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Coupling assembly: With the right tool...

31.01.2022

.... everything goes much better. That's not a truism, as anyone who has ever done any manual work knows. And that's exactly how it applies to repairs on our classic Volvos. The right equipment saves a lot of trouble and time.

Even though repairs and maintenance are in many ways easier on a PV, Amazon or P1800 than on modern cars, the list of special tools needed is still long. Most of them are, of course, no longer available from the vehicle manufacturer due to the age of the vehicles. Often, repairs have to be carried out by looking for something halfway suitable. In the worst case, a laborious search is made for a used original tool or a provisional solution is made.
Of course, not every hobby mechanic can do the latter, because skills and equipment are not available. Even in professional workshops, it doesn't always work right away.

We often work on classic Volvos, Saabs and vehicles from other manufacturers ourselves. Therefore, we know only too well what is missing and what is really necessary.
We have often enough searched for tools and solutions ourselves, often resulting in remanufactures which we of course offer in the shop.

Changing the clutch on PV, Amazon and P1800 with B16, B18 or B20 is no big deal. Er kann aber ohne das richtige Werkzeug ein paar Fallstricke bieten und für die haben wir die passenden Spezialwerkzeuge.

When removing the gearbox, the upper hexagon socket head screws between the clutch bell and the gearbox are such a problem, they can almost never be loosened with the usual tools and are almost impossible to reach. Especially in the PV, there is almost no air next to the gearbox, you can hardly reach it with a finger. For this we have our extra long hexagon socket 1080937. This is an excellent way to loosen and unscrew the screws.




If the gearbox and clutch are dismantled, it is advisable to replace the pilot or guide bearing in the flywheel, it is usually worn and will readily communicate this. Due to its construction as a ball bearing, it successfully resists attempts to pull it out. For this we have our extractor mandrel 1072815, which can be operated either with the internal extractor 1072814 or the slide hammer 1074165. The B16 has the peculiarity that the flywheel must be unscrewed for this. The flywheel's locking plate covers the pilot bearing.
Attention: In contrast to the later engines, the flywheel on the B16 only fits in one position and the screws between the gearbox bell housing and the engine are partially located behind the flywheel.




When screwing on the clutch, it is very important that the driving plate is exactly centred. If not, starting the gearbox will be an ordeal. The new clutch can be damaged in the process and can pick unsightly afterwards. This can easily be precisely loosened with our centring pin 1023786. On top of that, the pressure plate can be mounted with much less stress.




If the gearbox has already been out and perhaps oiled a little, now is a good opportunity to seal it. If the shaft seal at the gearbox outlet is necessary, the card shaft flange must be dismantled for this purpose. This sits very tightly on the toothing; if you use a standard two-arm puller here, you run the risk of pulling the flange crooked. New flanges are currently not available. Volvo used to make the puller 9992261 for this purpose, and we have had it reproduced in a slightly modified form. The puller 1072910 can also be used to pull off the round flanges on the rear axles up to the 940.




Our drive-in sleeve 1074169 is ideal for driving in the oil seal at the gearbox output without causing damage. With it, it can be knocked in straight as a die over the output shaft.




The gearbox oil also needs to be replaced after several years, even though the vehicle manufacturers have almost never prescribed it for manual transmissions. All oil ages and loses its lubricity, especially of course at such an advanced age. Switchability and service life are significantly improved by occasional oil changes. For the outer square of the oil filler and drain plugs on the classic Volvo gearboxes, there is of course almost nowhere to find a suitable spanner.
We have one:
The ratchet 1084355 for the through square fits perfectly here.

Important notes on this:

  • If space is particularly tight, the gearbox crossbar must sometimes be loosened and the gearbox lowered slightly in order to reach the filler plug reasonably.
  • Always loosen the filler plug before draining! If the oil is drained first and the filler plug cannot be loosened, then the problem is a bigger one.




Two more not unimportant tips from our repairing experience:

  • The rear gearbox cover cannot be easily loosened and pulled off. When trying, the main shaft pulls apart and the bearing needles fall into the gearbox. Then it must be completely disassembled!
  • The speedometer drive from M40 has a locking screw with copper ring as a seal. However, the thread of this screw is only very short in the cover and can usually withstand less torque than the copper ring would need for sealing. It is better to use additional liquid thread sealant 1062823 and tighten the screw to a maximum of 8Nm.




All these tools and tips can make a clutch change an easy task that can be done in under two hours.
On top of that, screwing is more fun when everything goes smoothly and the result is convincing. In any case, it is much nicer when the "old Swede" drives again on the same day and you don't have to spend days looking for tools or solutions.

Feel free to ask us!

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