) and didn't have it in stock. I've heard quite a few people say about such squeal that it's "typical of old volvo's, most do that". Those particular people should know better. To me such squeals are an indication that something's amiss and needs to be rectified on anything but a junker. And lets face it, why do a 5 hour plus $125 in parts job unsatisfyingly for want of an $8 bearing?

Bram

Don't want to cause trouble here, but unless you have owned a troublesome 960 you have no idea what a piece of garbage some of these cars are. It seemed that everytime I took mine out something failed on it. I sold it last fall and it was the second happiest day(the first was when I sold my boat). Luckily I kept the '84 760 powered by a 5.0 Litre Lincoln V8 as a second car because it came in handy as a parts runner. I will never own another 960 again and if I had to suffer driving a boring, dull, and reliable Toyota, so be it. I know exactly where the General is coming from and it pains me to have to read about his 960 troubles. Take care all!