Volvo RWD 444-544 Forum

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Either M40 or Clutch problem 444-544

I am looking for any advice before I pull the gearbox again. The clutch is at 1/2 free play. The gearbox fluid is even with the hole. 85-90w weight oil. 100f outside. Shifts correctly when not running, up or down. When running will shift up fine 1-4. Shifts down from 4 to 3 but refuses to shift into 2. Not even a grind. I put it up on stands and ran it through the gears. Again would shift up but not down to 2 or 1 until motion is almost stopped. I learned that when it was in 2nd and running and then I shifted into neutral it would not go back into 2nd without motion stopped. Same for 1st. I need help on this. Even if I pull the box I am not sure what to look for. I have a variety of manuals. This is the first time I have tried work on a gearbox. There are a couple of things that stick in my mind. First on the rear long dog slides does the long end go towards the front or the rear(towards the 1st gear or 2nd) The sources I looked at said rear or towards 1st gear. Second:The shifting bars did not look correct. The notches on them would not line completely up with the ball bearing hole. There was not enough room for them to travel all the way to the third notch. One of the shift rods was not straight up with the fork attached. Could I have a bent fork? I would think the shaft is assemble correctly or it would not shift up while moving. No missing or extra pieces. Looked at pictures of my shaft order. Everything went together will no problems.






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New Either M40 or Clutch problem [444-544]
posted by  lelshaddai  on Tue Aug 23 16:38 CST 2016 >


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