IPD sale XeMODeX - Experts in Volvo Electronics
Did you know? 🤔
Logged in users can get email notification of topic replies Log in or register (free).
Amazon Link Buy anything with this and it helps MVS!

91 240 output shaft seal removal Topic is solved

Help, Advice, Owners' Discussion and DIY Tutorials on all Volvo's "mid era" rear wheel drive Volvos.

1975 - 1993 240
1983 - 1992 740
1982 - 1991 760
1986 - 1991 780
1990 - 1998 940
1990 - 1998 960
1997 - 1998 V90/S90

e777
Posts: 134
Joined: Sun Jun 04, 2006 11:12 pm
Year and Model:
Location:
Has thanked: 1 time
Been thanked: 0
e777

91 240 output shaft seal removal

Post by e777 » Wed Jun 24, 2020 4:56 pm

Hello,

So, not so long ago, I noticed tranny fluid leaking from the output shaft area. I removed the extension housing, pressed in a new bushing and new output shaft seal and all was well for some weeks. Then, I noticed a slow drip coming from the output shaft seal.

Therefore, I am now having to do re-do repair and I really hope to not have to take the extension housing off again to do it.

However, it seems tricky to remove the seal by leaving the housing in place....

Any tips for doing this without removing the housing? Or is that just a bad idea?

Thanks!
Wagons:
93 940
91 240
90 740
86 740

User avatar
volvolugnut
Posts: 719
Joined: Sun Jan 19, 2014 9:51 am
Year and Model: 2001 V70
Location: Midsouth USA
Has thanked: 36 times
Been thanked: 75 times
United States of America
volvolugnut

Re: 91 240 output shaft seal removal

Post by volvolugnut » Wed Jun 24, 2020 5:24 pm

However you gain access to the seal, use a quality seal and be careful not to cut the lip on splines or edges. Use tape over splines to protect the seal. Use a seal driver to assure you do not damage the seal metal housing. If there is a gaiter spring inside the seal, do not damage it. Install in the correct direction - lip to oil side.
I think you have to remove the extension housing to replace the seal. Others may have another way.

volvolugnut
2001 V70 T5, 1986 244DL, 1983 245DL, 1975 245DL, 1959 PV544, multiple parts cars.

e777
Posts: 134
Joined: Sun Jun 04, 2006 11:12 pm
Year and Model:
Location:
Has thanked: 1 time
Been thanked: 0
e777

Re: 91 240 output shaft seal removal

Post by e777 » Wed Jun 24, 2020 6:19 pm

Your advice is much appreciated.

Question: when you say "lip to oil side," do you mean that the surface shown in the attached image will be driven *into* the housing, as opposed to facing outward?
Attachments
output shaft seal.JPG
output shaft seal.JPG (26.9 KiB) Viewed 68 times
Wagons:
93 940
91 240
90 740
86 740

User avatar
volvolugnut
Posts: 719
Joined: Sun Jan 19, 2014 9:51 am
Year and Model: 2001 V70
Location: Midsouth USA
Has thanked: 36 times
Been thanked: 75 times
United States of America
volvolugnut

Re: 91 240 output shaft seal removal  Topic is solved

Post by volvolugnut » Fri Jun 26, 2020 5:13 pm

Image below shows the cross section of a typical oil seal. Yours may be different. The round thing in the center is the gaiter spring that holds the oil seal in firm contact to the shaft. This side should go toward the oil (inside of housing). The smaller lip on the left side is the dirt shield. It goes to the dirty side of the housing.

I can't see the cross section clearly, but I think the top side is the dirty side (outside of housing). If installed opposite, it will likely leak.
volvolugnut
Attachments
oil seal section.JPG
oil seal section.JPG (13.61 KiB) Viewed 45 times
These users thanked the author volvolugnut for the post:
e777
2001 V70 T5, 1986 244DL, 1983 245DL, 1975 245DL, 1959 PV544, multiple parts cars.

e777
Posts: 134
Joined: Sun Jun 04, 2006 11:12 pm
Year and Model:
Location:
Has thanked: 1 time
Been thanked: 0
e777

Re: 91 240 output shaft seal removal

Post by e777 » Fri Jun 26, 2020 7:41 pm

Thanks! That's what I did the first time and will do again the second time.
Wagons:
93 940
91 240
90 740
86 740

Post Reply
  • Similar Topics
    Replies
    Views
    Last post