1990 240 clunking/ catching when in gear

  • Thread starter Thread starter lolo
  • Start date Start date
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lolo

Hello, I have a 1990 240 DL wagon that I just finished doing a whole
lote of work on. I started it and everything seemed fine, but when I
went to back it out of the garage, I noticed a clunking noise from the
drivetrain (not on startup - more like something is catching on
something else), and something feels like it is dragging? The clunk
seems to be based on speed, but it's hard to tell, because I pulled it
back into the garage right away and killed the motor. It happened in
first on the way back in, too.

Some background - M47 5 speed manual tranny with rubber Flex Coupler -
The tranny mount was broken, I replaced it, which changed the position
of it (it was sagging a little). One of the bolts holding the Flex
Coupler to the tranny flange was loose and being eaten away, so I
replaced that as well. The bolt I used was slightly longer (Volvo
prices TOO HIGH say Grog!), but I spun the driveshaft and it moved
freely - although, it was on jack stands at the time... I also
adjusted the parking brake, which could be it, although I did jack up
each rear wheel Post Noise, and they both spun freely with the parking
brake off, although, I did not jack the entire rear end up at once.
One side at a time. lazy. The only thing I did to the tranny was
change the nasty fluid, replaceing it with some ATF type F, which is
what my Bentley manual said to use.

When it first started moving, it felt fine, then - clunk - the shifter
moved as well. Went a little farther - clunk - shifter moved. I think
it was worse with the clutch depressed (zoloft?), but??? Like I said,
as soon as I heard it I pulled back into my garage and killed that
mofuzzle.

Anybody else have this issue?? i plan on getting under there to look,
but it's kinda hard to figure out, seeing as I would have to be under
it when its moving to actually SEE the problem, and that probably aint
gonna happen.

thanks

loren
 
lolo said:
Hello, I have a 1990 240 DL wagon that I just finished doing a whole
lote of work on. I started it and everything seemed fine, but when I
went to back it out of the garage, I noticed a clunking noise from the
drivetrain (not on startup - more like something is catching on
something else), and something feels like it is dragging? The clunk
seems to be based on speed, but it's hard to tell, because I pulled it
back into the garage right away and killed the motor. It happened in
first on the way back in, too.

Some background - M47 5 speed manual tranny with rubber Flex Coupler -
The tranny mount was broken, I replaced it, which changed the position
of it (it was sagging a little). One of the bolts holding the Flex
Coupler to the tranny flange was loose and being eaten away, so I
replaced that as well. The bolt I used was slightly longer (Volvo
prices TOO HIGH say Grog!), but I spun the driveshaft and it moved
freely - although, it was on jack stands at the time... I also
adjusted the parking brake, which could be it, although I did jack up
each rear wheel Post Noise, and they both spun freely with the parking
brake off, although, I did not jack the entire rear end up at once.
One side at a time. lazy. The only thing I did to the tranny was
change the nasty fluid, replaceing it with some ATF type F, which is
what my Bentley manual said to use.

When it first started moving, it felt fine, then - clunk - the shifter
moved as well. Went a little farther - clunk - shifter moved. I think
it was worse with the clutch depressed (zoloft?), but??? Like I said,
as soon as I heard it I pulled back into my garage and killed that
mofuzzle.

Anybody else have this issue?? i plan on getting under there to look,
but it's kinda hard to figure out, seeing as I would have to be under
it when its moving to actually SEE the problem, and that probably aint
gonna happen.

thanks

loren
Click to expand...

Regarding the transmission fluid: What does the VOLVO manual tell you to
use? It's the manufacturers word that is valid.

Johan
 
One of the engine mounts was broken - replaced it. The other one looks
and feels fine.
 
Called Volvo dealership, spoke to a tech - they said ATF is the way to
go.
 
Hello, I have a 1990 240 DL wagon that I just finished doing a whole
lote of work on. I started it and everything seemed fine, but when I
went to back it out of the garage, I noticed a clunking noise from the
drivetrain (not on startup - more like something is catching on
something else), and something feels like it is dragging? The clunk
seems to be based on speed, but it's hard to tell, because I pulled it
back into the garage right away and killed the motor. It happened in
first on the way back in, too.

Some background - M47 5 speed manual tranny with rubber Flex Coupler -
The tranny mount was broken, I replaced it, which changed the position
of it (it was sagging a little). One of the bolts holding the Flex
Coupler to the tranny flange was loose and being eaten away, so I
replaced that as well. The bolt I used was slightly longer (Volvo
prices TOO HIGH say Grog!), but I spun the driveshaft and it moved
freely - although, it was on jack stands at the time... I also
adjusted the parking brake, which could be it, although I did jack up
each rear wheel Post Noise, and they both spun freely with the parking
brake off, although, I did not jack the entire rear end up at once.
One side at a time. lazy. The only thing I did to the tranny was
change the nasty fluid, replaceing it with some ATF type F, which is
what my Bentley manual said to use.

When it first started moving, it felt fine, then - clunk - the shifter
moved as well. Went a little farther - clunk - shifter moved. I think
it was worse with the clutch depressed (zoloft?), but??? Like I said,
as soon as I heard it I pulled back into my garage and killed that
mofuzzle.

Anybody else have this issue?? i plan on getting under there to look,
but it's kinda hard to figure out, seeing as I would have to be under
it when its moving to actually SEE the problem, and that probably aint
gonna happen.

thanks

loren
Click to expand...
If the noise happened after you were working on it and it didn't happen
before, then recheck your work. Since the only thing you did that was
any different than before was to change the the drive shaft bolt, then
perhaps the cure would be to remove that bolt, cut it to the proper
length and reinstall it. If the noise only occurs relative to the
turning of the drive shaft then you could look closely at the bolts
through the flex-joint and see if the end of the bolt is contacting
anything. The alignment of the shaft is straighter when the wheels are
on the ground, so if there was clearance when the car was jcked up there
should be clearance when it is a ride height. What ever it is, if it can
move the transmission it will leave a mark.

Bob
 
If the noise happened after you were working on it and it didn't happen
before, then recheck your work. Since the only thing you did that was
any different than before was to change the the drive shaft bolt, then
perhaps the cure would be to remove that bolt, cut it to the proper
length and reinstall it. If the noise only occurs relative to the
turning of the drive shaft then you could look closely at the bolts
through the flex-joint and see if the end of the bolt is contacting
anything. The alignment of the shaft is straighter when the wheels are
on the ground, so if there was clearance when the car was jcked up there
should be clearance when it is a ride height. What ever it is, if it can
move the transmission it will leave a mark.
Click to expand...

Very true! I'm thinking that its hitting the tranny mount, because
when it catches it's kind of spongy. Either that or its the parking
brake doing the old nut/ bolt trick with the poorly spun drums, and the
"catch" is when the shoes reach the end of there "threading" and spring
back. hmmm, wither way I gotta get under that !@^#$%$$% thing. Oh,
well, almost done. The engine sounds great!! New rings and bearings
all around....

thanks to everybody who posted to try and help me figure this out, I'll
let ya know what it was in the end...


Loren
 
It was the bolt barely hitting the shifter linkage....

thanks again

byebye
 
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