Transmission, Installation
Transmission, installation
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.
Note! For tightening torques, Tightening Torque.
Cleaning and lubricating the input shaft
The input shaft must be lubricated before a manual transmission is installed. See Input shaft, cleaning, B5254T2, M56 Procedures.
Checking before installing
Caution! Check that the gearbox and engine mating surfaces are absolutely clean.
If the new transmission is not fitted with a reverse lamp switch, move over the reverse lamp switch from the old one.
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.
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 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 M10 transmission / engine screws crosswise.
Remove the fixture from the transmission.
Lower the vehicle
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 vehicle
Installing the rear engine mounting
Install:
- the rear engine mounting on the transmission
- the 3 x M10 screws for the engine mounting. Tighten.
Installing the bevel gear
Remove the tie strap.
Install the bevel gear.
Align the propeller shaft on the bevel gear and rotate the bevel gear into position. Install new screws. Tighten the screws crosswise lightly. Tighten. Tightening Torque
Installing the front propeller shaft (Applies to AWD)
Check carefully that the mating surfaces on the propeller shaft and flange are clean.
Note! Install the propeller shaft using the marking made earlier.
Use new screws when tightening the propeller shaft CV joint.
Tighten, Tightening Torque.
Installation of the collision protection above the steering gear (Only applies to right-hand drive vehicles.)
Tighten the screw and nut, M10 and M12.
Fitting the sub-frame to the body
Caution! Use new screws (4 x M14). Lubricate the screw threads. Make sure that the screws for the steering gear locate in the sub-frame.
Start on the left-hand side.
Raise the subframe with the mobile jack 998 5972 JACK 998 5972 Jack.
Locate the steering gear screws in the subframe.
Install the subframe and support bracket screws, start on the left-hand side followed by the right. Tighten as per Tightening torque Tightening Torque.
Move the mobile jack to the right-hand side. Remove the existing screws and repeat the operation.
Installing the sealing ring for the CV joint housing
Install the sealing ring for the constant velocity joint housing. See Seal CV joint housing, replacing Seal CV Joint Housing, Replacing.
Installing the left hand drive shaft to the transmission, wheel spindle and link 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.
Installing new lock nuts and screws on the steering gear
Remove the tie strap.
Installing new M10 lock nuts and screws on the steering gear.
Installing the screw in the rear engine pad
Lift the anti-roll bar mounting using a jimmy bar. This makes it easier to insert the tool and the M10 screw.
Installing screws for the bracket for the heated oxygen sensor (HO2S) wiring
Install the screws in the bracket.
Installing the crossmembers
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 to the cross members. Tighten in accordance with: Tightening torque Tightening Torque.
Installing the right-hand drive shaft to the gearbox, wheel spindle and link arm
Note! Take care not to damage the drive shaft seal in the transmission.
Install the pilot bearing cover for the drive shaft
Tighten.
Align the drive shaft in the wheel housing.
Install:
- the screw loosely in the drive shaft.
- the wheel spindle on the control arm
- the lock nut loosely.
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 M10 screw for the front engine pad.
- the torque rod mounting on the transmission.
Note! Use new screws. Tighten. See Tightening torque Tightening Torque.
Applies only to cars with parking heaters
Install the heater in the bracket. Tighten the nuts. Secure the fuel line in the sub-frame.
Installing and tightening front suspension components
Tighten the drive shaft screw. Use a new screw. Counterhold using a crow bar in the brake disc. Tighten. Tightening Torque.
Install the nut for the anti-roll bar at the spring strut (left hand side only). Use a new lock nut.
Note! Counterhold the ball joint pinion when tightening. This is so the ball joint boot does not turn.
Tightening the ball joint pinion
Note! Counterhold the ball joint pinion while tightening so that the ball joint boot cannot turn. Tighten. See: Tightening torque Tightening Torque.
For steel control arm, see: Ball joint, replacing Service and Repair
Installing the nuts on the fender liner
Rivet the fender liner into place.
Checking the oil level in the transmission
Top up the oil in the transmission if necessary. See Transmission fluid, replacing, B5254T2, M56 Service and Repair.
Install the wheels. See Installing wheels Service and Repair.
Installing the screws for the transmission and engine
Lower the vehicle
Remove the lifting beam from the engine.
Install:
- the remaining screws for the transmission and starter motor
- the 2 screws for the starter motor. Tighten
- the screw for the ignition position sensor. Tighten.
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 lever for the transmission
Install the bracket and screws. Tighten.
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 water hose
Install the coolant hose in the quick-release connector.
Remove the hose clips.
Top up the coolant.
Installing the upper torque rod
Install:
- the torque rod. See Brake fluid reservoir, replacing Brake Fluid Reservoir, Replacing.
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.
Connect the battery lead
First read Battery, disconnecting Battery Disconnecting.
Test driving
Check the coolant level and fill if necessary.