Transmission, Installing
Transmission, installing
Cleaning and lubricating the input shaft
The input shaft must be lubricated before a manual transmission is installed.
Checking before installing
Check that the transmission and engine mating surfaces are absolutely clean.
Also check that the guide sleeves towards the engine are in position and are free of faults.
Lubricate the holes in the transmission (for the guide pins). Use a little grease, F8.
Adjusting the position of the transmission and engine
Adjust height and angle with the mobile jack and the transmission fixture.
Locate the transmission on the engine.
Ensure that the transmission goes straight in, in relation to the engine, and that no deviation occurs in the clutch driven plate center.
Installing and tightening the screws for the transmission
Install all 7 screws securing the transmission to the engine.
First tighten alternately and crosswise to light contact.
At the same time, check that the whole of the transmission is in contact with the engine.
Then tighten the transmission/engine screws crosswise. Tighten to 50 Nm.
Remove the fixture from the transmission.
Lower the car
Lifting the engine and transmission to the horizontal position
Right-hand drive cars only:
Check that the lower and upper steering column sections have not separated.
Raise the car
Installing the rear engine mounting
Install
- the rear engine mounting on the transmission
- the 3 screws for the engine mounting. Tighten to 50 Nm.
Installing the bevel gear
Only applies to cars with bevel gear
Install the bevel gear.
Installing the collision protection system over the steering gear
Applies only to right-hand drive cars
Tighten the screw and nut. Tighten to 80 Nm.
Installing the sub-frame on the bodywork
Note: Use 4 new screws (M14). Lubricate the screw threads.
Note: When the sub-frame is raised, ensure that the screws for the steering gear locate in the frame.
Begin the installation of the sub-frame on the right-hand side.
Lift the frame to the body. Use the mobile jack.
Lift until the frame is approximately 10 cm from the body.
Installing the sealing ring for the CV joint housing
Install the sealing ring for the constant velocity joint housing.
Installing the left drive shaft on the transmission, wheel spindle and control arm
Note: Take care not to damage the drive shaft seal in the transmission.
Press in the drive shaft so that the snap ring locates in the groove. Pull the constant velocity joint to check that the drive shaft is secure.
Install the wheel spindle on the control arm.
Install the lock nut loosely.
Raise the frame to the bodywork. Install the frame screws. Move the mobile jack to the righthand side.
Installing new lock nuts on the steering gear
Remove the tie strap.
Install new lock nuts on the steering gear.
Tighten the screws. Tighten to 50 Nm.
Installing the screw for the rear engine pad
Lift up the anti-roll bar mounting. Use a jimmy bar. This will make it easier to position the tool and install the screw.
Tighten to 50 Nm.
Installing the screws for the bracket for the heated oxygen sensor (HO2S) cable
Install the screws in the bracket.
Installing the cross members
Install
- the 3 cross members and the brake pipe in its holders
- the screws for the exhaust bracket
- the heat shield in the front cross member
- the screws for the cross members. Tighten to 25 Nm.
Installing the right drive shaft on the transmission, wheel spindle and control arm
Note: Take care not to damage the drive shaft seal in the transmission.
Install the pilot bearing cover for the drive shaft
Tighten to 25 Nm.
Align the drive shaft in the wheel arch. Install the screw loosely in the drive shaft.
Install
- the mobile jack under the sub-frame. Remove both the sub-frame screws. Lower the sub frame approximately 10 cm
- the wheel spindle on the control arm
- the lock nut loosely.
Lift the sub-frame to the bodywork. Install the new screws for the sub-frame.
Press the evaporator cable and the oil pipe into place in the sub-frame clips.
Installing the screw for the front engine pad and the torque rod mounting in the transmission
Install
- the screw for the front engine pad. Tighten to 50 Nm
- the torque rod mounting on the transmission.
Note: Use new screws. Tighten to 50 Nm.
Applies only to cars with parking heaters
Install the heater in the bracket. Tighten the nuts. Tighten to 25 Nm. Secure the fuel line in the sub-frame.
Installing and tightening front end components (both sides)
Tighten the drive shaft screw. Use a new screw.
Counterhold using a crow bar in the brake disc.
Tighten to 35 Nmand angle tighten +90°. Use bevel protractor 951 2050.
Install the nut for the anti-roll bar link at the spring strut. Use a new lock nut.
Note: Counterhold the ball joint pinion while tightening so that the ball joint boot cannot turn. Tighten to 50 Nm.
Tightening the ball joint pinion
Note: Counterhold the ball joint pinion while tightening so that the ball joint boot cannot turn. Tighten.
Installing the nuts on the fender liner
Rivet the fender liner into place.
Checking the transmission fluid level
Top up the oil in the transmission if necessary.
Install the wheels.
Installing the screws in the transmission and engine
Lower the car
Remove the lifting beam from the engine.
Install
- the remaining screws for the transmission and starter motor
- the 3 screws for the transmission and engine.
Tighten to 50 Nm
- the 2 screws for the starter motor. Tighten to 40 Nm
- the screw for the ignition setting sender.
Tighten to 10 Nm.
Installing the pipe junction
Install the clutch pipe on the junction. Use a new seal. Ensure that the clip locates in its channel. Remove the hose clip.
Bleed the clutch
Use only Volvo Genuine parts brake fluid DOT 4+.
Installing the bracket and the lever on the transmission
Install the bracket and the screws. Tighten to 25 Nm.
Tap in the pin so that it locks the lever. Install the transmission cables on the transmission and the levers.
Note: The yellow marked cable must be outermost.
Installing the coolant hose, the torque rod and the Air Cleaner (ACL) housing in the engine compartment
Install the coolant hose in the quick-release connector.
Remove the hose clips.
Measure and fill with new glycol and water.
Install
- the torque rod.
Note: Use a new lock nut for the cross member mounting on the engine.
- the Air Cleaner (ACL) housing with all hoses and electrical terminals.
Checking the steering gear bearing in the boot at the firewall
Check that the steering gear bearing in the boot has not detached from the boot. If it has become detached apply a little grease to the edge of the boot (around the hole). Press the bearing back down into the boot.
Note: Check that the rubber boot is positioned correctly in the bodywork. Adjust if necessary.
There is a risk that noise from the transmission or engine and road noise may enter the passenger compartment.
Connect the battery lead
First read Note when disconnecting/connecting the battery lead.
Test driving