Volvo Maintenance Hints for 7xx/9xx - Bill Garland's Nuclear ...

slip them over the transmission line. Then, using a zip tie or tie wraps as they are called, I secured the rubber hose around the
transmission lines to stop chaffing.
Transmission Model Information. See the table in the Model Information file.
Troubleshooting:
Stripped Trans Drain Plug. [Inquiry:] Did a routine fluid change. Detected a slow leak from the plug area a few days later. Removed
plug. Threads were stripped. Purchased new plug. Unable to get a tight fit since threads in pan probably also be damaged. No leakage yet,
but I fear that plug may eventually loosen, I'll lose fluid and destroy the tranny. (so much for preventative maintenance.) Replacing the fluid
pan seems to be the obvious solution. I would appreciate any suggestions on a good source for a pan, or alternative solutions to the
problem. [Response: Simon Eng] No need to replace the pan. There is available a kit specially designed for this purpose. My mechanic
has several sets and he let me borrowed one of the sets. First check what size is the plug. Let say it is 12 mm by 1.5 mm. The kit for this
size has a drill bit and a tap with 14 mm by 1.5 mm. You drill the drain hole with this drill bit, then thread the hole with the tap. There is an
insert that has 14 mm by 1.5 mm on the outside and 12 mm by 1.5 on the inside. Screw this insert intp the hole and use the supplied
expander to expand the insert and to position it on the threaded hole. Now the insert is firmly anchored. If the old drain plug is still in good
shape, reuse it; otherwise get a new plug. [Response 2: Kane] Naturally, in upsizing the plug, you'll need to tap new threads for the hole
too. Drill the hole smooth, then tap - you don't want the new threads crossing the old ones. You may also try "chasing" the existing hole
with the exact tap size and thread count as the current plug. Sometimes this is all that's necessary to clean the remnants of the old plug
and whatever else is stuck in the threads. This assuming that you do have a tap and die set. Otherwise, plucking a pan from the junkyard
may be the best bet.
Removing Oil Pan. [Editor/Jay Simkin] In a pre-1990 700 series, removing the pan is simple: just remove all the 10mm bolts and drop the
pan. In a 1990+ 700/900 car with the intermediate exhaust bracket mounted to the rear transmission housing, removing the pan gasket is a
major undertaking because the bracket interferes with both the bolts and the pan itself. Here is how to do it if you must:
1. Drain the pan and loosen the fill tube fixing nut. If this is stuck, see below.
2. Support the front of the transmission with a jack, using a block of wood on the casting just ahead of the pan. The block of wood is
needed to go on top of the jack to allow the trans to be lifted, so the trans support can be removed. That block of wood cannot be
more than 1 1/2" wide, or it will interfere with access to the pan bolts. Before you begin, make sure you have clearance to remove