Lili the Volvo 240 gets New Clutch Parts!

[@bluej511]

That flywheel could still be glazed over without being blue. You can run some very fine sand paper over it to give it a little clean if you're not replacing it. New clutch might wear to the old flywheel if that makes sense.

[@Involvod]

That's a good point! It's operating nicely at the moment after a few drives hopefully it stay that way 🤞

[@bluej511]

@@Involvod I'm usually one to replace all 3 not a fan refinishing flywheels or brake rotors.

[@jfv65]

​@@Involvod offcourse it will. the disk will gradually bed in to the flywheel and pressure plate and it will be good for another 100kkm. it's not like it's a turbo car with 350Nm or so. it'll be just fine! When you slid that prise axel in and pushed the box all the way to the block face i was like "yessss, he's on the home stretch now!" jobs a good'n!👍

[@Involvod]

@@jfv65thanks, that makes me feel better and yes, it was a glorious moment!

[@julianherring5625]

@@bluej511 good luck finding a dog dish in this day and age! Those fly wheels are no easy find.

[@sjbock]

I had an 1985 240 GL sedan the same color with the same seat coverings as yours but with an automatic transmission and sun roof. I've never seen one like it in the US where I am. I bought it new and in October 1993 traded it in with 90,000 miles for a new 850 sedan. If KZbin had been around back then and I knew what I know now about cars, I would have kept it. I'm still driving the 850 thanks to Robert Spinner's KZbin videos.

[@Involvod]

Wow, from new, that's amazing! RobertDIY is a blessing to 850 owners I already watch him almost every day but will be watching even more when I inevitably buy one! I recently found out the seat covers are called Pullman, I can't get enough of them!

[@DeanofMachines]

Oh how I can’t wait to see you on a lift. Rolling around the garage gets ooold

[@charlie225]

Good day Sledge, u sir are an incredible mechanic to be able to do this job in a tiny garage space on ur back is incredible, hopefully ur new place will have more working room( maybe a lift )!🙂

[@Involvod]

Thanks buddy!

[@GentilsGarage]

Excellent work once again. It’s very rewarding to do all that work resulting in a car with a nice gear change and no loss of power

[@Involvod]

Thanks, it really is!

[@SiteUnscene]

Always pack the rear of the seal with bearing grease to hold the seal spring in.

[@mayflowerlash11]

Nice effort reinstalling that box. I have two automatics but if I had a manual I don't think I would try this. I'm getting too old. That deep blue paint really suites the 240 sedan body. The rims are lovely and the manual would be a joy to drive. It's a nice car.

[@Involvod]

I definitely wouldn't try it alone if it were an auto! They weigh at least twice as much 😬 And thanks, she's a real beauty

[@bodhi_db]

The flywheel surface had a similar ‘finish’ when I replaced the clutch. Also didn’t end up getting it milled.. So far so good. Enjoyed it as always!

[@Involvod]

That's good to know, thanks!

[@lifelong5425]

Well, that was quite the task, and you did it.

[@Involvod]

Thanks! I think it's a fair bit easier on the 2nd time, not that I want there to be one!

[@fhwolthuis]

I'm always amazed at what you manage to achieve on your own, Sledge. Really admire that 💪🏻😀

[@Involvod]

Thanks! I should have had Miss Involvo'd's help but was too impatient 😄

[@Phiyedough]

I had also never heard of getting flywheels machined apart from for racing.

[@SiteUnscene]

When the flywheel is machined, the step of the flywheel has to have the same amount of material removed, which means removing and reinstalling the guide dowels. A lot of machine shops won’t resurface stepped flywheels.

[@marcinbujok7388]

Congrats mate! Looks like a total success 😀. So much to learn on this video. Thanks again for documenting it for us! A Hero we didn't deserve 😆. Cheers!

[@Involvod]

Haha, too kind mate!

[@austintalley4070]

Thorough job. Well done.

[@Involvod]

Thanks!

[@jackjacko8706]

Good job, I have felt the same apprehension when you are ready to take the weight of the box and start wriggling. Before those alignment tools were available and we didn’t have the appropriate spline shaft from an old box, we had a mate sit inside and whilst wriggling the box an turning the shaft (box in gear) get him to put his foot on the clutch peddle to release the clutch and hopefully centre it.

[@Involvod]

Oh wow, what a job that must have been!

[@danjones2913]

Love the work and the teachings along the way. Keep it up, no easy feat doing a gearbox job on the ground!

[@Involvod]

Thanks!

[@fannycraddock99]

Great work Sledge. You have amazing patience and good memory as to how the pieces go back together. I can hardly change a battery in a clock without getting it wrong!

[@Involvod]

There's also some magic in the editing 😃

[@SimpsonsClassics]

Well done bud you smashed that fair play to you. Like mentioned the other day I really need a 240 in my life.

[@Involvod]

Definitely!!

[@geoffmoore7629]

A couple of self tappers either of the rear main seal and a pair of pliers will make for an easy removal of the seal and a cut down plastic bottle over the end of the crank ( well lubed) will help the new seal on

[@herrjonna2007]

Like, this is such great timing, like you would not believe! Re-assembling my clutch tomorrow! Wow am I glad this came tonight

[@Involvod]

Haha, perfect! But take it all with a pinch of salt, it was my first one, the information might not be reliable 😃

[@herrjonna2007]

@@Involvod Yeah, but honestly it's the best all-round information I've been able to find! Tried getting the transmission out a couple of days ago, and it was just so stuck! We had to give up since it was getting late... Patched it back up and it had developed a nasty shake from the axle (had to patch it up as this was on my office parking lot haha)

[@Involvod]

@@herrjonna2007 ah that's a shame, as you saw I really struggled to remove mine, I think it got easier once the box was lifted up high enough at the back so it's level. Good luck with it!

[@Bassalicious]

@@herrjonna2007 In case it really fights you and tapping it with a rubber mallet and wiggling doesn't help, there's a little cavity / cut-out on the bottom of the bell housing you can utilise. If you pause the video at 16:34 you can see it. Edit: might be easier to spot at 16:31 just above the lowest bolt.

[@herrjonna2007]

@@Bassalicious that's a really great tup, thanks!

[@ched999uk]

Well done for getting that gearbox back in. I once spent 3 hrs trying to get a used gearbox to fit only to eventually find out that an extra dowel was on new box - hitting the dowel on the block!!! Have to remove an alternator myself this weekend as not charging!

[@Involvod]

One of those nightmare scenarios! It happens to the best of us 😂

[@ched999uk]

@@Involvod It wasn't funny at time but is now.... Alternator out in 90 mins, which I was pleased at on modern vehicle. Have a great weekend.

[@Involvod]

@@ched999uk nice! Thanks mate, you too

[@mathuetax]

The radial play in the input shaft isn't exceptionally high, it has needle bearings and a sizable ball bearing supporting it inside the transmission and the tip of the shaft is supported by the pilot bearing. So long as the pilot bearing is in good condition (in your case, new!), there isn't an issue. I think I mentioned before about the Dana/Spicer 30 rear ends howling, certainly the 1970 145S that was my family's main car howled from when the car was new. When I drove it years later as a teen it still howled the same and I thrashed that poor car. It has to do with the hypoid gear alignment which is not a fun procedure to do. As for resurfacing flywheels, I suppose it might be truthful that it isn't done much anymore since manual transmissions have long since fallen out of favour. Ideally, this should be done with a new clutch to remove high spots and glaze but it isn't like you're driving it that aggressively. It's not an externally balanced engine so I don't see why the machine shop would say it'd need to be rebalanced, it just needs the glaze removed :D

[@Involvod]

Thanks, I was hoping someone would give a bit more insight into the shaft set up. To let you in on an upcoming video, I checked the oil in the diff and found why it was noisy, bad times indeed!

[@mathuetax]

@@Involvod Oh no :/

[@Parknest]

Sledge, I feel your pain. I've done this very job quite a few times. The last time was on a 2007 VW Beetle. Getting the gearbox back on is the hardest part for me. Lining up the gearbox is like docking with the ISS. With the Beetle, I ended up borrowing an engine crane from the local garage to get the gearbox back on.

[@Involvod]

It's really not a fun job is it! 😩

[@Bassalicious]

I changed the clutch on a VW Passat I had when I was 20 or so. Swore myself to never ever do a FWD clutch without a crane and alignment tool ever again. Shit was a nightmare. Took me 2 full days of pure pain and despair. 5.000km later the engine shat itself. I still hate those shit-boxes with a passion. The only redeeming quality about that soulless piece of rubbish was teaching me to keep my fingers off of them and FWD clutches in general. After suffering through that freaking ordeal the 240 clutch job feels like a walk in the park.

[@Parknest]

Yeah, FWD cars are a pig of a job to change the clutch, the Beetle being a case in point.

[@Bassalicious]

@@Parknest I got a little carried away by my disgust for that POS I used to drive there. I wanted to say I feel for you and anybody attempting that job at home. RWD is just superior in every way important to me. Especially as maintenance friendly ones as the old Volvos are. God I still despise that utterly emotionless pile of steaming excrement though. *shudder*

[@RichieRouge206]

Awesome job, well done fella! Your perseverance paid off!

[@Involvod]

Thanks bud!

[@Bassalicious]

The flywheel looked good enough to me. A little wavy with slight heat spots but nothing major, it'll be fine. Only thing I'd have done differently is to put a piece of wood on the jack to extend its reach and put it a little further back underneath the gearbox. Might have saved you a bit of wrestling. Nice safety setup holding the box in the interior though haha. Just the right amount of creative jank, very nice. :P

[@Involvod]

Thanks man, it looked a bit better to the naked eye but the camera definitely showed up the waves didn't it. I've got a bigger jack in the UK can't wait to have it back 😅

[@Bassalicious]

@@Involvod Weird how that works yeah. I can tell you from experience my ugly mug looks much worse on video than in a mirror too :D

[@bremms1]

Run a piece of masking tape around the output flange. The main seal will slide right on.

[@mattwelch4025]

Woo Hoo! I felt so good after watching this, you'd have thought I'd done it myself..... great video!

[@Involvod]

😄 Thanks!!

[@SiteUnscene]

The clutch lever ball retainer can be installed into the lever beforehand, then just push it on the ball.

[@johanvandermeulen1665]

Another job well done!

[@Involvod]

Cheers!

[@SiteUnscene]

You can remove the pilot bearing with bread, or grease.

[@julianherring5625]

I have a Volvo 240 that is currently being m47 swapped. I got the flywheel lightened, I was told by a Volvo mechanic of 35+ years that if you take off equal weight the flywheel doesn’t usually need to be rebalanced. Which makes sense to me because If the weight is equal all around why would it need to be rebalanced? We took 6 pounds off of mine.

[@Involvod]

That's what I thought!

[@Schwedenstahl245]

Whenever I do a clutch job, I always have the flywheel re-surfaced. Mostly for peace of mind, I suppose. That said, the "dog dish" flywheels as found on the later cars are a bit harder to re-surface (because they are not flat) and not so many machine shops have the correct tool to complete the process. You're lucky that your 240 has LH2.2. On the LH2.4 cars with manual transmission, you have to properly align the flywheel upon re-installation. Failure to do so will result in an erroneous reading from the crankshaft position sensor and this equals a no-start condition. Which means you get to pull the transmission AGAIN.

[@JMassengill]

If you installed the whole clutch and didn’t draw blood did you even replace the clutch? I hate drawing my own blood but it seems to be the way things go.

[@Involvod]

Definitely! I normally always wear those purple gloves for that reason, take them off for 5 minutes...

[@JMassengill]

My wife always ask “wouldn’t you wear gloves while doing that job?” And I never do or did. I could never get used to them……

[@Involvod]

@@JMassengill I used to be the same, but ever since I tried these oil plus wonder gloves, not sure what they're called, it was a game changer!

[@alexkobko7549]

As far as I know you had problem with get 1 or 2 ⚙. Had you solved the problem via replace the clutch? Could you tell me approximately repairing price?

[@Involvod]

Yeah it's all ok now, could have been due to replacing the pilot bearing too as someone mentioned in the comments in the last video. I spent probably around €150 on the bits

[@dbt2787]

I always wonder why you get into the passenger side but then I remember that cars over there are LHD😂 Great video as always mate!

[@Involvod]

Will get some funny looks in the UK I'm sure 🥴

[@jimralph8066]

Great job as always in such a cramped space 👏

[@Involvod]

Cheers!

[@lisah2804]

Very helpful video makes me wanna attempt it I believe I only need a pilot bearing but might as well do it all

[@Involvod]

Thanks! You can do it 💪😁

[@williaml8000]

My M46 input shaft wiggled the same as yours I think it’s normal

[@Involvod]

That's reassuring, thanks!

[@jackharriet4814]

Sledge you missed a few opportunities to say 'that's what she said' around 12:30...

[@Sam-km8vo]

Love the video. I used to have a 1987 740 GL and loved it so much. I am trying to find a 240 but struggling have you any advice for me. Have you considered looking at the Volvo 360 as that has a 2.0 red block engine.

[@jfv65]

a 360 is even rarer. Specially the 5dr GLT sport version. Many 2.0L inj. cars in NL ended up as race cars because there used to be a 1 model racing series on Zandvoort circuit. (Volvo 360 NOT-Modena Cup) So if you fund a good 360GLT for a good price snap it up because there are not many left!

[@Involvod]

I noticed how rare and expensive the 360 is now, would definitely buy one! Good luck with the search, our usual tactic is to keep checking online and be very quick when one does come up!

[@Sam-km8vo]

I knew some friends was selling a B reg 360 glt at the time they offer it to me for £1200 wish I snapped it up. I regret ever selling my 740 and I even own a J reg 940 auto I prefer the saloons to the estate though.

[@Sam-km8vo]

Another classic Volvo to also consider would be a 260 if you can find one or the 760 or 960 if u can find them

[@stevenmiller7731]

Sam, I am in New York, USA. Where are you? I have three Volvo 245s. 1988 automatic, 1989 five-speed, 1992 automatic. I will be selling one of them, maybe two. Let me know if you’re interested and I can tell you a lot more about each one.

[@salsolo2403]

well done man 👍👍

[@Involvod]

Thanks!

[@seanwade58]

Just took out trans on my 240! Balanced on my face 🤣😬 we’re did you get clutch kit? Cheers Sean

[@Involvod]

Haha, gotta do what you gotta do! I actually moved an M47 around the other day and it was really not too heavy, I think there's a big difference when your arms are above you and the blood has drained out of them 😅 I think I got the clutch from Skandix, but on the next one I'll probably use either Autodoc or Motointegrator, much better prices 👍

[@seanwade58]

Top stuff man!! Much appreciated 👍🏻

[@LongbowMedia]

@15:04 is way too relatable 😂

[@rickwilkinson1843]

Another great video 👍

[@Involvod]

Thanks man!

[@hungryboy424]

Well done , i feel your pain, was in to doing jobs like this when i was younger and a lot fitter !

[@Involvod]

I'm already wanting to consider myself not young or fit enough to do these kind of jobs 😄

[@enriquelopez9124]

Awesome 👌 👏 job.

[@Involvod]

Thanks a lot 😊

[@mikestinyshedofdreams]

well done, thats a hard job to do without a lift or any help

[@Involvod]

Thanks mate

[@mitchmurrell753]

I enjoy the content and your dedication as a creator, but the cubic dollars you spend on these cars is crazy!

[@egbertgroot2737]

All of a sudden my clutch lever coming out the 240 gearbox mounted on my 144 Volvo is loose! I did manage to drive home without a clutch pedal by starting the engine while in 1st gear. Do you have any idea what might have happened?

[@SiteUnscene]

Heat glazing should be machined off the flywheel. But you do you.

[@zarkozare6765]

Mislim kada se montira semering na radilici da se ne koristi mast

[@surrumobonyi7387]

I need a 1992 Volvo 240GL, please confirm availability.

[@ColinBradley-rs9sk]

When I do the pilot bearing I fill it with grease then put something the same size as the centre of the bearing the pressure pushes the old bearing out still messy 😂

[@honestaquarian]

R.I.P. London Bridge is down (The queen has passed)

[@Involvod]

Well I heard it from you mate, I appreciate that. Never nice to find bad news whilst scrolling social media.

[@SiteUnscene]

I bought a cheap scissor transmission jack, but to use it you have to have the car on jackstands all four corners as high as it will go.

[@worldhello1234]

@4:46 You mean the Weird Beard, right?

[@doctorsocrates4413]

I would love to be you for a week..save a fortune in garage repairs lol.

[@Involvod]

Haha, thanks! The problem is when you can do more, you do more and it costs more 😂

[@schande]

all of the sub 100 horses ... hahaha