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Here are the instructions we have had posted on the website. I'd just send you the link but the website is down temporarily. There were pictures so some of the references are to pictures that don't appear here. It gives you the general idea though...
Instructions for installation of Volvo short shifter kit
Tools required:
1. Flathead screwdriver.
2. Electrical crimper/cutter.
3. Fine needlenose pliers or c-clip remover (or even something with a pointy tip)
4. 4mm or 5/32” hex key, ideally a 3/8” driver style. A similar size of torx will do in a pinch. Driver extensions are very handy.
5. 8mm and 10mm socket driver.
6. Work light!
Procedure:
1. Remove leather boot (if equipped).
2. Remove shifter knob
a. Using screwdriver, carefully pry out knob cover:
b. Pull out overdrive button (later models may be attached with small screws). Disconnect from wires.
c. Pull off knob, it should be on snugly.
3. Pry out the 4 plugs holding the shifter boot to the chassis.
4. Remove the boot.
5. Leaving some slack, cut the 2 overdrive button wires:
6. Remove the (2) 8mm bolts (arrowed) holding on the reverse lockout gate and remove the gate.
7. Using fine needle nose, or c clip remover, or pointy tool, remove the c-clip:
8. Put the transmission into reverse.
9. (under the car) using the hex key, remove the set screw on the bottom of the shifter. It’s a tight squeeze under there so this is where the extensions will come in
handy. If you have trouble, you may try different shifter positions. If all else fails, drop the driveshaft out of your way.
10. Either from underneath, or from the top, push out the shifter retaining pin.
11. Now the shifter should lift right out.
12. Remove the old bushings from the transmission linkage.
Installation of the new shifter is reverse of removal. Some tips though!
*Inspect and clean the lower shifter seat bushing and seal. Generally clean what you can while you’re in there.
*Don’t forget to crimp the bullet connectors on the old chassis wires.
*MAKE SURE THE SET SCREW IS LOOSELY IN PLACE BEFORE INSTALLING THE NEW SHIFTER! It is a b*tch to get in from underneath.
*When re-installing the reverse lockout gate, run the tranny through first and second gears to make sure the gate is at the right angle so as not to interfere with 1st and 2nd but won’t allow you to slip into reverse accidentally. Adjust and tighten.
*If your car didn’t come with any sound deadening (I think most pre-86 240’s didn’t) you may want to rig something up to cut down on the noise coming from underneath. I used some old packing insulation. Ain’t pretty, but it’s under the shifter boot and it works!:
*When re-installing the rubber shift boot, you may consider using 10mm bolts with large washers. The holes are pre-threaded for a fine thread bolt and it will hold much better than those crappy stock plastic pieces.
ENJOY YOUR NEW SHIFTER!!!!!
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Dale
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