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Here is IPD's opinion on the matter:
"As I suspected, there is clearly an issue with the cam woodruff key.
The picture you sent shows a mangled key and perhaps a missing piece." Their stance is that the gears were installed improperly with the woodruff key pushed askew in the shaft slot so that the gear was cocked.
The speed shop believes that there isn't enough play between shaft and gear to allow for the gear to be cocked. Its all history now. I purchased a NOS steel gear set from a different supplier who has always been there for me.
The new gears sound fine. Unfortunately, a low rpm tapping that started after the IPD gear failure is still there. A rebuilt engine is in my near future. I know where I won't be buying parts from.
How do these engines make it to 1,000,000 miles? Obviously there must be a book besides the Volvo manual for correct procedure. If this is a known problem, where is the cautionary note?
End of rant
Rappin Joe M in WV
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