Volvo Splines

nigelhudson

nigelhudson

Well-Known Member
Joined
27 Mar 2005
Messages
439
Location
UK South Coast
calculuscontracts.co.uk
We've just suffered the dreaded spline failure on our VP2002. The problem is compounded by the fact that we were away from our home port at the time so we have had to leave the boat in another marina.

I have seen posts on this subject before but my searches only seem to show up one post which contains an address of a specialist in Cornwall. As the boat is currently stuck in Chi Harbour I could do with information on specialists in the Solent/SE Coast area.

Also my workshop manual only covers the engine and contains no information on the gearbox or how it attaches to the engine. Please can anyone point me to a download for the gearbox manual - it's a shaft drive?

I'd be grateful for any assistance.
 
There's a good summary of the problem and the solutions here on the Westerly Owners' Association website. Your best bet would probably be the DB Marine conversion. The gearbox just bolts to the flywheel housing and is easy to remove (although you'll probably need a torque wrench). There's an exploded drawing of the gearbox in the Parts Catalogue which you can download from here. For the record, I installed the Volvo conversion kit on my 2003T a couple of years ago.
 
Forgot to mention...

Forgot to mention that one of the most difficult bits I found was replacing the plate bolted to the flywheel. It's necessary to lock the flywheel so you can apply sufficient torque to the bolts. I found that it's possible to jam a meaty screwdriver through a hole on the starboard side of the flywheel housing, to engage with the ring gear and prevent the flywheel from turning. Probably not the recommended way, but it works!
 
Although you are after Solent specialists, I got mine from Watercraft Services at Penryn Cornwall; 01326 376084, sales @ watercraft services.com.

Yes I live nearby which made life easier but he was very helpful and will give full advice. The most "difficult" bit is shimming up the new coupling - not a problem for anyone with a little bit of engineering experience and full instructions come with the kit.
 
Hi Nigel,

I've done this job on my 2003 and found DBmarine very helpful, but they do require your old spline to re engineer. I think mine took around 10 days.

If you need any help dismantling/assembling, PM me as I live locally to Chi and would be happy to assist.
 
Thanks Gerry

I've dismantled the gearbox and removed the input shaft this evening. I've parcelled it up and I'm sending it to DB tomorrow. They've quoted me two weeks turnround by email but I'm going to call them tomorrow once the shaft is in transit and see if they can better this.
Two things that perhaps you could answer - firstly how much did it cost? I've seen figures of £250+vat but I'm not sure that these are current.
Secondly, do I have to take the bellhousing off? I can see the drive plate and the bolts through the hole in the bellhousing but there doesn't seem to be enough clearance to remove the plate through the hole.
 
Nigel,

you shouldn't need to remove the bellhousing as the plate will fit through the gap after the gearbox is out. You will need a long reach socket though.

As I recall, the DB marine bill was in the region of £250 - 300.
 
Hi
I read with interest the possible failure problem of the gear box spline, so I tried to locate my engine number.The only one I can find is on a plate at the front, it is FL 2742 which does not seem to be enough digits to the engine numbers quoted on the DB Marine site, it states engine numbers prior to 2300059128. The boat was built in 1984 and I assume it is the original engine
 
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