Transmission, Installing
Transmission, installing
Special tools:
999 7089 Adjustment tool 999 7089 Adjustment Tool
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 is always correct.
Preparatory work
Moving components
When replacing the transaxle, the gearshift cable bracket must be transferred to the new transaxle.
Move the ball catch to the new transaxle.
Apply the thread lock 1161056 to the threads.
Tighten to 32 Nm.
Installation
Note! For tightening torques see:
Tightening torque Tightening Torque
Tightening torque [1][2]Manual Transmission/Transaxle
Tightening torque [1][2]Specifications
Cleaning and lubrication of input shaft
The input shaft must be lubricated before a manual transmission is installed. Input Shaft, Cleaning
Checking before installing
Check that the transaxle 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 transaxle (for the guide pins). Use a little grease.
Installing the transmission
Adjust height and angle with the mobile jack and the transaxle fixture. Locate the transaxle on the engine. Ensure that the transaxle goes straight in, in relation to the engine, and that no deviation occurs in the clutch driven plate center.
Installing engine mounting
Install the engine mount for the transaxle using screws, 4 pcs M12 and 1 pcs M8. Tighten. Refer to Specifications [1][2]Manual Transmission/Transaxle
Lifting the engine and the transmission
Lift the engine/transaxle. Align the mounting against the transaxle in the engine pad.
Install the M14 screw for the engine mounting.
Remove the lifting beams and the lifting hook.
Installing the screws in the transmission / engine
Install:
- the 4 pcs M10 screws for the transaxle/engine. Tighten
- the starter motor
Installing the clutch line
Use a new O-ring for the clutch line. Install the clutch line. Lock using the locking pin.
Remove the pedal jack (if applicable). Lift up the clutch pedal. Bleed the clutch.
Installing the bracket
Install:
- the bracket holder
- the bracket and the coolant hose.
Installing gear selector cable
Note! Ensure that the cable and sleeve do not crack or break.
Install:
- the connector for the back-up lamp switch
- the transmission cables to the bracket and levers. Adjust the transmission cable. See: Transmission cable, adjusting, B5254T7, M66 Adjustments.
Installing the air cleaner (ACL) module
Install the air cleaner (ACL) module. Service and Repair
Installing components
Install:
- the ground cable on the transaxle
- the torque rod mounting to the transaxle, 3 pcs M10. Tighten.
Installing the charge air pipe
Install the charge air pipe under the engine.
Installing the sub-frame
Secure the sub-frame against the fixture plate using a retaining strap.
Lift the sub-frame. Align the sub-frame in the front mountings in the side members. Install the screws loosely, 4-5 threads.
Allow the sub-frame to hang down at the rear edge and to rest on the mobile jack.
Remove the temporary mounting for the steering gear. Allow the steering gear to rest on the sub-frame.
Installing the anti-roll bar
Install the stabilizer bar. Use 4 x new M10 screws. Tighten. See: Tightening torque [1][2]Specifications.
Securing the sub-frame
Install 999 7089 Adjustment tool 999 7089 Adjustment Tool on both sides. Carefully raise the sub-frame so that the adjustment tools are lined up with the holes in the side members.
Installing the screws
Install the screws for the rear mounting of the sub-frame. Loosely install the new M16 screws, together with the brackets and the four M8 screws.
Tighten the M16 screws. Tightening Torque.
Tighten the 4 M8 screws for the brackets. Tighten.
Install:
- the screw for the lower torque rod mounting. Use a new screw. Tighten. See: Tightening torque, B5254T7 Tightening Torque
- the rubber mountings for the exhaust pipe mounting
- the catalyst monitor sensor cable harness to the subframe and to the tab on the torque rod mounting in the transaxle.
Installing the screws, continued
Tighten the front M12 screws to the subframe. Tightening Torque.
Install:
- the new screws loosely in the steering gear and the sub-frame.
Tightening is performed later from the engine compartment.
Finishing
Installing drive shafts
Install the drive shafts. See:
- Drive shaft right Drive Shaft Right
- Driveshaft left Manual Transmission
Checking the transaxle fluid level
Top up the transaxle with fluid if necessary. Transaxle Oil.
Installing wheels
Install the front wheels. See: Wheels Service and Repair.
Installing components in engine compartment
Tighten the two M12 screws for the steering gear.
Installing the battery cable
Install:
- the box for the battery
- the battery negative lead. See: Battery Disconnecting
Check the brake fluid
Check the brake fluid level. Use only Volvo Genuine parts brake fluid (Volvo DOT 4+) when topping up.