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Fig. 4-17.
Fixture for removing gearbox
VOLVO
103102
The upper ancho.rage bolts for the radiator, the
nuts for the eXihaust
manifold
flange
,
the battery
lead,
the throtfTl,e shaft and
clutch
wire from the
flywhee
l
Gasing.
4.
Release
andremove the
suppo
rt>ing
member under
the gearbox.
Discon
nect
the bracket for the
ex-
haust
pipe.
Disconnect
the
speedometer cab le.
Disconnect the propeller
s haft.
5.
Lower the
rear
,end of the
e
ngine
about
4.5
cm
(1 .8")
and
then
s,lacken
,
t he lines for the
reversing
lights
and
ove
r.drl1ive if
fitted.
6. Replaoe the
lifting
plate on
the
jack with fixture
SYO
2833.
The pin
in the
fixture
shou1
ld
rt-hen be
lecated
in
its
front
iposi,
t i'on
for gearbox
M 400
and
in
~he
rear
posi~ion
for
the
M
410
gearbox.
Support the g.earbox
with rthe
fixture. Slacken the
boMs in the
clu~oh
,casing. Pull the gearhox rear-
wards and then lewer it,
see Fig.
4-17.
DISMANTLING
Applies
a lso
to
M
410
after the overdr,ive has been
removed.
l.
Fit fixture SYO
2825
in
stand
SYO
2520,
see
Fig.
4-12.
Secu,re
the gearbox in the
fixture.
2. Slack.en the bolts and
lift
off the geO'rbox cever.
Remove the springs and the interlock balls for
the
se
lector
mils.
3.
Sla'
c
k'
e n
,
t he nut for the fl ange. Use for this tool
SYO
2837.
Pul,l
the
flong'
e off
wi,
t h pulle'r
SYO
2261,
see Fig.
4-14.
4. Remove the release bearing. Release the belts
and rem ove the cover fer the input shaft. Then
release the bolts for the clutch
cas
ing
and remeve
t,he ca,sing.
5. Turn the gea'rbex
upsid
e down.
Pull eut the
front
bearing ef the int-ermediate
shaft
wi,
t h tool
SYO
Fig. 4-18.
Removing intermediate sh af t front bearing
Fig.
4-19.
Removing
intermed ia
te
shaft
rear
bearing
VO LVO
103 103
2826,
see Fig.
4-18.
Remove the
re
ar cever and
then pull eff
the rear
bearing of the intermediafe
shaft
with
tool SYO
2827,
se'e Fig.
4-19.
6. Restore
~he
gearbox
te
,its normal position. While
doing th is
e
nsur'e that the te,e,th
ef
t-he
inter-
me-
diate shaft are
not
damaged
when it drops
down into the beMom of the
gearbox.
7. Unscrew
rt -
he holts
for
the
se lector
fo.rks. Push the
se
lector
rai ls
badewards and
drivl
e out the ten-
sioning
pin
in
lIhe
flange of the
sel'
e ctor rails.
Push out the seledO'r rails. When dOiing this,
hold
the
se
l,
e
ot,or torks
s'
e that they do net come askew
and jam on the rails. R
'
e move the
s-
e leclor forks.
8. Remeve the speedemeter gear.
PUI
II
out the
re'
a r
bearing of the mainshaft
wi~h
tool SYO
2828,
see
Fig.
4-20.
If
,
t he bea'ring
sticks
in rt-he gearbox
housing, push the mainshaft ferwards se that its
drive and
synchron'izers
ge
aga'
i nst
the drive of
the intermedi'ate shaft. Te prevenrt- this, place
a
pie·ce ef flat
iron
or similar between the front
,
e nd
of the mainshaft and the gearbex heusing.
For
the
M
410,
remove the
.bolt in rtoel
SYO
2828
4:7
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