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Old 07-22-2020, 04:13 PM   #1
Fresh Air Inspector
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Default AW71 Output Flange Nut

Hello All,

Started the process to replace the output shaft bearing on my 1994 940T. First problem is the 4 (of 6), extension housing bolts that snapped. Fortunately enough stud is sticking out to either grab with Vice-Grips or weld a nut on.

However, the more serious issue is the 30 mm nut that holds the output flange onto the output shaft. The nut is 'dimpled' into a recess in the shaft to lock it in place, unfortunately this dimple is impossible to remove resulting in damaged nut threads when it is removed.

Does anyone know where this nut is available? I can't find it in the Volvo parts lists - hopefully one of you has found an alternative?
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1971 VW Beetle Cabriolet, 1994 Ford Escort, 1994 940 T Sedan, 1994 940 NA Wagon
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Old 07-22-2020, 04:45 PM   #2
DET17
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I'd almost swear I bought one of these years ago from FCP Groton. Talked myself out of changing it on my 94 AW71..... decided to leave the 126K mile gearbox well enough alone. Might still have, but not sure.

I'd likely try and cut right thru the dimple with a dremel and small cutoff wheel. When you install the NEW locknut, dimple another spot or just use some red Loctite and it will take HEAT to remove. Good luck!
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Last edited by DET17; 07-24-2020 at 12:38 PM..
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Old 07-22-2020, 08:57 PM   #3
84B23F
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Quote:
Originally Posted by Fresh Air Inspector View Post
can't find it in the Volvo parts lists
It's not in a transmission parts listing: PDF

Check with Toyota...same transmission

1983–1985 Toyota Cressida
1982–1985 Toyota Land Cruiser
1982 Toyota Celica Supra
1990–1992 Volvo 740 2.3L Turbo I4 (AW71L)
1991–1997 Volvo 940 2.3L Turbo I4 (AW71L)
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Old 07-24-2020, 04:15 PM   #4
Fresh Air Inspector
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Hello DET17,

Checked FCP Groton and they no longer show that item.

Hello 84B23F,

Many thanks for the 'Toyota' link, I had heard that they also used the AW gearbox.

Unfortunately since I posted this message I've discovered that I can't repair it. The 4 extension housing bolts that snapped won't come out despite my best efforts including welding nuts on the end. To add to that, the fresh ATF (less than 1k km / ~600 m), is VERY brown. So, I'm going to 'write off' the gearbox. I had planned to swap out the AW71L for a M46 with O/D - my schedule has now been moved forward. :-)
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Old 07-24-2020, 08:21 PM   #5
84B23F
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I heat studs cherry-hot before welding a nut on them..and try to remove with vicegrips...if not, then weld a nut on them...

old motorcycle trick with a punch, before removing nut/bolt, place a punch on bolt/stud, and whack it with a hammer.
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