I'm replacing the clutch on my 1987 245 for my first time, just got the tranny down and was surprised to see the bellhousing was as dirty on the inside as it was on the outside. In my head I was imagining everything nice and tidy in there. Is this perhaps indicative of a leaking oil seal in the tranny? The clutch doesnt appear to be dirty or oiled. here's a photo:

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1987 245dl w/ 271k miles

I would say that your condition is not particularly unusual - remember it has
been closed up for 20 years. One drop a week would probably do that.
A couple things I noticed - your throwout bearing face is a bit rusty.
Also your throwout fork is pretty clean but it is dirty behind it.
You may also have some oozing from the tranny front seal, which is fairly easy
to replace.
--
George Downs, Bartlesville, Heart of the USA!

Speaking of throwout bearings, does one need a puller to extract it from the fork?

Thanks!
-Ryan

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Athens, Ohio
1987 245 DL 314k, Dog-mobile
1990 245 DL 134k M47, E-codes, GT Sway Bars
1991 745 GL 295k, Regina, 23/21mm Turbo Sway Bars
Buckeye Volvo Club

Usually they just slip out to the side. Are you having trouble with one?
Maybe a sharp rap with a hammer.....
--
George Downs, Bartlesville, Heart of the USA!

I think mine's starting to squeak a bit. A little clutch pedal pressure can modulate it, and I can hear it when stopped in neutral and when going. That should rule out the pilot bearing I imagine.

Hope I don't have to dig into it soon... Probably a job for the spring and summer... or fall! The car is laid up (for other reasons) for a while now anyway.

Thanks!
-Ryan
--

Athens, Ohio
1987 245 DL 314k, Dog-mobile
1990 245 DL 134k M47, E-codes, GT Sway Bars
1991 745 GL 295k, Regina, 23/21mm Turbo Sway Bars
Buckeye Volvo Club

Ryan,
You just love keeping that carport occupied, eh? :)

The throw-out bearings will literally just about fall out of the fork once you have the mainshaft out.

When you do the job, be sure to do the rear main seal, pilot bearing, resurface clutch, new clutch disc and pressure plate, too. Also check out the transmission for any faulty gaskets.

Given the labor, it's a lot cheaper in the long run to do the entire trick rather than a piece at a time.

Jim

Thanks, Jim!

Yeah... I've decided this is really the 240 from hell. I love the car, but it seems to love me doing stuff to it. On the plus side, it's been a great excuse for buying tools, on the down side I've had to buy a lot of tools. :)

What gets me is that the car got a new clutch right before I bought it 20k miles ago. Who ever did it did about as crappy a job as imaginable, in that they broke the old crank sensor and lost the exhaust pipe bracket. Of course they didn't replace any of the other bits that one should do while in there.

I think I'm willing to give the labor a try, so no "financial" labor costs, still I'll do everything imaginable while in there. As much as I'd like to save a few bucks by only doing what's truly necessary, doing big jobs on my back is one of my least favorite pursuits! :)

Oh, BTW, I haven't forgot about those 240 parts.... I'll get PayPal to you maybe tonight...

-Ryan
--

Athens, Ohio
1987 245 DL 314k, Dog-mobile
1990 245 DL 134k M47, E-codes, GT Sway Bars
1991 745 GL 295k, Regina, 23/21mm Turbo Sway Bars
Buckeye Volvo Club

Good morning logsaysned,

I think you need to renew the rear main seal. Look behind the flywheel. It will be oily and dirty there too.
--
Mr. Shannon DeWolfe -- (I've taken to using Mr. because my name tends to mislead folks on the WWW. I am a 51 year old fat man ;-) -- KD5QBL

Don't forget the clutch dust will make it look worse! (Although I couldn't view the picture at work!)

+1 on changing the rear main seal too!