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PostPosted: Sun Nov 08, 2015 10:00 pm 
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If you have been mad enough to read my restoration thread, you will have seen that I replaced my gearbox mount to cure a violent judder (very similar to axle tramp) when setting off. Now I was quite disappointed by one aspect of my work, though the judder was cured, the cabin noise was more track day car than smooth cruiser to put it mildly. All of the engine, gearbox and exhaust (which is bolted to the gearbox) noise was so loud that I took everything apart to check my work but without change.

I have a spare mount that whilst old has not yet jellified with oil contamination, and with that you could move the centre by hand in all planes relatively easily though harder to fore and aft. Not so with the replacement mount, I could not get that to move even a jot when it was bolted up and had some weight behind it. So I set about looking for a replacement, and read on here that a Sierra Type 9 mount had been successfully used. They seemed a bit expensive for an experiment, anything from £24 to £45, and needed quite a bit of fettling on the crossmember to enlarge the aperture, so went looking for something else.

A visit to the local motor factors and a rummage through their catalogue came up with something that was not a million miles away from what I needed, and was still being made by the OEM supplier, a Febi 22394 which says on the box "To fit Volvo PKW", total cost £8.
Attachment:
File comment: FEBI 22394 Top view
IMG_20151108_135158_s.jpg
IMG_20151108_135158_s.jpg [ 54.42 KiB | Viewed 2100 times ]
Attachment:
File comment: FEBI 22394 Side view
IMG_20151108_135210_s.jpg
IMG_20151108_135210_s.jpg [ 44.05 KiB | Viewed 2100 times ]
Comparing the Febi with the TKC1044 more closely showed a few differences in dimensions, which I'm sure is not going to surprise anyone who has read this far. Well done for that by the way, this has to be driest thing I've written since my thesis on the the Atacama Desert, which didn't actually happen but I'm using it as a writers device *cough*. With the Febi mount there was give with fingers alone in the fore and aft directions, but nothing left and right, which whilst the opposite of my OEM mount, seemed more logical, very little twist, but allows a little push and pull movement. Fetched my crayons and vernier calliper, and come up with some (un)helpful pictures to show the differences, first dimension shown is for the OEM TKC1044 followed by Febi 22394.
Attachment:
File comment: TKC1044 vs FEBI 22394 side dimensions
IMG_20151031_164515_s.jpg
IMG_20151031_164515_s.jpg [ 92.96 KiB | Viewed 2100 times ]
Attachment:
File comment: TKC1044 vs FEBI 22394 top dimensions
IMG_20151108_135130_s.jpg
IMG_20151108_135130_s.jpg [ 118.46 KiB | Viewed 2100 times ]
Not wanting to ruin my existing crossmember, plus I could mess around with this idea and keep using the car at the same time, I took the crossmember off my spare gearbox, it was a tad rusty.
Attachment:
File comment: Rusty Crossmember (terrible singer)
IMG_20151031_164349_s.jpg
IMG_20151031_164349_s.jpg [ 166.24 KiB | Viewed 2100 times ]
Actually that doesn't look so bad, let's have a look at the other side then.
Attachment:
File comment: Really Rusty Crossmember
IMG_20151031_164602_s.jpg
IMG_20151031_164602_s.jpg [ 189.21 KiB | Viewed 2100 times ]
Can't even imagine putting that on my car, it might catch something! Took a walk to Wilkinsons and bought a wire brush for my drill, some rust converter and a rattle can of Hammerite £16, that place can be stupidly cheap sometimes. A little bit of spit and polish and hey presto, one cleaned up crossmember with 5mm elongated mount holes done with a round file.
Attachment:
File comment: Crossmember elongated mounting holes
IMG_20151106_153625_s.jpg
IMG_20151106_153625_s.jpg [ 101.41 KiB | Viewed 2100 times ]
As the Febi mount height is 9mm lower than the TKC1044 I made some shims up from 40mm flat washers, just needed to drill out the centre with a 12mm drill bit.
Attachment:
File comment: Shims
IMG_20151108_141008_s.jpg
IMG_20151108_141008_s.jpg [ 54.03 KiB | Viewed 2100 times ]
And et voila! The finished crossmember with new mount ready to be bolted up.
Attachment:
File comment: Finished article with FEBI 22394
IMG_20151108_141041_s.jpg
IMG_20151108_141041_s.jpg [ 191.62 KiB | Viewed 2100 times ]
Took the original crossmember off and was dismayed to see that the new TKC1044 mount's aluminium centre had already parted company with the black stuff pretending to be rubber that I think is the same stuff that they seal road joints with. I just plain do not understand how no one else has the issue that I did with it noise wise, maybe I've just been unlucky with a bad batch?!

Bolted on my new crossmember, using only 6mm of shims to get the right height, all looked good and fit together well. Put away the tools, cleaned up and went for a test drive, pulling out of my drive extremely cautiously at first I must admit, but already with just going down the side street it was so much quieter, and so it proved to be as I continued driving with gaining confidence, total and utter bliss, and no judder still.

Good grief I thought, this has actually worked!

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Current fleet: Triumph Dolomite Sprint '75, Daihatsu Fourtrak, Honda CG125, Yamaha Fazer 600, Shetland 570

Disposal fleet: Golf GTi 16v MK3 Anniversary

Past fleet: Triumph 2000, Lancia Beta Coupe, BL Mini Clubman, Austin Metro, Vauxhall Cavalier MK1 & MK2, Renault 18 D, Rover 216 GSI, Honda Accord (most expensive car purchase, hated it on pickup from dealer, was made out of magnetic metal as only car I've ever been crashed into, 4 times), Golf GTi MK3 16v x 3


Last edited by Galileo on Mon Nov 09, 2015 11:21 pm, edited 1 time in total.

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PostPosted: Sun Nov 08, 2015 10:13 pm 
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Congratulations! We need pioneering work like this to keep our cars on the road in the face of inferior quality replacement parts.


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PostPosted: Sun Nov 08, 2015 10:23 pm 
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Excellent work here, so its a Volvo 740 transmission mount?

All you had to do was elongate the holes by 5mm and fit some washers to shim it up?

I'll buy you a beer if you're at the NEC next weekend!!


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PostPosted: Sun Nov 08, 2015 10:42 pm 
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Ta for the thumbs up Pippin!

You know what James, I never thought to do a reverse lookup to see what it originally fitted! Here is the list from a quick google Volvo 740 87-92 B230 (automatic only), 760 87-90 all, 780 all, 940 91-95 (automatic only) B230.

And yes, quite embarrassing considering how long my post is, the TL;DR is elongate holes by 5mm each towards the centre, shim out with washers to suit! :lol:

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Current fleet: Triumph Dolomite Sprint '75, Daihatsu Fourtrak, Honda CG125, Yamaha Fazer 600, Shetland 570

Disposal fleet: Golf GTi 16v MK3 Anniversary

Past fleet: Triumph 2000, Lancia Beta Coupe, BL Mini Clubman, Austin Metro, Vauxhall Cavalier MK1 & MK2, Renault 18 D, Rover 216 GSI, Honda Accord (most expensive car purchase, hated it on pickup from dealer, was made out of magnetic metal as only car I've ever been crashed into, 4 times), Golf GTi MK3 16v x 3


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PostPosted: Sun Nov 08, 2015 11:34 pm 
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Superb effort, Sir!

How about we send you some spare cross members and you start a new line for Club stock? :wink:


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PostPosted: Mon Nov 09, 2015 7:09 am 
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Thats great detective work and a very nice solution. Well done! :)

Tony

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PostPosted: Mon Nov 09, 2015 7:13 am 
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Just found this on ebay is it the same? Also Febi (bilstein)

http://www.ebay.co.uk/itm/Gearbox-Mount ... SwDNdVoKQn

Tony

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PostPosted: Mon Nov 09, 2015 10:19 am 
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Rarely in the field of dolomiting has such an excellent solution been found for so little effort.

The few of us left who use our cars a lot will now be clearing out NOS of these mounts so be quick everyone...

Jonners

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Note from Admin: sadly Jon passed away in February 2018 but his humour and wealth of knowledge will be fondly remembered by all. RIP Jonners.


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PostPosted: Mon Nov 09, 2015 6:56 pm 
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Quote:
Just found this on ebay is it the same? Also Febi (bilstein)
http://www.ebay.co.uk/itm/Gearbox-Mount ... SwDNdVoKQn
Tony
Is indeed, there seems to be a lot of Volvo part numbers for the same part, I see down at the bottom it says MPN 22394 so spot on. Volvo part numbers I've found are 982793, 1330831, 30812002, 3528069, 3528070, 946440, 966807 and 974209.

Seen this one on ebay at £4.81 delivered and they have 10 showing!

http://www.ebay.co.uk/itm/Mounting-auto ... Swo0JWHh4c

Meyle do a heavy duty version if the OEM one is too soft for you:

http://web2.carparts-cat.com/default.as ... 004&12=140

http://www.dvsegmbh.info/PDF/einbau/420 ... 008_EN.PDF
Quote:
Superb effort, Sir!
How about we send you some spare cross members and you start a new line for Club stock? :wink:
Ha! Not sure on the long term future of this career change, it seems to be a little limited! I'm quite sure that you are all more than capable of doing your own, but in all seriousness if not then I'd be happy to help and mod one.

Gave a mate a lift tonight and without me saying anything they straight away asked what I had done to the car it was so quiet. Glad to give something back, but hey, maybe prudent to wait a bit just in case I come back to the forum with a sad tale of how my gearbox has just dropped off! ;)

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Current fleet: Triumph Dolomite Sprint '75, Daihatsu Fourtrak, Honda CG125, Yamaha Fazer 600, Shetland 570

Disposal fleet: Golf GTi 16v MK3 Anniversary

Past fleet: Triumph 2000, Lancia Beta Coupe, BL Mini Clubman, Austin Metro, Vauxhall Cavalier MK1 & MK2, Renault 18 D, Rover 216 GSI, Honda Accord (most expensive car purchase, hated it on pickup from dealer, was made out of magnetic metal as only car I've ever been crashed into, 4 times), Golf GTi MK3 16v x 3


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PostPosted: Mon Nov 09, 2015 8:00 pm 
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Well done Raf. I'm sure you've put it on correctly. You should be able to do it in your sleep. Wilko is a good place for stuff. That's where I got my vinyl silk from for the headlining. This is what it's all about - finding alternative parts which can be safely adapted to fit with minimal fettling.

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Meetings take place on the 1st Wednesday of every month at The Hollies Sports & Social Club, 12 Hough Lane, Bramley, Leeds, LS13 3NE
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PostPosted: Mon Nov 09, 2015 9:29 pm 
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I like it Raf superb. I never noticed the lack of voids in that horrible mount . I have only fitted original old stock mounts. I keep old original engine mounts because I know the reproduction ones cause problems and I have no faith in the quality of this stuff anymore. Top man Raf.


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PostPosted: Mon Nov 09, 2015 9:58 pm 
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This is really interesting. I have never been able to obtain an 'OEM' mount for my car since I converted it to overdrive. I have replaced the mounting a few times in order to try and improve the refinement to no avail. It also judders (especially in reverse) so I may go down this route too before I get too carried away!

Well done!


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PostPosted: Tue Nov 10, 2015 7:10 am 
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Ive just ordered 2! :0 New old stock in 30 years :)

Tony

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PostPosted: Tue Nov 10, 2015 5:59 pm 
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Superb work Sir!.. I salute you.. :)


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PostPosted: Mon Nov 16, 2015 7:54 pm 
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Firstly may I add my thanks for the work done here, this really is a fine replacement for a poor re-manufactured unit.

But I would like to add one thing. You need to slot the mounting holes in the cross member to fit the mount. If you do this there is very little left and there would be a big risk of them breaking through when in use. So I will be adding plate to each side of the hole where the mount goes through the cross member to ensure it doesn't break through.


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