1981 Volvo 244 gearbox noise

Seggle02 · Dec 11th, 2014, 07:40

Hi all,

I have a 4spd manual overdrive 244. At idle in neutral, there is a dull rattling noise coming from the gearbox area. When the clutch is pressed down, noise goes away. Noticeable without being overly loud. Car drives and shifts fine, don't really hear the noise whilst driving about. Recently I checked the gearbox oil, oil was a nice cherry red and clear with perhaps a few tiiiny metallic slivers in it (or it could have been debris from surrounding environment - my garage is a bit filthy.)

Should I be concerned? What should I do (if anything?). Car is getting gear oil changed (drain plug is in too tight and has become somewhat rounded...) at a mechanic on Monday. Mileage is 415,000km! I have been told by a fellow 240 enthusiast this noise is normal, and will still be present even after a full rebuild.....thoughts?

Clifford Pope · Dec 11th, 2014, 08:13

Are you sure it's from the box and not the clutch release mechanism?
This often gets a bit rattly, invariably fixed in my experience by a short burst of spray oil or grease down the red tube onto the release bearing/carrier.

Seggle02 · Dec 11th, 2014, 08:26

Checked with stethoscope, sound seems to be coming from gearbox assembly itself. All the way along the length of it.

twoluckyone · Dec 11th, 2014, 09:51

Are you sure it's not just the release bearing that is worn out?

Seggle02 · Dec 11th, 2014, 10:56

Well, clutch was recently replaced (I assume release bearing is part of the job) but I see from YouTube release bearings make a high pitched squeal, this is more a dull rattle.

Derek UK · Dec 11th, 2014, 11:36

Recent clutch replacement - Check that the cable adjustment is correct and the arm spring is properly fitted. Click on the illustration on this page. Note the so called damper where the cable attaches to the arm. It these were fitted from the start of the 240 series you should have one but note that IPD says it will work without one. I can see a mechanic not bothering with it, especially if it was oily and breaking up rather than getting a new one. I'd guess they don't come with an aftermarket cable but may with a pukka Volvo one.

http://www.ipdusa.com/products/7214/...utch-cable-240

Seggle02 · Dec 13th, 2014, 06:04

Well I changed the oil, there was a fair bit of metal in what came out. However, after putting new oil in, the noise is gone, so I will consider the issue resolved for now.

Seggle02 · Dec 14th, 2014, 02:56

ok update - noise has returned, but only when the car has warmed up.

I put in a mineral 80-90 oil. Time for 80-140 I suppose?

Dec 11th, 2014, 07:40	#1
Seggle02 New Member Last Online: Dec 17th, 2015 08:45 Join Date: Nov 2014 Location: Cowra	1981 Volvo 244 gearbox noise Hi all, I have a 4spd manual overdrive 244. At idle in neutral, there is a dull rattling noise coming from the gearbox area. When the clutch is pressed down, noise goes away. Noticeable without being overly loud. Car drives and shifts fine, don't really hear the noise whilst driving about. Recently I checked the gearbox oil, oil was a nice cherry red and clear with perhaps a few tiiiny metallic slivers in it (or it could have been debris from surrounding environment - my garage is a bit filthy.) Should I be concerned? What should I do (if anything?). Car is getting gear oil changed (drain plug is in too tight and has become somewhat rounded...) at a mechanic on Monday. Mileage is 415,000km! I have been told by a fellow 240 enthusiast this noise is normal, and will still be present even after a full rebuild.....thoughts? Last edited by Seggle02; Dec 11th, 2014 at 07:48.

Dec 11th, 2014, 08:13	#2
Clifford Pope Not an expert but ... Last Online: Yesterday 14:54 Join Date: Dec 2001 Location: Boncath	Are you sure it's from the box and not the clutch release mechanism? This often gets a bit rattly, invariably fixed in my experience by a short burst of spray oil or grease down the red tube onto the release bearing/carrier.

Dec 11th, 2014, 08:26	#3
Seggle02 New Member Last Online: Dec 17th, 2015 08:45 Join Date: Nov 2014 Location: Cowra	Checked with stethoscope, sound seems to be coming from gearbox assembly itself. All the way along the length of it.

Dec 11th, 2014, 09:51	#4
twoluckyone Junior Member Last Online: Jun 19th, 2016 23:22 Join Date: Mar 2008 Location: breda	Are you sure it's not just the release bearing that is worn out?

Dec 11th, 2014, 10:56	#5
Seggle02 New Member Last Online: Dec 17th, 2015 08:45 Join Date: Nov 2014 Location: Cowra	Well, clutch was recently replaced (I assume release bearing is part of the job) but I see from YouTube release bearings make a high pitched squeal, this is more a dull rattle.

Dec 11th, 2014, 11:36	#6
Derek UK VOC Member Last Online: Yesterday 14:01 Join Date: Jul 2006 Location: Chatham	Recent clutch replacement - Check that the cable adjustment is correct and the arm spring is properly fitted. Click on the illustration on this page. Note the so called damper where the cable attaches to the arm. It these were fitted from the start of the 240 series you should have one but note that IPD says it will work without one. I can see a mechanic not bothering with it, especially if it was oily and breaking up rather than getting a new one. I'd guess they don't come with an aftermarket cable but may with a pukka Volvo one. http://www.ipdusa.com/products/7214/...utch-cable-240

Dec 13th, 2014, 06:04	#7
Seggle02 New Member Last Online: Dec 17th, 2015 08:45 Join Date: Nov 2014 Location: Cowra	Well I changed the oil, there was a fair bit of metal in what came out. However, after putting new oil in, the noise is gone, so I will consider the issue resolved for now.

Dec 14th, 2014, 02:56	#8
Seggle02 New Member Last Online: Dec 17th, 2015 08:45 Join Date: Nov 2014 Location: Cowra	ok update - noise has returned, but only when the car has warmed up. I put in a mineral 80-90 oil. Time for 80-140 I suppose?

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