Transmission, Installing
Transmission, installing
Special tools:
951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor
999 7057 Counterhold 999 7057 Counterhold
Note! As the illustrations in this service information are used for different model years and/or models, some variation may occur. However, the essential information in the illustrations is always correct.
Move the ball catch to the new gear box.
Apply the thread lock 1161056 to the threads.
Tighten to 32 Nm.
Installation
Note! For tightening torques, see the relevant specifications.
Installing the transmission
Before installing the transmission, it must have been checked and cleaned.
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 the guide sleeves and guide pin for the starter motor align in the guide holes on the transmission.
Installing and tightening the screws for the transmission
Install the 7 M10 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 screws crosswise.
Remove the fixture from the transmission.
Lifting the engine and transmission
Lift to slightly above horizontal position to make the rear engine mounting/pad more accessible
Note! Check that the connection on the hose for the heater is not trapped between the engine and firewall when the engine is lifted.
Raise the car.
Installing the rear engine mounting
Remove the tie strap temporarily holding the steering gear.
Install:
- the rear engine mounting for the transmission to the engine mounting. Use 3 x M10 screws. Tighten
- the screw for the engine mounting/steering gear.
Installing the bevel gear
Ensure that the mating surfaces on the transmission and bevel gear are clean and not damaged.
Install the bevel gear. Use 5 x M10 screws. Tighten alternately to light contact. Tighten.
Installing the left drive shaft on the transmission and the wheel spindle
Press in the constant velocity joint housing firmly so that the snap ring engages in its groove in the transmission.
Pull the constant velocity joint to check that the drive shaft is secure.
Lubricate the drive shaft splines. Use a small amount of thin oil.
Locate the drive shaft in the wheel hub. Install a new screw loosely in the drive shaft.
Installing the subframe on the bodywork
Note! Use new screws. Lubricate the screw threads.
Lift the subframe until it is about 150 mm from the side member.
Secure the power steering pipe at the front edge of the upper side of the subframe. Use the rubber covered clamp. Install the screw loosely. Apply a small amount of soap solution so that it glides into the clamp easily.
Note! Ensure the following when lifting the subframe:
- that the steering gear screws align in the frame
- that the brake pipe passes the bracket for the exhaust pipe
- that the ball joint pinion for the spring strut aligns in the control arm.
Install:
- the new screws and the support bracket at the rear edge
- the screws loosely in the bracket.
Only applies to vehicles with fuel driven parking heaters:
Tighten the subframe screws. Tighten to light contact.
Remove the mobile jack.
Installing the right-hand drive shaft on the transmission, wheel spindle and control arm
Install the drive shaft and the cap for the pilot bearing. Use 2 x M8 screws. Tighten.
Lubricate the drive shaft splines. Use a small amount of thin oil.
Locate the drive shaft in the wheel hub. Install a new screw loosely in the drive shaft. Press down the control arm. Locate the spring strut in the ball joint pinion for the spring strut in the control arm.
Positioning the mobile jack lightly applied under the right side of the subframe
Install:
- new screws in the subframe
Note! Lubricate the screw threads.
- the screws loosely in the rear edge of the support plate.
Remove the mobile jack.
Tighten the subframe screws on both sides.
Tighten. See the relevant specifications. Use bevel protractor 951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor. Then tighten the 4 M10 screws of the subframe brackets.
Installing components on the engine and subframe
Install:
- new M10 lock nuts for the steering gear and the M10 screw. Tighten
- the M10 screw for the front engine pad. Tighten. Tighten the M10 screw for the rear engine pad
- the mounting for the engine stabilizer brace to the transmission. Use new screws.
Installing the collision protection system over the steering gear
Only applies to right-hand drive cars
Install the 2 screws.
Installing the servo pipe in the holder
Press the power steering pipe and the evaporator pipe into the holders on the subframe.
Applies to certain versions
Tighten the screw for the clamp securing the power steering pipe above the right hand side of the subframe at the front edge. Install and tighten the clamps for the power steering pipe at the rear of the frame.
Installing the propeller shaft
Install the propeller shaft using the marking made earlier. Check carefully that the mating surfaces on the propeller shaft and flange are clean.
Use new screws. Install the 6 screws with the washers. Tighten. See the relevant specifications. Use counterhold 999 7057 Counterhold 999 7057 Counterhold.
Installing the center bearing and member for the propeller shaft
Install:
- the 4 x M8 screws for the support for the center bearing. Tighten
- the 2 x M8 screws for the propeller shaft bearing in the support for the center bearing. Tighten.
Installing the front mounting for the exhaust pipe
Install the rubber mountings for the exhaust system on the brackets on the subframe.
Installing the cross members on the bodywork
Install:
- the M8 screws for the front member
- the brake pipe in the holders on the member
- the M8 screws for the rear member
- the clamp with the heated oxygen sensor (HO2S) cable on the front cross member.
Installing and tightening front end components (both sides)
Install:
- a new M12 nut for the ball joint pinion. Counterhold the ball joint pinion while tightening so that the ball joint boot cannot turn. Tighten
- the link for the anti-roll bar. Use a new M10 lock nut. Counterhold the ball joint pinion while tightening so that the ball joint boot cannot turn. Tighten.
Tighten the drive shaft screw. Counterhold using a screwdriver in the brake disc vents. Tighten. See the relevant specifications.
Install the soundproofing over the drive shaft (applies to certain versions).
Installing components for the fender liner
Install the support plate and the fender liner.
Check and fill with oil. See Transmission fluid, replacing, B5244T5, M66 Service and Repair.
Installing the cable duct
Install:
- the cable duct on the subframe
- the parking heater (if applicable) in the mounting in the subframe and the fuel line in the mountings
- the front splash guard
- the splash guard under the engine
- the wheels. See Installing wheels Service and Repair.
Removing the lifting beams
Lower the vehicle.
Remove the lifting beams and hooks from the engine.
Installing the coolant hose
Install the connector securing the engine coolant hose to the heater.
Remove the hose clips.
Installing the remaining screws for the transmission and starter motor
Install:
- the 3 x M10 screws for the transmission and engine. Tighten
- the 2 x M10 screws for the starter motor. Tighten. See Tightening torque [1][2]Specifications.
Installing components for the transmission
Install:
- the bracket for the engine coolant hose and cable harness
- the bracket for the cable harness clamp and the mounting for the heated oxygen sensor (HO2S) connector at the rear edge of the transmission
- the clamp for the cable harness at the rear edge of the engine
- the connector for the back-up lamp switch
- the gear selector cables on the transmission. See Transmission cables, replacing, B5244T5, M66 Service and Repair.
- selector cables to levers.
Note! When working with the mechanical cables ensure that there is no cracking between the cable and sleeve.
Installing service clips
Note! The automatic transmission has a gear selector cable while the manual transmission has two gear selector cables.
Ensure that the gear selector cable is engaged before fitting the blue clip. Press the clip into position as illustrated.
Check that the clip is positioned in the groove as illustrated.
Installing the clutch line
Install:
- the ground lead on the transmission and subframe
- the clamps for the cable harness on the transmission
- the clutch cable hose on the junction.
Remove the hose clip from the clutch cable hose.
Bleed the clutch. Only use Volvo original brake fluid.
Installing engine compartment components
Install:
- the charge air pipe to the charge air cooler (CAC)
- the charge air pipe over the engine
- the engine stabilizer brace between the wheel arches. Use 4x M10 screws. Tighten
- 1 x M12 screw for the engine stabilizer brace/engine mounting. Tighten
- the air cleaner (ACL) housing to the intake manifold and connections. Hook the valve onto the air cleaner (ACL) housing
- the fresh air intake hose
- the cover on the side of the air cleaner (ACL) housing.
Fill with coolant. Carefully check while reaching operating temperature or test driving that the level remains the same and that there is no leakage.
Checking the boot for the steering shaft/firewall
Check that the bearing in the boot is in position.
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.
Check that the boot is correctly positioned against the firewall and that the snap ring is correctly positioned. Adjust if necessary.
Note! It is essential that the above checks are carried out. Otherwise there may be noise from the transmission/engine and road noise in the passenger compartment.
Installing the battery lead
Connect the battery lead.
First read Battery, disconnecting Battery Disconnecting.