Volvo 280 outdrive clunks going into gear

[Shouldn't Have]

Hello,
I have volvo 280 outdrives that clunk when they go into gear, one more noticeable than the other. I've read on here about looking into the upper housing and checking a gap. I've also read on another site about there being a wearable washer in there as well. I'm mechanically inclined but have not really done much with these outdrives besides oil changes and ujoint greasing. There are no metal shavings in the oil, so i hope to get this fixed before bigger problems are made.

So my question is, can someone point me in the right direction so i don't just start taking apart pieces that don't need to come out. I have the workshop manual but it pretty much just tells me how to rebuild the entire drive, not too specific on certain problems.

Here is the link to the upper unit part diagram http://www.volvopentastore.com/mall/image/vendor/699/EPC/bigger/7285_big.png

If you could point me to specific part numbers that would be great.

Thanks in advance for your help.

Scott

 

[Don S]

Re: Volvo 280 outdrive clunks going into gear

Before you start taking things apart, is it clunking into gear on muffs or in the water? What is your idle rpm? If too high, it will clunk no matter what you do. Do you have Aluminum or SS props?

 

[Shouldn't Have]

Re: Volvo 280 outdrive clunks going into gear

Don, It definitely clunks in the water. I usually don't shift it much on shore, but for what I recall last year when i winterized it, it doesn't clunk much on land, maybe a small clunk. I have aluminum 15", 21 pitch props.
The engines idle between 600-800 rpm.

 

[captmello]

Re: Volvo 280 outdrive clunks going into gear

Some of the clunking can be from the play in the retaining pawl which keeps the outdrive from kicking up. Which is why testing on land eliminates this type of clunk since there is no water resistance. Having a similar outdrive, I have intermittent clunking as well.

 

[Shouldn't Have]

Re: Volvo 280 outdrive clunks going into gear

It's not intermittent in the water. I haven't un-winterized yet as we are still expecting some freezing temps, so i can't run down and test the shore test. I figured i'd do some outdrive work while waiting for the weather to break.
In water it is a very noticeable and sometimes uncomfortable.

 

[captmello]

Re: Volvo 280 outdrive clunks going into gear

reach down and pull out on the outdrive. if there is movement, you can expect to feel that as a clunk when you shift into reverse. It's also possible, you have some worn parts in your upper gear box contributing to the clunk.

Have a look at this thread.

http://forums.iboats.com/showthread.php?t=367401

 

[Shouldn't Have]

Re: Volvo 280 outdrive clunks going into gear

The clunk is more noticeable going into forward. Everything is always so difficult. Well i have a good place to start and now i know where to measure the gap and what parts to look at. I think maybe this next weekend i'll at least pull one of the uppers off and see what it looks like.
At least i can bring it home and work in my garage.

 

[Shouldn't Have]

Re: Volvo 280 outdrive clunks going into gear

I pulled the upper and was able to measure the gap on the top nut.
It is 0.055. I'm going to attempt what you did captmello and see what happens. If that doesn't bring the clearance down to spec, then i guess it will have to go to the shop. We'll see what happens.

 

[captmello]

Re: Volvo 280 outdrive clunks going into gear

Ya, thats way out of spec. I hope replacing that washer helps with the clunking. Once I figured out how to get the top nut loose, it was an easy repair. Make sure you replace all the gaskets and orings when you assemble.

FYI - as I mentioned in the other thread i linked, I only had to back the top nut off a couple turns and did not remove it completely. Also it's a left hand thread.

Let us know how it goes and what your new measurement is once you replace the washer.

I still get some intermittent clunking but I blame the play in the outdrive. I may test it out this summer by strapping the outdrive tight to the shield to eliminate the outdrive play.

Good luck!!!

 

[Shouldn't Have]

Re: Volvo 280 outdrive clunks going into gear

Well I was able to get the job done! Yep, that brass washer/spacer was shot! It took my brother and I about an hour to get a good system to be able to get that nut loose. We ended up clamping the upper gear box to a work bench and using a large breaker bar/socket on the nut and vice grips on the shaft sleeve. The wood trick did not work for us. The vice grips left a couple of marks on the sleeve, so we filed that smooth and all looks well.
After getting it all back together, I now only have a 0.004" which is the smallest spec. It should be good to go now for quite a few years. I can't wait to get it in the water and see how she acts. Hopefully we will get some nice weather so I can get working on her and get her launch in the next couple of weeks.
Thanks for the input and advice.

Scott