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

8. Remove all 6 bolts holding rear housing
9. Remove housing HERE COMES THE ATF! (you will lose about a quart)... you may have to tap with block of wood to break loose
from gasket. be gentle so not to crack the housing
10. HARDEST STEP for me ... remove the old gasket material [Editor's Note: See Removing the Gasket]
11. Punch out the old seal and bushing ... the seal was easy ... the bushing requires care not to crack the housing. You may want to
have a machine shop remove and replace the bushing. I was successful but could just as well messed up at this point
12. Install seal & bushing in housing [Editor's Note: See Bushing Orientation]
13. Install housing with new gasket and six bolts
14. Insert shaft with some ATF on bearing, seal and shaft. [Tim] After the flange is installed it will fit tightly in the new bushing.
15. Torque shaft bolt.
16. Hook up shift linkage
17. Shift to transmission to neutral
18. Install drive shaft and bolts spinning elevated rear wheel for easy bolt replacement
19. Install speedometer cable
20. Install cross member ... elevate transmission as required
21. After removing car from ramps check ATF and add as needed.
[Another Procedural Note from Don Foster:]
The parts you'll need are: new bushing; new seal; new gasket. In general, the procedure is:
1. Jack up the car -- from the rear may be preferable.
2. [Editor's note: mark the flange and shaft for proper balanced re-assembly.Carefully mark the linkage placement before removing it
from the side of the tailshaft housing.] Drop the driveshaft at the tranny -- I don't think it needs to be removed any further, only pulled
aside.
3. Remove the companion flange -- I used an air gun (with the tranny in park). Some purists among us will probably tell me how wrong
that is -- but both cars logged at least 50k flawless miles since.
4. Drop the crossmember -- you might want to support the tranny.
5. Remove the speedo cable.
6. Position a pan under the rear of the tranny -- some fluid might decide to get in your face. Transmission fluid will run out when you
remove the piece the driveshaft was bolted to (flange?) as well as when you loosen the tailshaft housing so be prepared with a pan
to catch it.
7. I think you need to remove the tranny mount bracket from the housing to gain access to the housing bolts.
8. Unbolt the housing from the tranny. Pull back gently -- a little tapping may be helpful.
9. Knock the old seal out of the housing. The oil seal is the metal ring/lipassembly with rubber molded around it. Both the rubber and
the metal ring/lip come out.
10. Note the orientation of the old bushing as a reference for installing the new bushing. Note as well the orientation of the hole to the
groove. in the housing. Examine the inside of the housing -- note there is a 1/4" gap, or opening, under the bushing, at the bottom of