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Thanks for the excellent information.
The "whacking" suggestion was from the previous owner and was a "last" resort to freeing up a stuck the axle. He wasn't talking about using a sledgehammer or anything. Still, worth avoiding if you don't have a spare rear differential laying around.
At the moment, I'm working from an assumption that the driveshaft may be incorrectly attached to the output flange of the gearbox. I was not as careful about this as when I did it back on my 1972 145. When I put the shaft back up, it only seemed to attached one way (the holes were not equidistant). It was also quite unpleasant to "pull" back together.
It was suggested that maybe I put the bolts in backwards. I checked them and the bolt-end and nut are pointing towards the gearbox. If they were pointing the other way, I'd worry that they were hitting the U-Joint brackets. I read up on u-joint failure, as well as your rear-end posts and my symptoms are similar, but not quite the same. I only get the noise when i get the car into upper gears (or coasting faster than 35 mph). It doesn't get worse with braking or steering. Its just there when the car is moving at fast(er) speeds. I'm also going to inspect the rear suspension bushings as Ben suggested.
My windshield is presently out of the car and I've got a few other things to address this week, so I may not get to this until the weekend. I plan to disconnect the driveshaft and rotate it a quarter-turn then reattach. The FAQ covered this on 700/900 cars and I know it's a very similar setup, so I'm starting there.
Although, I don't see what difference it will make as I did not disconnect the two halves of the driveshaft. The U-joint flanges are still where the factory installed them
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1967 P220 Amazon, 1972 145S, 1976 245 DL, 1983 245 GL, 1986 745 GLE, 1990 745 GL, 1995 945....
You mean to tell me that Volvo makes cars that are *NOT* Wagons?!?
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