240, 1993, 360000 Manual difficult to get in 1. and 2. gear

kaerlighedsbamsen · Post by **kaerlighedsbamsen** » 31 Aug 2009, 08:08

My beloved Volvo 240, 1993 (manual 5 gear model, Denmark) is starting to be difficult to get in the lower gears. It has always been slightly hard in the gears but this have started quite suddenly over the last 2-3 weeks. No sounds or other things indicate a specific problem.

Is this due to a gear-lever-to-gearbox problem or is it more likely to be inside the gearbox? And is this a possible DIY project for a intermediately experienced amateur?

The gearbox is leaking (a little) oil- can this have a possible connection to the problem? And how do you check the level of oil? (my manual does not mention anything here)

Any help will be really appreciated!

/Ty

Post by **billofdurham** » 31 Aug 2009, 11:14

Is this due to a gear-lever-to-gearbox problem

There is no adjustment of the linkage from the lever to the box.

If the fluid is low it could cause problems with the lower gears. To check the fluid simply remove the filler plug. The fluid should be up to the bottom of the filler hole. There is a magnet built into the filler plug so, while you have it out, clean the magnet with solvent. If you need to top up only use Type F automatic transmission fluid in the Volvo manual box.

Another thing to check is the clutch fork free play. This should be 3 - 4 mm (0.12 - 0.16 ins). You will also feel this as free play at the clutch pedal. If you have the Haynes manual it tells you how to check and adjust this. If you need the information post back.

Bill.

kaerlighedsbamsen · Post by **kaerlighedsbamsen** » 31 Aug 2009, 14:37

Once again you are the man with the prompt answers Bill. Thanks a lot!

I will check the clutch and oil level and get back with a status rapport later.