|
11744 NE Ainsworth Circle
Portland, OR 97220
Google Maps
503-257-7500
1-800-444-6473
|
 |
| | | 200•700•900 Series Product Specials for May-June 2009
Page 3: TRANSMISSION PARTS: For Manual Trannys | If you place your order by phone, please provide the customer service representative with promotion code "EP" to apply any sale pricing that may be available through this promotion. This Promotion may include products that are not discounted below our normal competitive pricing structure. Promotion effective from May 15, 2009 through July 3, 2009 | Tech Tip: 200 Series with Slipping Clutch 
There are two possible causes of apparent slipping other than a worn disk. The 200 series models since 1979 do not use a clutch return spring. Usually this set-up works fine. Occasionally we’ve had customers with new clutch components installed that still have slippage problems.
If you’ve encountered a similar problem, installing a clutch return spring to the clutch fork may solve your slippage problem. Before tackling this area, check out the next set of symptoms to see if they match what you’re experience.
Solution: Use a spring from a 240 turbo ipd #1228794E (attach it between clutch fork and cross member).
The other possibility is related to the overdrive. If you still have slippage after installing a new clutch, chances are the clutch in your overdrive is failing (If this is the case, it is especially noticeable in reverse and first gear, but it won’t be slipping while engaged in overdrive.)
Solution: See your dealer or a qualified repair shop to check out your overdrive unit. | |
Overdrive Mini-Service Kit
This mini-rebuild kit contains parts to repair the most common internal failures of worn or cracked hydraulic seals (o-rings) and/or broken pressure-relief valve springs. Be sure to determine if you actually do have an internal problem before tearing into your overdrive, as the most common reason an overdrive won’t operate is usually related to simple electrical problems.
Removing the overdrive for inspection and installation of our mini kit is not too difficult for the experienced do-it-yourselfer. In most cases the overdrive can be separated from the transmission without removing the transmission from the car. If it goes smoothly, plan for the job to take about 6-8 hours. Our mini-rebuild kit includes early- and late-style pressure relief springs, overdrive-to-transmission spacer gasket, inspection plate gasket, rear output shaft seal, nylon seals for the top mounting bolts, O-ring seals, and general instructions with exploded view of overdrive.
Mini Rebuild Kits and Seals
| Model | Year | Type | | 240, 260 series | 1976-85 M46 | J-type o/d | | EP-4160 | Reg. $51.87 | | Each | | 240 series | 1986-93 M46 | J-type o/d | | EP-4162 | Reg. $45.29 | | Each | | 740,760 series | 1983-85 M46 | J-type o/d | | EP-4162 | Reg. $45.29 | | Each | | 740, 940 series non-turbo | 1986-95 M46 | J-type o/d | | EP-4162 | Reg. $45.29 | | Each | | 700, 900 series turbo* | 1986-95 M46 | P-type o/d | | EP-4164 | Reg. $153.87 | | Each |
*Includes new HD style pistons and seals. This is an upgrade to all J-type overdrives
Individual Parts
| Gasket OD pan/sump | | | EP-1G0004 | Reg. $8.37 | | Each | | Output shaft seal | J-type overdrive | | EP-1232013 | Reg. $3.72 | | Each |
|
Clutch Kits by Sachs, the original equipment supplier to Volvo
When you replace your clutch, you should check all u-joints for smooth and tight operation, check the center driveline support and transmission mount for cracks or breaks in the rubber and, if oil soaked, replace. Replace the driveline center support spring and cup washer if missing or weak. Replace the pilot bearing and rear main seal and have the flywheel inspected for stress cracks and resurfaced. Check transmission gaskets and seals (pinion seal too), and the condition of the wiring harness and switch functions. Inspect clutch fork for cracks and clutch cable for stretching or high pedal effort. Don’t forget to order a clutch alignment tool, and remember, the drivelines are balanced and must go back together at the splined area in the same orientation as they were removed to prevent vibrations (mark them for alignment before separating them).Clutch Kits (pressure plate, disc and release bearing)*
| Model | Year | Engine | Clutch Type | | 240 series | 1975-78 | B20, B21 | M41, M45, M46 4 spd. and 4 spd. w/OD | Sachs | EP-4K1001 | Reg. $185.37 | | Each | | 200 series turbo | 1981-84 | B21FT | M46 4 spd. and OD (not factory intercooled) | | EP-4K1004 | Reg. $310.37 | | Each | | 200 series turbo | 1984-85 | B21FT | M46 factory intercooled (recessed) flywheel | | EP-4K1020 | Reg. $418.33 | | Each | | 240, 740 series | 1979-84 | B21, B23, B230 | M45, M46 4 spd. and 4 spd. w/OD | Sachs | EP-4K1002 | Reg. $178.69 | | Each | | 200 series | 1985-86 | B230F | M45, M46 4 spd. and OD | Sachs | EP-4K1010 | Reg. $241.32 | | Each | | 200 series | 1987-93 | B230F | M47 5 spd. (not OD) | Sachs | EP-4K1007 | Reg. $228.79 | | Each | | 700 series | 1990-93 | B230F | M47 5 spd. (not OD) | Sachs | EP-4K1007 | Reg. $228.79 | | Each | | 700 series | 1988-89 | B230F | M47 5 spd. (not OD) | | EP-4K1003 | Reg. $179.71 | | Each | | 700 series turbo | 1985-91 | B230FT | M46 with OD | | EP-4K1009 | Reg. $305.00 | | Each |
*Pilot bearing not included |
Overdrive Access Cap Removal Tool
When inspecting or rebuilding the M46 overdrive for manual transmissions, you’ll need our spanner, used to remove the 3 caps under the overdrive inspection cover. The caps must be removed to access the high pressure filter, the pump piston and the pressure relief valve assembly. Our cap removal tool provides a nice snug fit with plenty of leverage for easy removal for your 1970-94 M41 and M46 4-speed overdrives.
| O/D solenoid cap tool | | EP-T1402 | Reg. $92.43 | | Each |
|
Clutch Alignment Tool
A must-have for clutch work. This tool aligns the clutch disc to the pilot bearing so the input shaft of the transmission will line up and allow for a quick and proper installation. There’s nothing worse than trying to install the transmission in your Volvo and finding it will not align through the clutch. For old timers this may have happened once when we were teenagers. But we do learn quickly and we never install a clutch without an alignment tool to make the job smooth as silk.
These plastic tools are inexpensive, so there is no reason not to have one.
| 1975-78 | B20,B21 (10 spline) | | EP-T0034 | Reg. $6.90 | | Each |
| 1979-95 | B21,B23,B230 (23 spline) | | EP-T0036 | Reg. $6.90 | | Each |
|
Shift Knob Kits and Overdrive Switches for Manual Transmissions
If the shift knob on your 200 or 700 series Volvo is cracked, broken, or just plain missing, we’ve got the kits that make it easy to replace. Kits include the knob, the shift pattern indicator, and instructions.
When your manual overdrive has stopped working, the switch in the shift knob could be the cause. Another solution to an overdrive that doesn’t go could be the relay or the contact switch that mounts to the transmission. An easy solution to a major problem.| Model | Year | Product | | 200, 700 series | 1981-92 | shift knob & cap kit (switch not incl.) | | EP-2K1232 | Reg. $18.46 | | Each | | 200, 700, 900 series | 1981-95 | OD switch (MT) | | EP-1258505 | Reg. $11.66 | | Each | | 200 series | 1975-80 | OD switch (slide type) | | EP-1234508 | Reg. $48.78 | | Each | | 200 series | 1981-84 | OD relay M46 | Kaehler | EP-1259750 | Reg. $64.06 | | Each | | 200, 700, 900 series | 1981-95 | 4th gear contact switch (on trans.) | | EP-1324496 | Reg. $21.56 | | Each | | 200 series | 1975-91 | shift boot | MTC | EP-1264859 | Reg. $17.76 | | Each | | 200, 700, 900 series | all | reverse lock out repair kit | | EP-4170 | Reg. $34.28 | | Each | | 200, 700, 900 series | all | shift lever wiring harness for OD | | EP-22565 | Reg. $29.76 | | Each |
|
If you would like to e-mail us with your inquires, please use the form here: http://www.ipdusa.com/contact.asp Promotion effective from May 15, 2009 through July 3, 2009 | | | |
|
