Keystone State Thread

Just booked it - seeing this thread reminded me that I needed to get scheduled. I'm in!!

 

Get a load of the "fun" I've been having. I rarely complain about my Volvo 240, but this is entertaining.

Was in the midst of a huge list of preventative maintenance, proud dad stuff... trying to get this thing to 30 years old. I thought it would be a good idea to do one of the checklist items on maintenance of dropping the transmission fluid pan, changing out a filter screen for the tranny in there, cleaning the pan and its magnet, putting on a fresh gasket (was leaky), and then doing a transmission flush. Shoulda been a real simple 30-60 minute task.

Step 1, drain the pan. Check. Step 2, disconnect the dipstick fill tube from the side of the pan by its 24mm flared connection (its like a huge brake line).

Ummm.... stuck on step 2. Heat didn't do the trick to loosen the flare nut out of the socket attached to the pan. Got the right wrench and got it off, woohoo, full steam ahead. Pan down, cleaned out, filter and gasket changed. Time to reassemble.

But then I realized I only got that flare nut off because it snapped some threads on the way out the 1st time. I hoped I'd still be able to use it. Nope, trashed it as I could only feed it about halfway back on before some snap, crackle, pop.

Thought, ok, these cars are dime a dozen and there's good suppliers of parts and lots in junkyards, I'll just find a new pan and dipstick fill tube. Let me go ahead and take that dipstick off so I can just buy one and flippity flop be done the job.

Dang filler tube is held in by two 19mm x about 5" long bolts that are the exact bolts that mount the starter into the trans. Both mount head facing back toward the firewall, one comes out, the other hits the firewall and can't come out because its still about 3/4" deep into the trans mount.

So, I'm somewhat stuck. But I got a guy. He's a literal 240 genius, ex-Volvo mechanic retired and does his own side work. Loves to chat for hours about all this stuff and keeps me running.

He's seen this problem time and again. Bad design. Or else you might say the cars are so well designed to last this many years that nobody expected problems like this 20-30 years down the road, who keeps cars that long? He's got a pan and tube for me. But good luck with that bolt! So, I've gotta drop the rear cross member that mounts the trans and driveshaft, drop it low enough not to bend and strain the exhaust pipe, but enough angle to get that dumb filler tube starter mount bolt out past the firewall. I asked him if I could either chop the bolt and reverse it, or maybe use one about 1/2 inch less length. Not good he says. I ask him if one could just drill a hole through the firewall to access the bolt. For fun to get my part off his parts vehicle he goes and tries that. Then he comes back and says the hole through the firewall idea is fun and that's how he did it to get my part... but I shouldn't do that with my car that's all assembled (i.e. pedals, carpeting, too complicated its just that that car didn't have any of that stuff attached).

Uggh. Gotta lower the tranny. So much for my 30-60 minute good owner maintenance idea. I did the friggin timing belt, tensioner, engine seals, water pump, alternator, wheel bearings, rear differential fluid, etc. in this whole job and the stupid pan for the trans oil is causing all this headache. And its not even some kind of hidden hard to reach part, just right there laughing at me.

 

I attempted this on my escort once at 150,000 miles. It ended with 4 broken off bolts that needed to be drilled and tapped, helicoiled. It is good to know that I am not the only one this stuff happens to. It seems like every time i take on a project it end up this way. I am not very mechanically inclined, so I usually have to do it once to realize it isn't right, twice to realize that I could've done something a little better, Third time I usually get it all the way it is supposed to be (actually figuring it out). It is not the cheapest way to learn, but it is effective. Once I get something I rarely forget it.

 

It is not a problem when those bolts are installed before the engine is dropped in.

Working on them Foreign built vehicles see what happens

Didn`t you get drug off to GM plants when you were a kid to see that stuff

 

Ordered a gift for my self today!!! Of course it’s truck related.

 

Good morning from northeast PA - the rain is just beginning here at our place. I have a whole stockpile of items for my new Pro sitting on my workbench and more enroute. Most are small things like flag and Army unit ID badges, a key fob, flag licenses plate and tow hitch covers, but I've got a tonneau coming and have high hood lifts and Raptor-style lights sitting there too.

I need this truck to get here soon so I can clear off my work bench!!!! To my wife's credit, she has not yet complained about all the things I've ordered. Oh well, back to the forum to find something else to order.

 

i can find out. The owner of my company goes a lot. I had a bricklayer on my job at Pitt last Summer that was an actual instructor. I think they go in Grove City.

 

Exactly!!!

 

My wife doesn’t understand the things i have done to my truck. The next thing I want to get is a cap.

 

Morning Pennsylvania

 

What kind?

 

Awesome, thanks! I looked into it and they are currently booking for April, but I would love to have a contact so I can learn more about it and have somebody there I can meet.

Thanks!

 

Most likely a A.R.E. And would like windors. I like the way they look. If I find one used for a good price I won’t be as picky.

 

The bricklayer that was the instructor is named Craig Kushing. Goes by “Kush”. He lives in Cranberry

 

PA folks need this today.

 

And these!

 

Weird day. Out of body experience really. I'm at work and thankfully its slow because I'm feeling poopy. Daughter came down with Flu last week and a I didn't bother to see a doc but likely have it too. Jacked up on medicines. I cannot smell, nor taste the cough drop in my mouth. And I'm taking the wife on a fancy date tonight, dinner and an event. Let's hope I can taste the expensive food I'm going to buy.

 

Back from 3 days in Nashville. picked up a cough myself.
Hoping it doesn’t develop into something else.