This School Boy Error led to a Ruined Differential | Volvo 240

Checking the rear axle/diff oil on the Volvo 244 and finding something I didn't want to. At least now we know why it was making a noise.
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#volvo #volvo240 #differential

[@Involvod]

Update! 6 months and a few thousand miles later and I have a slight seepage from the "homemade" gasket. So definitely not advisable as a long term solution, but definitely a viable get-home bodge!

[@bobjohnson1587]

Here's something that may help brighten your situation. I had a similar thing occur to me 18 months ago. I removed the fill plug on the differential of my '90 740 with the 3.73 rear end and found the level to be way down. I mean WAY DOWN! Even lower than yours. I had been experiencing occasional on and off whining from the back and had thought it was the carrier/hanger bearing. (It wasn't.) When I drained the differential only about half of the fluid that should have been in there came out. It was a very scary moment! However, there were no chunks of metal, metal filings, etc. present in the fluid. So, I refilled it with the correct grade, quality Castrol differential fluid. The first time I drove it I immediately noticed that the on-off whine that I had been experiencing was now gone. That was now about 10K kilometers ago and the differential is still as quiet and as good as it ever was. Those Dana diffs are tough, well-built rear ends. So, you might be ok, too.

[@Involvod]

Sounds like you caught it just in time! Hopefully they both hold up. Everyone has been saying how tough they are

[@corychecketts]

I love your resourcefulness. Really inspiring for when I get frustrated with working on my 240.

[@Involvod]

Thanks buddy!

[@davec6724]

240, 740, 760 & 940 have taper roller bearings on the axle shafts sealed off from the rear end fluid. Typically every 3-4 years I'll pull the axles out, repack them with a lot of wheel bearing grease and do a rear end fluid at the same time. To get the maximum amount of gear oil in the diff, spin the drive shaft while squriting in the last bit fluid in until you reach overflow. I believe these are Dyna rear ends and can take a lot of horsepower and abuse. Good luck.

[@Involvod]

That's a great tip, thanks!

[@jctaiter]

Just put liquimoly mos² for gears and let it rebuild the teeth. & Bobs yer uncle

[@colleenisaac6647]

I love watching your KZbin’s because it reminds me of my auto shop classes in high school! (1970’s!) where I could actually change (find) spark plugs, etc! It was odd to have a girl in auto shop back then but I had fun.

[@Involvod]

Those were the days 😃 Glad you're enjoying it!

[@Burritosuupreme]

That’s my worst fear with installing a “new” axle in my 245. Sorry you’re going through that too. I’m wondering if one of your axle seals went and let the fluid out. They’re super sneaky and go unnoticed until you have the rotors off and by then it’s too late. That’s what happened to my buddy’s 240 rear axle.

[@Involvod]

That's a very good point, could be as I was really sure the level was fine last year, but maybe I just checked the fluid condition and didn't do a final level check when it was installed. Either way I'll remove the rotors when I pull the axle and see 👀

[@Burritosuupreme]

@@Involvod best of luck finding a new axle and on your move!

[@RobReynolds]

So is nobody commenting on "This is the end of Involvo'd Germany". Is this just a road trip? Are you moving to the UK? What's the craic?

[@Involvod]

I think alot of people know, the rest don't care 😂 We're moving to the UK 👍

[@mortimergladbreath]

I wish my 92 had a drain plug! I want to change oil but I also don't want to reseal the cover. I might vacuum it out. Good luck with your journey!

[@Involvod]

Yeah much nicer to have a dedicated plug, I even noticed my fuel tank has one whilst I was under there! So happy about it 😄

[@Involvod]

And thanks!

[@bodhi_db]

No worries! You can still drain her via the lower cover bolt. It's threaded pretty much all the way through the diff and acts as a drain instead.

[@frankvitullo3735]

If you take out the bottom bolt on the cover, it acts as a drain. No need to remove the cover and re seal it. I did my 1992 240 wagon last week and that’s what I did. The older units had a dedicated drain plug under the differential. The newer models used the bottom bolt on the cover as a drain plug. Just unscrew the bottom bolt and the hole goes through to the inside of the differential allowing you to drain the fluid.

[@jfv65]

Don't take this absolute gospel but sometimes the lowest bolt hole in the cover/dif housing is also a drainhole. Just remove that 1 bolt and see if oil drains out. If nothing comes out just bolt that bolt back in.

[@christiaansparidaens8810]

Have you all looked in the Netherlands? On a auction site i found one

[@Involvod]

Thanks, will keep an eye out!

[@martij30]

The diff will hold up just fine. They're overbuilt anyway and when you push it they can handle about 300 horsepower I think. My 360 has the same (or very similar) diff in the rear and even though it's been serviced well it also has a very distinct whine at 100 to 130 or so. Doesn't sound bad, it's just not common on modern cars and it's there. I got used to it and even like the sound now.

[@Involvod]

That's what I'm relying on! If the noise doesn't get any worse I could definitely get used to the added character it gives the car, a bit like piston slap!

[@nachoangeloni6062]

I replace diff oil every 3 years independently of mileage I put on it. It is cheap and easy to do. The only headache is that if you lift the car then is uneven for refilling it ... but anyway I typically use the car entrance and then lifted from the lower side to make it as balanced as possible. Regards, Nacho.

[@Involvod]

It's definitely a good idea. I normally lift the body of the car and take up the travel in the suspension to give me room to squeeze in but leave the wheels on the ground, seems to give enough space

[@mattbooden559]

I have a few questions!! I own a 92 240 with ABS. This week my diff started making that same noise. My diff is leaking, definitely from the pinion seal. Mechanic said it might be some of the bearings that are shot. Since there is no drain plug, is taking the cover off the only way to change the fluid? Also, what did adding the thicker fluid do? Just curious. Cheers.

[@Involvod]

TanzanianDevil is right. As for the thicker fluid, it helps fill the space in-between the worn parts better than a thinner fluid would do, so it can slow down the wear and also help a bit with the noise

[@OlaJustin]

My '76 245 has a whine too at 80 km/h and above. They can go on for that forever. It sucks though that your diff hid the oil. Where did it go, did you find out? You have a leak at the end of one of the axles? Oh, and don't trust that gasket... Oil will desintegrate that paper with time and I bet you it will start dripping sooner than later. Any car or mc related shop should have gasket material to make your own gasket. ;)

[@Involvod]

Good to know and thanks for the heads up! Not sure if it's leaking from there, could be, or I didn't check the level/correctly. But once I arrive in the UK I can remove it and get another one in there

[@OlaJustin]

@@Involvod I think the leak will be at the diff but you notice it when oil pours out the other end. Not sure though. Good luck and it'll be an interesting video at least! ;)

[@papplet1]

Those axles can clonk and whine for a long time before they give up if you dont abuse them 🙂

[@fannycraddock99]

Sad that the German adventure has come to an end Sledge but I'm looking forward to your homecoming and more videos from you. Safe travels.

[@Involvod]

Thanks!

[@mikestinyshedofdreams]

must check the oil in mine, it makes a lot of noise.

[@Stale_Mahoney]

it seems like it was the smal gears that had taken the beating not the big ones to be fair, those you can buy new and replace in the diff if it is of interest

[@Involvod]

Thanks that is good to know 👍

[@wad4865]

Hi @involvod, I have a problem with my volvo 960 AT. It clogs the strainer with clutch material. Have you ever experienced something like this? thanks

[@stephonwingard]

Thanks for the vids dude I’m working on my 940 and ur videos help a to!

[@Involvod]

Thanks for watching, glad I could help!

[@dreamsun69]

Yes lad, great timing!! Right before work

[@DeanofMachines]

Much quieter for sure!!! It'll definitely make the trip!

[@Involvod]

Thanks, makes me feel better!

[@fhwolthuis]

What about replacing the diff only? Or are the shafts gone too?

[@Involvod]

The problem is finding the bits and having the tools and expertise to set one up, apparently it's not the easiest thing to get right 😬

[@Gianmarco750]

Hi, I have a 1993 volvo 245. I also wanted to change the differential oil but there is no drainage plug in the differential. I've looked everywhere, the diff underneath is completely smooth. How is it possible? Thank you

[@Involvod]

On the later 240 with the aluminium diff cover, the way to drain the oil is by removing the lower bolt in the cover and it should drain out 🙂

[@Gianmarco750]

@@Involvod Molte grazie. Voglio provare

[@cheharrison7107]

Thanks for this, I need to do this to mine, I pause your vids and screen shot them so i get the right stuff. Sorry about your centre console, old Volvo plastic is not the strongest! Take care buddy 🤘

[@Involvod]

Very welcome mate! The interiors were doing quite well until I bought them, now with daily use they have aged more than in the 34 years previously 😅

[@matollsen2523]

On the dif, any play is bad, obviously. But how this happened: English man, Swedish classic car on German number plates?

[@1961kickboxer]

My 1993 torslanda hasn’t got drain plug for diff but my 1990 740 has I changed diff oil on both.

[@JuanRodriguez-jn7zx]

Gracias!!!

[@kosakristof2138]

My 460 also have this sound but only in 4 gear (fwd car) but i thing its just the gear's theeth.

[@ثائرالعبادي-ص9ن]

Hello my friend, please tell me about the percentage of Valvo 940 . oil

[@DScottDay]

Yah, I can relate to a smart guy who calls it a "big, spinny thing." You rule, Bro!

[@timbre7999]

Poor you, getting eaten alive by your Volvo's interior. I had a lockup once but always forgot to bring band-Aids there so I developed my own from pieces of paper towel and masking tape. Works a treat and for a the time I was 'famous' for my DIY bandages :) I see you make your own as well and a mean DIY paper gasket, Kudos!

[@Involvod]

Haha, cheers!

[@lifelong5425]

Soldier on man...pip pip...you can do it. Love that you can work through the aged DL issues...Such a nice looking 4 door, and the new wheels really give it that upscale edge.. Enjoy the ride back to Blighty, and anticipating your hook ups with other Volvo types on your return...Always enjoyable to see what u r up to....BTW..that bloody plastic get so brittle....ouch

[@Involvod]

Thanks man, much appreciated!

[@AstraWerke]

An old farmer's trick was to fill a howling diff with oily sawdust... And then sell it while you could ;P

[@Involvod]

I did consider it 🤣

[@haardkaar]

Coming up! Quaife diff or aussie locker Brr.brra..braaap..brraaar

[@peterwalker6446]

Gonna check my diff oil level now I think. Last time I checked was easily last year and it never leaks but this video might save me from catastrophe if I catch a problem now!

[@Involvod]

Thanks, I'll definitely be checking all of mine on the regular going forward!

[@KeithintheWoods]

I also took a big chunk out the centre cover, feels like its made of stale waffles

[@doctorsocrates4413]

Absolutely love the creativity with the amazon envelope..wonder if that trick works as a head gasket lol...thank you for the video..Much appreciated and safe travels.

[@SimpsonsClassics]

Oh mate the main thing is that you found it and sorted it. She will make it over to the uk no issue 👍

[@Involvod]

Thanks mate 🤞

[@dbt2787]

im only a rookie mechanic but never in my life have i heard of a paper gasket!

[@theAngelofhevn]

I had that exact same sound for over a half year. Nearely had to have hearing protection on. When i bought mine it haf like 2dl of oil in it but no shavings. Now i got a new rear end in it and its good.

[@Schwedenstahl245]

As alluded in previous comments, the whine / noise could be the ring and pinion, but it would also be worn rear axle shaft bearings causing this noise (or the fluid to drain out). You can check the outside edge of the rear brake shields for seepage. Don't feel bad or beat yourself up - a mate of mine and I once did a transmission conversion on his S70 T5. We didn't know that after the wrecking yard drained the gearbox oil, they didn't torque the drain plug - they just put it back in hand tight. We filled up the transmission after the swap and went for several drives. After a few hundred miles, the drain plug rattled out and dumped all its fluid. This lead to a trashed gearbox.

[@Involvod]

Ah damn! One of those sickening moments! Really happens to the best of us 😄

[@Schwedenstahl245]

@@Involvod I wasn't in the car when the transmission locked up, but my mate was driving it on the highway and both front wheels froze completely. There was smoke from the tires dragging on the concrete for a hundred feet, along with all the heat from the transmission. Funny thing is, the engine survived just fine!

[@JMassengill]

That diff looked better than the 1960 Fury Coldwarmotors just did the diff on. The glitter in that pan made my heart sink. Good luck with the repair

[@Involvod]

Thanks, I'll check it out!

[@walterthater6338]

Only the brave! All the best to you!

[@mayflowerlash11]

Is the whine caused by poor adjustment between the pinion and crown? That seems to be where the slack or play is when you turn the tail shaft while looking at the diff with the cover off. My amateur guess. The other suggestion of a leak into the axle housing is another possibility (guess). Good luck.

[@Involvod]

Yeah I think it could be, will have to check that

[@julian7868]

Where does the whine come from in Lili? 🤔 Cause a week ago, I’ve got a whining sound as well but it’s not always there and it seems like it’s coming from middle/front of the car. Sounds a bit like a failed bearing so I suspect the bearing that supports the drive shaft but I’m still not quite sure as it’s just quiet sometimes which would be quite odd. Maybe it’s caused by the worn engine mounts that put some kind of pressure on it but yeah idk really

[@Involvod]

It could be the carrier bearing on yours, it is quite common to need replacing 👍

[@boobbutthole9537]

Time to weld the diff and make some drift videos

[@ched999uk]

Does the pinion have a brass shim to set insertion depth? Looked like a lot of brass coloured filings in the oil can. I wonder if that has worn due to the low oil level and that's what is causing so much play in the crown wheel and pinion? If it was full of oil there is a slight possibility the oil seals at the wheel ends could be leaking? Might be worth checking the drums and maybe getting ADAC or equivalent cover for the journey?

[@Involvod]

I'm not sure, I've no clue about diffs, would like to learn one day though. You're right though the glitter did look a bit gold-ish. I've got ADAC cover, hoping I won't be getting dragged straight back to Berlin after trying to get out for so long 😅

[@fgrecki]

So what was the issue in the end? Wrong type of oil, wrong level??

[@Involvod]

Thanks for the comment, going to pin this because a couple of others weren't sure either. So the differential got noisy because the fluid level got too low and caused damage. I've been driving it around like that and didn't check it, that was the error

[@jean-marclestic8150]

The level was not catastophically low though... Well at least you can drive.

[@tomgodfrey5891]

Not low enough to cause any damage

[@bobjohnson1587]

It's not all bad news, Sledge. Just think of it as more 'content'! Right? 😆

[@Involvod]

Haha, always 😄

[@bodgymechanic9948]

I admire your persistence. I've had my faith in my Volvo tested this week. Admittedly it's because the Holden engine that's been fitted into it has blown an exhaust manifold. I think this is due to the transmission changing on pressure because no speed sensor was fitted to the gearbox when the engine was installed. Why would anyone get a car with a retro fitted engine 😖

[@Involvod]

Ah yeah, I once had a 1983 BMW 5 series with a 1.7 Isuzu Diesel engine badly fitted, had so many problems!

[@Juancheros]

Nice video thanks for posting! Interesting to see lots of metal in the diff oil. I had an 84 automatic wagon that had a diff whine since I got it. I then put more than 200k miles on it. The whine stayed the same and never got louder. It had a Dana 1030. Because you have a manual, yours is probably a Dana 1031 which has a larger crown gear.

[@Involvod]

That's reassuring to hear, I wasn't sure if the noise got very slightly louder, but now with oil at the correct level hopefully it doesn't get any worse 🤞

[@vaughanwarburton9623]

I've used lucas non slip for auto transmissions in my 1971 manual land rover in gearbox and diff works great 👍

[@Involvod]

Thanks, thought about chucking an additive in there, wasn't sure which one

[@RichieRouge206]

My original 740 had the diff go and at the time I couldn’t locate a reasonable replacement plus family things so that’s why that had to go. Really regret it. The thick oil should cover you, the gears look very clean and undamaged so you have a good chance of getting back.

[@Involvod]

Ah that's a shame, it's a big problem to sort out. Fingers crossed man, I hope so!

[@marcinbujok7388]

Nice! I bet this thing is gonna last for a long time now :). And yes, 240 diff has that much play as I checked recently 😅. You will arrive to UK with no issues, mate!

[@Involvod]

Thanks for the info! And for the confidence boost!

[@sebastianbrrrr7372]

Though probably not much fun for you to do, I enjoyed watching the video nonetheless, having just now come home from lying under an old Passat for hours. As for the noise: have you ever tried MoS2 or any ceramic stuff?? I did with 50:50 results, but since I never got any problems after using it, maybe it's worth a try. Well, then again... Won't put back the metal chunks of course.

[@Involvod]

Fair play to you, I've worked on a couple, not quite as fun! I thought about an additive but wasn't sure what to go for, it's probably worth a shot, can't make things worse surely!

[@sebastianbrrrr7372]

@@Involvod In my old Moto Guzzi I use LM MoS2 Gearbox additive, as recommended, and the white 850 got the same and for that it made a big difference. Oh, and for the brighter side: I once had Toyota Celica with a diff whine, made 40000kms and sold it for stock car racing still in perfect working condition.

[@GentilsGarage]

This is a bit of a grey are for me to be honest, but good luck!

[@Involvod]

Cheers!

[@enriquelopez9124]

That is a creative way to make a gasket

[@andrewmcmanus432]

Just put plenty of sawdust in the axle that will fix the noise 😂 .

[@Involvod]

I heard about that used car salesman trick 😄

[@andywarrington4738]

safe journey

[@Involvod]

Thanks mate!

[@ronfolkersma3877]

Nice video

[@Involvod]

Thanks!

[@ASDASD34RDFS]

You are probably going to want to change out that gasket as soon as you can. I also did something similar after reading about it online, and a bunch of people swore by it. So I did it on various parts where it comes into contact with oil. Worked great for a few days or a week even. Then one day it just didn't work anymore. It just started leaking all over and when I took it off the gasket had basically swollen and started to deteriorate as the oil has been wooshing around, also nice bits of carton everywhere where I didn't want it. Just get a proper gasket material, costs less than 10 pounds.

[@Involvod]

Thanks for the heads up! Hopefully it will just make it to the UK and then it shouldn't be DIFFicult to find another axle there 🤞

[@ASDASD34RDFS]

@@Involvod If you are lucky it will work just as those people on the internet say, but I doubt it. So many different forums where they swore by the cereal boxes and some where they hate the cereal boxes and preach the big thick pieces that you get from moving boxes, oh and that you have to cut it against the grain or it doesn't work. If you plan on changing the axle either way it doesn't matter though, just as long as it has some oil in it.

[@BeardedWrencher]

I decimated a differential many years ago over an axle seal leak that I didn't see because it stayed behind the tire:( It sucks but it's the joys of vehicle ownership.

[@Involvod]

Damn, yeah it's all part of the fun and games