Transmission Cooler: Service and Repair

Oil cooler transaxle - flushing and cleaning

Warning! Avoid skin contact with the oil.

Note! When replacing the transmission, the oil cooler must always be flushed clean since there may be dirt or particles in the oil cooler.

Preparations
A vacuum oil extractor is used to suck the oil through the oil cooler when flushing the oil cooler.
The following material is required to flush the oil cooler:




Vacuum extractor.




5 litre plastic container.

Plastic hose
Inner diameter: - 10 mm.
Length: 900 mm.
Assemble as illustrated.




Upper oil hose and pipe. This oil hose must be on the upper section of the oil cooler.
Cut the pipe as illustrated. Smooth of the edge of the pipe.

Note! Blow clean the pipe.




Connecting components to the vacuum extractor.
Remove the air cleaner (ACL) housing. Service and Repair
Raise the car. Remove the front air baffle.




Slacken off the nut on the return line for the oil pipe bracket a few turns.
Remove the screw nipple on the oil return line from the connection. Counterhold in the gearbox.




Pull out the oil pipe. Plug the connections in the gearbox.
Press a 10 mm diameter plastic hose (compressed air hose) into place.
Length: 200 mm on the lower oil pipe.
Clamp the hose into place in the sub-frame.
Lower the car.

Detaching and installing the upper oil hose and pipe
Detach and push the upper oil hose away from the oil cooler.





Install the cut oil hose and pipe on the oil cooler.

Filling with oil
Fill the plastic container with 2 liters of oil.

Note! Oil grade: Only ATF-oil Dexron III (with G-license). Transmission oil, Volvo part no. 116 1521-8 (1 litre), 116 1621-6 (4 liters).




Connect the hose from the plastic container to the cut oil pipe. Hang the plastic container under the bonnet.
Raise the car.

Flushing
Charge the vacuum extractor.





Connecting the vacuum extractor
Connect an oil pipe with an external diameter of - 10 mm from the vacuum extractor. Connect the oil pipe to the short hose.

Flushing
Open the cock and suck the oil out of the oil cooler. Check that the filler container is not completely drained. (There should be a little oil left in the hose.) Flow: 2 liters take approximately 40 seconds.
If the level sinks slowly the flushing must be repeated. If the level still sinks slowly replace the oil cooler.

Reinstallation




Remove the hose and reinstall:
The oil return line on the gearbox.
The oil pipe and screw nipple on the connection.
Tighten to 30 Nm.




Tighten the nut for the oil pipe bracket. Tighten to 25 Nm.
Reinstall the air baffle.
Lower the car.




Remove the plastic container and the oil pipe from the oil cooler.
Reinstall the existing oil hose on the oil cooler.

Checking the gearbox fluid level
Check the level.