Volvo 240/740/760/780/940/960 1990-1998

Extension Housing Seal

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REMOVAL & INSTALLATION



This procedure covers removal and installation of the extension housing seal with the transmission mounted in the vehicle.

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Matchmark the driveshaft with the coupling.
  6.  
  7. Disconnect the driveshaft.
  8.  
  9. Using tool 5244 or equivalent for a round coupling flange, remove the coupling flange nut. Use a spanner (tool 5149 or equivalent) to prevent the flange from rotating.
  10.  
  11. Remove the coupling flange, using a suitable puller (tool 2261 or equivalent).
  12.  
  13. Unfasten the retaining bolts and remove the housing with the governor assembly.
  14.  
  15. Remove the gasket from the housing.
  16.  

To install:
  1. Clean the sealing areas thoroughly.
  2.  
  3. Install a new gasket onto the housing.
  4.  
  5. Install the housing with the governor housing attached, and tighten the bolts to 20-35 ft. lbs. (27-47 Nm).
  6.  
  7. Press the coupling flange into place, using tool 1845 or equivalent.
  8.  
  9. Install the coupling flange nut and tighten to 65-85 ft. lbs. (90-110 Nm).
  10.  
  11. Install the driveshaft.
  12.  
  13. Lower the vehicle.
  14.  
  15. Connect the negative battery cable.
  16.  

 
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