52 ft lbs

Hey Roj (and anyone else that may have wanted to lend a hand)
It looks like friday and Saturday are going to be a write-off cause I have to work all day both days. I'm thinking I have to finals early next week, so maybe it should just be put off 1 more week, then I can also get the flywheel lightened! Hope that works for you.

Thanks for the torque specs!!!
-Trev

That next weekend is the July long weekend and I'll be in BC for the entire weekend. Maybe the following weekend ?

Roger

So I went to Calgary machine today to try and get the flywheel machined lighter, but the guy said he did'nt have the machinery to do a stepped flywheel like mine. Chrome and grind said flat out they don't do flywheels... Before I go through the phonebook tomorrow calling machine shops, does anyone have a shop they would suggest trying?
-Trev

We have a machine at work, but its only for resurfacing - not for lightening

- R

thats really odd....I've gotten quotes from alberta chrome before for flywheels. Some part source stores do machining but other then that I can't think of anything off the top of my head.

So what's the status of the project now ? When do you plan on doing the swap ?

Roger

So me and Roger tackled the transmission swap Sunday and got the AW out and called it a day. Got my rear main sea and tranny fluid today so I'm now ready for part II! Just had one thought though. Since the aw-72 does'nt have an input shaft, will there be pilot bearing already in there, or am I going to have to press one into there?
Thanks guys!
-Trev

Plan on installing a pilot bearing. Shouldn't need a press, just tap it in gently applying force to the outer race only.

So I spent all day today putting in the manual with Roj. Tranny is now in and the car starts, only one problem. With the engine running I can't get it into gear. Right now it's on jack stands and I can start it in 1st and spin the tires, but if I start it out of gear, it won't go in gear. I'm thinking that the clutch must not fully be disengaging, does that sound like a good diagnosis?(god I hope it not a bad tranny...) I'm thinking I'll bleed the system again tomorrow but if that fails do you guys think I should try a new master or slave cylinder? Any other ideas?
Thanks all!
-Trev

Not being able to get it into any gear is the clutch not releasing.
This is usually caused by adjustment, but also not enough release arm travel, bent clutch disk, clutch plate in backwards. Really anything that will cause the clutch to drag.

Make sure the system is bled really well, then recheck your adjustment at the slave cylinder (if the Volvo has an adjustment there)

Trev,

Please tell me you put the clutch plate in the right way !!

I looked in the Haynes manual for the 940 and it doesn't indicate that there's a way to adjust the clutch at the slave cylinder. If the system is bled completely and if you're sure you installed the clutch plate right way out then it's a bit of a head scratcher as to why you're not able to get enough release arm travel. Sticky slave cylinder perhaps ? That cylinder did come apart on us when we washed the tranny. Maybe some grit got in there and is jammin' up the piston a bit ? Could that be possible ?

Hopefully it'll be something simple and we don't have to pull that tranny to fix the problem.

Roj

In the "I hope this didn't happen" department.
I hope the trany was not left to hang by the input shaft when installed through the clutch disk and not seated into the pilot bearing. This can bend the center of the clutch disk ... did the trany side through the clutch and seat easily?

When I did the V8 swap in my 244, the engine/tranny was sitting in the car for about a month before I actually fired it up. When I actually fired it up, I couldn't get the tranny into any gear.

I put it in 4th and with my foot hard on the brake, I cranked the motor over, and voila: a little bit of a bang, and it released. Apparently the clutch was just stuck to either the flywheel or the pressure plate. Don't know why, but it worked perfectly since.

Yes it did slide through and seat quite easily when we put it in. We first tried installing it with the gearshift lever mounted but quickly realized that wasn't going to work. We then pulled it back out, dropped it down and removed the gearshift lever. We then jacked it back up and slid it forward into the clutch. We were able to slide it forward by hand (with minimal effort) to a point where the bell housing was maybe about 1/4" from the engine and then we got it in the rest of the way by tightening up a couple of bolts. The tranny was always supported by a jack and by our hands until we got the cross member up. Based on that I very much doubt the center of the clutch disk got bent when we were installing the tranny.

Maybe ya ought to try Matt's little trick and see if the thing comes unstuck and starts working. Gotta try everything and eliminate every other possibility before giving up and pulling the tranny again. The one thing that would be worse than having to pull the tranny because the clutch disk got put in backwards would be pulling the tranny and discovering it was put in correctly and realizing that pulling the tranny was completely unecessary. That would suck huge !