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Discussion Starter · #1 · (Edited)
I picked up an M66 from a member of another Volvo owner forum and did the MT swap in ‘17. I had it shipped directly to the mechanic. All gears engaged and turned. Unfortunately, from day 1 it never ran smoothly.
-Clank/metal to metal sound when changing gears, especially 1->2. That is regardless of how gingerly you shift.
-Very hard to negotiate smooth 1->2, and sometimes 2->3 shifts.

I tried to cover all of my bases when diagnosing the problem:
https://forums.swedespeed.com/showthread.php?461697-Failing-front-diff

I work in my driveway, but I wanted to get the car on a shop rig with two people fault tracing. One person in the car shifting through the gears and another person underneath it to track down the drivetrain noise.

Last year a local shop confirmed that the clank was actually there in all shifts and that it was coming from the transmission. Most likely the diff.

Fast forward to now. I have the transmission out and open on my bench. The diff has damaged teeth and the side and spider gears are noisy with a lot of play.
Confirmed. The diff and the ring gear are toast!


https://flic.kr/p/24LKdxa

https://flic.kr/p/RBUAbX

https://flic.kr/p/24LKdq6

https://flic.kr/p/RBUA6B

https://flic.kr/p/24LKdhR

https://flic.kr/p/2dZpx2B

https://flic.kr/p/24LKda6

https://flic.kr/p/2dZpwXi

https://flic.kr/p/2ehkUxh


VIDEO: You can see and hear the play/slack in the gears.
https://flic.kr/p/RCCcvT
 

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Discussion Starter · #2 ·
Replacement is en route.
 

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How does this kind of damage even happen? Launching?
 

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Discussion Starter · #4 ·
I'm not one to launch and even though I like the technical part of tuning and modding, I don't race or track the car either.
I'm thinking the original owner of the trans had a habit of dumping the clutch.

I bought the transmission and angle gear a couple of years ago. By the time it got to my mechanic and he inspected, it was out of the 30-day return period.
We found that the angle gear's splines were in bad shape. I had to source another. On the bench, the transmission itself seemed smooth and everything engaged.
The M66 is also known to be pretty stout so we did not open up the bell housing. Now, of course... hindsight is 20/20.

I have all of the replacement internal gears/shafts from a fellow R-Forum member's know working unit. They're going in along with the differential that's en route.
 
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