Disassembling Overdrive
NOTE: They are two types Of overdrive, type J and type P.
1. Clamp overdrive rear end in a vice protected by soft laws
2. Remove solenoid valve. Use crow-foot wrench P/N 5172. Disconnect ground wire.
3. Remove bridges, front and rear housing nuts.
NOTE: Last two nuts removed should be opposite each other. Loosen the nuts stepwise.
4. Remove front housing assembly
5. Remove brake drum, springs. Lift out clutch, thrust bearing and sun gear assembly.
NOTE: Type P: Proceed to operation 7. Operation 6 only applies to Type J. Overdrive.
6. Remove planetary gear assembly. Replace planetary gear assembly if gears or carrier are damaged.
NOTE: Proceed to operation 9. Operations 7 to 8 only refer to Type P Overdrive.
7. Remove planetary gear carrier and thrust washer. If one-way clutch or planetary gear carrier is to be replaced prossed to step 8.
8. Pull off one-way clutch from planetary gear carrier.
- Use universal type puller.
- Place washer P/N 5973 under puller spindle.
- Replace planetary gear assembly if damaged.
Disassembling Front Housing
9. Clamp overdrive front part in a vice protected by soft jaws.
10. Remove oil pan, strainer and pistons. Use pliers.
11. Remove oil filter plugs, check valve and relief valve. Use plug wrench P/N 2836. Tap plugs with a plastic mallet to facilitate removal.
12. Remove:
1- Oil filter
2- Check valve and spring, ball and seat
3- Relief valve assembly. (If replacing, always use new type relief valve).
NOTE: Examine relief valve piston. If scored, it will damage O-ring. Replace relief valve assembly.
5183 Puller:
13. Withdraw cylinder and relief valve seat. Use extractor P/N 5183.
14. Examine relief valve:
- If engagement valve is slow or if overdrive slips on engagement, it is particularly important to check following.
- Check valve seat. If there are signs of wear replace relief valve assembly.
15. Remove cylinder and pump piston.
Disassembling Clutch Assembly
16. Remove lock ring. Pull out sun gear and clutch disc from bearing carrier.
17. Remove lock ring. Tap out bearing from carrier. Use drift P/N 5103.
NOTE: Type P: Proceed to operation 22. Operations 18 to 2l only refer to Type J.
Disassembling rear housing. Type J Overdrives
18. Clamp overdrive rear housing in a vice protected by soft laws.
19. Remove lock ring and one-way clutch oil slinger.
NOTE: Turn one-way clutch in locking direction and make sure that outer ring does not slip on input shaft.
20. Remove one-way clutch. Use ring P/N 5210. Turn ring clockwise
21. Examine roller cage. Invert ring with one-way clutch in it. Check to see if roller cage is oval. If so, replace with new type, Volvo P/N 1 209726-7.
22. Disassemble one way clutch. Replace any damaged parts.
NOTE: Illustrations show an early version of one-way clutch.
If early type one-way clutch is fitted, replace it with new type: Volvo P/N 1 209 484-3. Location of lock spring hole is new. See illustration.
NOTE: Proceed to operation 26. Operations 22 to 25 only refer to Type P.
Disassembling Rear Housing, Type P, Overdrive
23. Clamp overdrive rear housing in a vice protected by soft laws. Pry up oil slinger in two places to install puller P/N 5069. Place a socket on hub. Use a screwdriver to pry up oil slinger.
24. Modification to tool P/N 5069. Replace center bolt with a 40 mm long bolt, threaded along entire length. P/N 998 9709.
25. Place drift P/N 5103 (group 21 tool) in bottom of housing. Use puller P/N 5069 to draw out oil slinger. Remove roller cage.
26. Remove drive flange nut.
- Round drive flange: Use wrench P/N 5149 to hold.
- Three-arm drive flange: Clamp drive flange in a vice.
NOTE: Use wrench P/N 5303 when removing drive flange from vehicle.
27. Withdraw drive flange. Use puller P/N 5304 if required.
28. Remove oil seal with puller P/N 5069.
29. Press out output shaft.
30. Remove spacer sleeve. (On Type J: speedometer drive gear.)
31. Withdraw output shaft bearing.
32. Tap out bearing from rear housing. (Only if bearing is to be replaced.) Use brass drift.