Hello, brickers!

I finally got free time enough to breathe (and give myself tennis elbow in my dominant hand in the process). So I draine a couple quarts of ATF from my transmission and pulled the extension housing off my 1990 740GL to replace its output shaft bushing. I was trying to fix a horrible vibration for like 6 months with this thing.

The old bushing was pretty trashed and the driveshaft shop re-checked the balance. They straightened a portion that they had missed before, but I figured that the parts were cheap, so I would prefer to change out the extension housing bushing while the driveshaft was out. The bushing was the original volvo bushing and it looked like most of the damage was from corrosion from a failed seal.

Once I put the new bushing in (poorly), I left a few burrs along the top of the new bushing. I tried to clean them up and the flange goes right into the first half of the housing without issue. Then it binds up once it's about halfway into the bushing. (This is when I gave myself tennis elbow by straining to pull the flange out of the new bushing). I looked at the bushing and it looks out of round. There is a seam on the new bushing and there is a channel where fluid flows to reach the flange. The edges of the channel seem to be pushing the new bushing out of round and in towards the center. I'm going to have a machine shop work on it, so I will ask them to check the centering of the housing and check that it's actually round.

Has anyone notice this on a bushing before? Maybe I got a bad casting or was just too rough when putting the new bushing in?

I'm starting to think this 740 is cursed... anyone want to buy it? Half joking, but I don't plan to keep it past next year - 89 wagon should be up by then. Portland Oregon if anyone is interested.

Happy bricking!
Will