transmission oil leak

[Paul-C]

anybody any thoughts on this problem?
I have a leak on the 960 AW 30-40 transmission sump pan (leaking from the propshaft end) so I removed the pan (some difficulty) and re-sealed with loctite black (what the garages use according to Andrew page)
this didn't work so spoke to loctite who said the sealant needed to be ( lost the detail of this but was obtained from Halfords) so I resealed with this sealant and its still leaking
The sealant was to a good thickness all around the pan and around each bolt hole
The pan was offered up to the g/box with no sideways movement to ensure what should have been, a good seal and all the bolts tightened to 7Nm
The oil that's leaking is from the joint of the box/pan not from above it so what am I doing wrong? and should I change the pan
the pan was checked for damage and also I ensured the face was flat.
ps when I removed the pan the first time I found a 6mm bolt sat on the magnet! I found its home and replaced it!
any thought's on the next step?
Thanks
paul-c

[treehorndogsbody]

Are you trying to seal the trans pan with or without the AW pan gasket? Are you using the apropriate 3/8"torque wrench to preplace the the pan bolts? Has someone been there before you? Was the 6mm bolt from the filter housing?

[Paul-C]

the gasket material that I removed initially appeared to be a red tube applied' type material that would be applied with a mastic gun.
The correct gasket material supplied by Volvo dealers is the same sealant as above `red in colour' but about £100 a tube and according to them nobody buys it from them they obtain it from andrew page or equivilant, that's the reason I spoke to Loctite to ensure I was getting the right stuff.
I have thought about making a gasket with some gasket paper (thick) to help to seal it and using some of the tube applied material to help
I have also tried to obtain another pan to make the job easier as it takes forever working under the car cleaning the pan and g/box face, and also ensure its flat face which on the bench seems to be ok. but I am struggling to source one.
I am using the appropriate 3/8 torque wrench and initially set the torque at 7Nm since then I have increased the torque to 8.5NM to resolve it but to no avail
I have had the car since new 1996 with 160k and it started leaking for no apparent reason.
The bolt was from the opposite end of the filter housing in a corner,
Thanks for your thoughts
paul-c

[lovejoy633]

I also would have thought that you need a gasket as well as the sealant (always have on other cars I've done).

As for making one........can't be that expensive from your main dealer and a lot less hassle.

[Paul-C]

Lovejoy 633,
When I asked the main dealer for the gasket he offered me the tube of gasket material that i mentioned earlier, and said that it was the only gasket the Volvo's recommend.
So as far as they are concerned there is no cork or paper gasket material used.
What I was saying in the last post was that I would have thought there would have been some and although it's a hassle I cannot think of an alternative, other than giving the car to somebody who car resolve the issue, but who?
paul-c

[lovejoy633]

I've just done a quick search on ebay and found this :-

http://cgi.ebay.co.uk/VOLVO-240-340-...item3f0411fcf3

However it does not mention the 960 3.0 24v which If memory serves is what you have.

I'll have a check thru the parts supliers I use and see what I find.

You can't always rely on the advice/info give from some youth in the parts dept.......... as I said, in my experience I've always used a gasket with the sealant.

[Paul-C]

lovejoy633, Thanks you your help
I have been in touch with the link and they do not know of a gasket for this transmission
They also do not stock the pan so it's back to the drawing board
I have checked with the volvo dealers again and there is definately no gasket material used other than the chemical gasket in the tube that I mentioned in the previous post
The cost of a new pan from them is £110
I have a call out to "Cleckheatons g/box centre" to see what there advise is
Thanks again
paul-c

[treehorndogsbody]

Cleckheaton is only a few minutes drive from me so if I can call and pick up then post any parts, I will, if they do not have a post facility. I would give the automatic gearbox chaps at Huddersfield ring 01484886285 they are very good. I was supplied with a thickish paper gasket in the filter kit I bought in 2008 and there was a paper gasket on the pan when it was removed. Are you sure the tail casting on the box isn't leaking? Does it only leak when car moves? I would have thougt using liquid type joint compound, would be risky as you can not see if it squeezes into the pan contaminating the ATF with the risk of tiny bits going heaven knows where and cocking up the valve block.

[Paul-C]

Thanks for the help treehorndogebody I will see what they say tomorrow.
The oil leak is continuous when the car is stood.
The oil leak, after wiping the joint clean shows itself at the propshaft end of the gox at the sump joint and I cannot see oil leaking from the output bushing that's directly above this.
Thinking of your experience with the Huddersfield place what is the way forward, Cleakheaton or Huddersfield, as the first phone call?
What I am thinking is to try and arrange to take the car in to make it their first job of the day, so I can stay with the car until it is resealed then drive home.
Distance wise there is little difference so it's down to recommendation
thanks
Paul-c.
ps which car was you on with when you obtained the filter kit? as I have tried to get info. re. this g/box from sources other than the main dealer and it seem's impossible

[treehorndogsbody]

I would try Huddersfeld first as Cleckheaton are mainly manuals and clutch fitters. I have had two of my car's ATF changed a 1996 (P) 940 CD estate and a 1997 960 CD Lux saloon. Both have high mileage and auto box problems,the 960 was improved by the ATF change and the 940 needed a new kikdown cable as it was frayed and sticking causing the box to hold gears. I am just going into the office(spare bedroom) to see if I can find the invoice and name of the transmission specialist I bought the pan and filter kits. The Hudderfield chaps used to have loan cars (you insure) but I have not been since mid 2009, with a friends Volvo S80 with a duff solenoid, so things mayve changed with the loan cars.