Volvo ujoint spline won't go onto the intermediate shaft - Help!

[bobvonryan]

I recently rebuilt my intermediate housing or Bell housing on my AQ290 drive. I removed the clips and used a brass drift to drive out the shaft. It all went back together fine. Today I tried for over two hours to put the gearbox/ujoints onto the shaft and never did get it to happen. Would the brass drift cause damage to the spline or something to prevent the splines from lining up? I can't see any damage to it. I'm stumpted? I rebuilt the ujoints before and had little trouble getting the bellows and gear box back on. The only problem I had with that fix was I must have tightened the outer hose clamp to tightly because it busted and water got into the gears. I found it it pretty easy to over tighten with a ratchet. Also, I tried to find the intermediate housing diagram for over an hour today and can't find it. If anyone knows where I can find it please let me know. Thanks!

 

[bobvonryan]

Re: Volvo ujoint spline won't go onto the intermediate shaft - Help!

Any ideas on this?

 

[Don S]

Re: Volvo ujoint spline won't go onto the intermediate shaft - Help!

What engine do you have? The flywheel cover with the intermediate bearings is covered in the engine service manual, not the drive manual.
For parts breakdown of the intermediate bearings, go to the engine and look under the heading of "Connecting Components".

As far as why it doesn't go on, have no idea, must be some damaged splines somewhere or you just didn't get it lined up straight.

 

[bobvonryan]

Re: Volvo ujoint spline won't go onto the intermediate shaft - Help!

Thanks Don. The motor is a 350/260 HP sbc. I know I saw a side view diagram of the intermediate housing that was pretty easy to see how things went in relation to the shaft. I printed it out but tossed it after completing the job. I would think it pretty difficult to damage splines with a brass drift rod, but that said, I just doesn't want to go on. Is there any trick to getting it to go in? Thanks!