As you know from previous threads I have had, on occasions, the need to have a "laying on of hands" on Varts car (86 340 3dr. 4speed (yes 4speed) manual box).

Well he has decided he wants a 5speed - so heh! ho! off to the scrappy we go today (one about 8 mls. away where they let you wander at will - and take things off yourself - and are helpfull - and are resonably priced - and will obviously shut down soon. This place is like scrappys used to be 30 years ago!!).

Found an 89 B172 and relieved it of its transaxle - covered in mud and general filth. £35 for whole lot on its mounting frame - not too bad if its a good one.

Back to the lair of the Mac and a good pressure wash (on the front drive - yes the neighbours are moaning) and into the workshop with it.

Gearbox and diff were both full of clean oil - no glittery bits, nothing on the magnetic plugs - diff backlash 0.12mm - washed the diff out and engineers blue on the crownwheel - pattern excellent!! - Could be a goody.

Cover off the box - visually perfect - all gears select easily - no wear on selector plates - Could be a goody also.

Sent Vart off to see what gaskets he can buy before stripping further.

"The transaxle split and ready for checking"


"The diff. cleaned and checked"


"And the diff. cover gasket" - waiting for me to make a template and start producing new cover gaskets - my new career beckons!!


When I have sourced the correct gasket material and am in a position to make some I will let everyone know !!


Only thing left now is to put it all together, take the 4speed out, put the 5speed in, make sure it works, fit my holiday in (in 2weeks time) and run around the garden shouting "wubber, wubber, wubber"

Thank goodness there aren't lots of V3M members near here or I might really have to retire!

Having had to have my second bath this year - Mac.

Nice work mac and Vart! Watching this in interest....

Beautiful

Again I feel like I really need some garage to get deeper into repairing, kitchen table is not quite well suitable for car stuff...

Could someone make a DWG, PDF or similiar scan of that gasket. I think it would be a good help if someone needs to make a gasket and hasn't got an existing one which to use as a template. And btw what is the thickness of that original gasket?

I think I might replace my end plate as it seems to be a bit battered.. This shop nearby me sells all kinds of gasket materials to use with drivetrain parts, motors, turbo oil feeds etc... I just need to figure out the correct thickness.

Fuse wrote:I think I might replace my end plate as it seems to be a bit battered.

Unavailble again... Andy bought one a few years ago, they weren't that expensive. Although one from a scrapped car should be fine.

Fuse wrote: And btw what is the thickness of that original gasket?

It's roughly 1/16" (1.5mm), cos I bought 1/8" gasket cork, which turned out to be about twice as thick as the original, but seems to work fine, touch wood...

SteveP wrote:

Fuse wrote:I think I might replace my end plate as it seems to be a bit battered.

Unavailble again... Andy bought one a few years ago, they weren't that expensive. Although one from a scrapped car should be fine.

Yeah I know, luckily there are plenty of good used ones available.

Nice piccies, I made the same gasket last autumn out of thick card and it still seems to be holding the oil. Previously I had terrible trouble with leaks due to the tin cover being deformed. The trick was to smear orange sealant on both metal surfaces generously, do up the bolts semi-tight, leave for a few days to set, then do up the bolts to final torque and fill with oil. A year on, still no leaks.

Hi Fuse,

I am intending to produce a template but also to produce some new gaskets but I want to research materials first, rather than just 'knocking a few up' out of cork.

I we are going to have to produce our own in the future I would rather get it right from the start.

The used gasket is made from a composite fibre (asbestos free) blue/green material and is marked with the no.3820 (which I imagine is a material identifier). Used it is 1.2mm thick so Nick is probably spot on at 1.5mm for new stuff.

As soon as I have 'dug' around a bit I'll post a progress report.

Mac.

i've ordered the other gearbox gaskets from the volvo dealership at criminal prices. templates for these can be made up i spose to avoid the shocking rip off volvo parts dept. provide.

i think the inspection hatch one is around £7

a quick search for gasket material 3820 brings up a gasket for cold and hot water up to 85^c whether this is the same stuff (same colours) it can be found on google as first result of "3820 gasket material"

regards

Hi all,

I found that too Vart - seems 'the stuff' could be 'Centellen WS3280' it's made by a German co. - Hecker Werke and is listed as universal sealing sheet material of aramid fibres with NBR rubber as a bonding agent. It is resistant to all hydrocarbons and requires a fairly low surface pressure of only 10Nm/mm2 for fluid sealing.

It seems to be a fairly standard material in the oil. gas. and potable water industries and will handle up to 250c.

Now to find a supplier in the UK and get a sample.

Hmm, would that stuff work well in carb base seal too? Those originals will be not available soon too, I guess and that is quite often needed

The story continues,

For those of you who havn't had the side plate off an M47R11 box I have added a few captions.



1 is the hole where the detent spring goes, 3 is the selector plate spring. 3 early cars had a plate spring here as well.

Next two picks show the selector plate removed and in place,



The selector plate


The 5th gear end of things



And finally - methinks someone has been chewing on this drain plug!!!!
(don't panic Vart - it's out and the threads are still in the box).



Will post more as the conversion progresses.

Mac.

Just out of interest, are Macs available to buy? I could do with one, I think

Excellent work. What exactly did you clean the 'box up with? It's really gleaming!

cheers

James

foggyjames wrote:Just out of interest, are Macs available to buy? I could do with one, I think

Our survey says "Neh Nuh"... no longer available I'm afraid...

PS. no offence to mac, just a dig at Volvo!