Re: cracked overdrive.
I suspect the reason it cracked was because whoever did the modification did not understand the importance of proper alignment. It is important that when the torque tube is sectioned and welded to the two flanges for the overdrive housing everything must be in perfect alignemt and the overall length must be exactly as before the modification. Any deviation in length and you will not be able to insert the large bolt that holds the two radius rods to the front of the torque tube. Misalignment in the housing, torque tube, or the driving elements will cause the splines to tear up.
Over the years I have seen a number of these Volvo modifications fail. One unit came into the shop that was too short in length. During the installation the owner had loosened all the bolts on the overdrive housing so he could insert the radius rod bolt. When he tightened the housing bolts back up the housing cracked. Others have come in with the splines torn up or the stub shaft broken off at the end of the key in the pinion gear taper.
The modifications done by Rich & Mitch in Bakersfield, CA appear to be done very well. I have never seen one of their units fail. I suspect they use some kind of an alignment jig when they build their units.
Tom Endy
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