Hello all, I'm new to the forum. I am located in Canada and have a 1980 240DL 4spd sedan (300,000km). which has developed what sounds like a serious problem in the differential. I haven't taken a look yet, but just listening is disturbing to say the least. (A loud metalic grinding, concrete mixer type noise, which diminishes considerably when the clutch is applied. Needless to say, the car is not being driven at the moment!)
I also have a 1992 240 5spd wagon (300,000km) which I am parting out. Is it feasible to switch the rear axle assembly from the wagon to the sedan?
Looking forward to any input.

 

Totally interchangeable.

 

I swapped out an axle from an '89 245 into a '91 244 with no problems. However, the age difference beween the two vehicles may be more of a concern. I believe in the earlier models they used a different driveshaft than the later ones. However, I don't know if meant any difference in the axle.

I would take a close look at the two and their mount points and where the driveshaft connects. Take some measurements to see if they are the same, etc.

 

Not sure I totally understood - the noise is when you're moving, right? Not when you're sitting still? Your remark about the clutch makes me wonder about the throwout bearing.

 

Thanks for your replies.
Yes noise was only when moving.
Closer inspection, has revealed two things.
1) The age difference is a factor. The '92 wagon's driveshaft is fatter and slightly shorter than the '80 sedan.
2) Removal of the diff cover revealed little or no oil, some metal filings, no visible damage to the gears, (but possibly the bearings?), and a pin hole in the cover.
The hole has been temporarily repaired, new oil in the diff, and I will take her out for a gentle test drive on Thurs.
I'll let you know.

 

Check this out diff_lsd_volvo_dana
Some great info as to how some of this stuff works, and the differences between the two differentials you have an 1030 and 1031. You must have ran that unit on no oil for quite a while as these things are pretty tough, but the swap should be no problem. I didn't think they would be much of an issue as the tail shaft flange bolt pattern and threads are simple and changing them (by Volvo) would be unnecessary. The site indicates no problem with interchangeability unless you want to exchange internal parts. You can't because the newer model (1031) is all beefed up on the inside. Flange pattern should be the same.

The problem you might run into is the speed and ABS sensor. I know the plates that house the speed sensor are different, so I'm not sure if your '92 connections will like the 1030 differential speed sensor.
What do the connections look like?

 

The test drive showed no improvement, so further investigation is needed. Thanks for the link Burn Stains, although this is starting to go way over my head. Fortunately I have a friend to help me, who has a far greater knowledge of mechanics than I have!

 

The fact that your late model rear end has a speed sensor is of no consequence; the 80 doesn't need it as up until 85, they used a cable driven by the transmission...ditto the abs tone ring inside the differential. Sure, the drive shafts are different diameters, again...no consequence. The drive shaft length? Only the front portion changes. Both the M45 in the early car and the M47 in the newer car are non-overdrive units but slightly different in length. You're swapping axles, not transmissions so it doesn't matter. It will totally swap into the 80 with minimal issues. The main one will be axle ratio. The late model will most likely be a 3.73. The 80, with an M45 may have a different ration. I'd swap the transmission too...better gas mileage...IF the tranny is still good. In my GT build thread, I swapped a 1031 late model axle into the 80 GT...zero mounting issues.

 

Yeah, I thought he was swapping the '92 with an '80, so ABS will surely not work...