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

the housing into which you can cut.
11. Using a hacksaw blade, cut through the old bushing into this opening. Note the orientation
of the original and align the new bushing the same way.
12. "Peel" the old bushing inward and it'll pull right out.
13. Scrape off any gasket material (most frustrating part of the job.) [Editor's Note: See
Removing the Gasket]
14. Wash the housing, insuring that all chips are removed. [See Chip Removal]
15. Be sure to prelube the new bushing and new seal before final assembly. Position and orient AW70 Tailshaft Bushing Orientation
the new bushing -- and using either a proper bushing/seal driver OR a socket of the correct
diameter (perhaps with a 6" extension on it), drive the new bushing into position. I've found it
slides into position easily, with only slight tapping from a hammer. [See Bushing Orientation]
[Tip from Randy:] My automotive supply store has a full service machine shop and I never
mess with this stuff- I take the tailshaft to them and have them press in the bushing. For the
seal I apply a coating of grease to the outside diameter and tap it into place with a socket
just slightly smaller than the diameter of the seal.
16. Examine the new bushing to confirm the edge was not dented -- if so, clean it up slightly with a fine rat-tail file (and rewash). Be
careful to not damage the main bearing surface of the bushing.
17. Drive the new seal into position. I like to use a touch of Permatex aircraft gasket sealer, but it's not necessary.
18. Clean any remaining gasket from the mating transmission surface.
19. Install the new gasket. Again, I like to use a touch of gasket sealer, but it's not required.
20. Lubricate the bushing and seal with ATF.
21. Position, install, and tighten the housing.
22. Wash the rear flange, lubricate the bearing and seal surface, and slide it over the splined tailshaft. [Tim] After the flange is installed it
will fit tightly in the new bushing.
23. Install and tighten the nut. I'm sure there is a proper procedure and torque.
24. Install the speedo cable.
25. Lift the tranny and install the mount bracket and crossmember. This might be a good time to install a new mount.
26. Connect the driveshaft. [Editor's Note: 30 ft-lbs.]
[Tip from Randy:] On assembly be sure to bolt the linkages according to the marks you made before disassembly. Don't forget to check
the transmission fluid level, particularly if you lost some during this work.
[Removing the Gasket: Randy] I've replaced two bushings and both times the most time consuming part of the job is removing the gasket
between the transmission case and the rear housing from the transmission case. There isn't a lot of room to work your way around with the
various tools to scrape the gasket off. I found a single edge razor blade worked best for me, and the second time I did it I was armed with a
spray on gasket remover which helped a whole lot. Spray it on, let it soak, scrape a little.... repeat numerous times, being careful not to dig
into the soft aluminum case when you become frustrated and begin to use that sharp wood chisel that always worked so well on removing
gaskets from cast iron casings. Also it would probably be in your best interest to take extra pains to protect the exposed portion of the