Transmission, Installing
Transmission, installing
Special tools:
951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor
Cleaning and lubricating the input shaft
The input shaft must be lubricated before a manual transmission is installed. See Input shaft, cleaning, B5244T7, M56, B5234T9, M56 Procedures.
Checking the gearbox
Check that:
- the gearbox cover and engine mating surfaces are clean
- the guide sleeves on the engine are in place and undamaged.
Apply a light coating of grease in the holes for the guide sleeves (on the gearbox).
Installing the gearbox
Use the gearbox fixture and the mobile jack to line up the gearbox with the engine.
Note! Ensure that the gearbox goes straight in towards the engine without any deviations in the clutch plate centre.
Install the 7 screws. Tighten crosswise. Begin with screws A and B which pass through the guide sleeves. Lightly tighten the screws alternately. Check that the gearbox and engine are in contact all the way around.
Then tighten the screws alternately as above. Tighten to 50 Nm .
Note! Correct tightening is vital. Misalignment between the gearbox and engine can cause gearbox noise.
Remove the gearbox fixture and the mobile jack from the gearbox.
Lifting the engine and gearbox
Screw lifting hook 999 5460 Lifting hook 999 5460 Lifting Hook up so that the engine is hanging horizontally.
Ensure that no cables or hoses are trapped.
Installing the rear engine mounting on the gearbox
Install the mounting on the gearbox (3 screws). Tighten the two rear screws to 50 Nm . Remove the front screw again.
Install the cover. Use the screw for the mounting
Press up the cover against the mounting. Tighten the screw. Tighten to 50 Nm .
Installing the engine pad using a new nut
Align the engine pad locating pin in the cover. Install the new nut loosely.
Install the screw in the engine pad and steering gear
Do not tighten the screw.
Remove the load relieving hook 999 5045 COMPRESSION HOOK 999 5045 Compression Hook or the tie strap.
Install the heated oxygen sensor (HO2S) cable on the cover using clamps.
Aligning the steering gear and the collision protection system in the sub-frame (right-hand drive cars only)
Raise the sub-frame so that it is 100 mm from the bodywork.
Locate the steering gear and collision protection in the sub-frame.
Install the left bearing and the cap for the anti-roll bar. Tighten both the bearing caps. Tighten to 50 Nm .
Installing the sub-frame
Caution! Use new screws (4 x M14). Lubricate the screw threads. Ensure that the screws for the steering gear locate in the sub-frame!
Start on the left-hand side. Raise the sub-frame using mobile jack 998 5972 JACK 998 5972 Jack. Locate the screws for the steering gear in the sub-frame.
Install the screws on the sub-frame and support bracket. Tighten the screws on the left-hand side of the frame first, then those to the right-hand side to 105 Nm + 120° , and then the screws on the frame brackets to 50 Nm . Use a bevel protractor 951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor.
Move the mobile jack to the right-hand side. Remove the existing screws and repeat the operation.
Removing the lifting tools
Tighten the nut for the rear engine pad splash guard. Tighten to 50 Nm .
Installing the screws and nuts for the steering gear and the sub-frame
Install:
- 5 new nuts on the steering gear. Tighten to 50 Nm
- the nut for the crash guard / sub-frame (A) (right-hand drive cars only). Tighten to 50 Nm
- the screw for the sub-frame - front engine mounting. Then tighten the screws for the front and rear engine mountings. Tighten to 50 Nm .
Installing the torque rod mounting
Install:
- the torque rod mounting on the gearbox using new screws. Use bevel protractor 951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor. Tighten to 35 Nm + 40°
- the screws for the oil pipe brackets. Tighten to 25 Nm .
Installing the right drive shaft on the gearbox
Ensure that the rubber seal is in position on the constant velocity joint.
Caution! Take care not to damage the sealing ring in the transmission or the boot on the drive shaft.
Install the bearing cap. Tighten to 25 Nm .
Installing the collision protection system over the steering gear (right-hand drive cars only)
Tighten the two screws. Tighten to 80 Nm .
Installing the left drive shaft on the gearbox
Ensure that the rubber seal is in position on the constant velocity joint.
Ensure that the pulse wheel for the ABS sensor on the drive shaft is clean.
Press in the drive shaft firmly so that the snap ring engages in its groove in the [1][2]differential gear. Carefully pull the drive shaft constant velocity joint to check that the drive shaft is secure.
Caution! Ensure that the seal ring in the gearbox and the boot on the drive shaft are not damaged.
Installing the drive shaft on the hub
Use holder 999 5563 SUPPORT 999 5563 Support to hold the control arm down.
Fold out the spring strut and locate the drive shaft in the hub.
Install the drive shaft screw by hand. Use a new screw.
Remove the holder.
Note! Take care not to damage the drive shaft boot.
Installing the ball joint on the stub axle
Clean off any rust from the ball joint and stub axle.
Lubricate the ball joint pinion and the stub axle.
Install the ball joint in the stub axle.
Note! Press the ball joint upwards so that the conical top is visible above the screwed joint on the stub axle.
Install the screw and a new nut.
Tighten to 50 Nm .
Install the control arms on the anti-roll bar using new nuts. Tighten to 60 Nm .
Tightening the drive shaft screw(s)
Tighten the drive shaft screw. Use a new screw. Counterhold using a crow bar in the brake disc. Tighten to 35 Nm + 90° . Use bevel protractor 951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor.
Installing the ABS sensor
Install the bracket for the brake pipe / ABS cable on both sides.
Note! Ensure that the ABS sensor seating is absolutely clean.
Install:
- The ABS sensor in the stub axle after first cleaning the sensor using a soft brush. Tighten to 10 Nm
- the soundproofing over the drive shaft
- the plastic nuts for the wing liner on left-hand side.
Installing the cable conduit, carbon filter holder and the cover under engine
Install:
- the cable conduit on the sub-frame
- the carbon filter container. Clamp the hoses to the sub-frame. Use a tie strap. Hook the hoses into the sub-frame.
Tighten the clamp for the exhaust pipe. "Twist" the pipe when tightening.
Installing the front cover and the wheels
Install:
- the front cover. Press the front edge into place. Press the cover forward and upwards at the rear so that cover guide is seated in its slot. Install the screws
- the wheels. See Installing wheels Removal and Replacement.
Installing the five screws between the gearbox / engine and the gearbox / starter motor
Tighten the screws for the gearbox and engine. Tighten to 50 Nm . Tighten the screws for the gearbox and starter motor. Tighten to 40 Nm .
Install the cable duct on the gearbox.
Installing wiring and the quick-release coupling
Install
- the wiring. Clamp the cable harnesses and the ground lead
- a new quick-release connector on the clutch cable connection. Lubricate the rubber seal using a drop of brake fluid before joining.
Check that the striker plate is located in the adapter. Then press the clutch cable into place in the adapter so that the striker plate audibly snaps into the groove.
Install the clutch cable in the holder on the side of gearbox.
Remove the hose clips from the hose at the clutch master cylinder.
Bleed the system. Top up the brake fluid if required. Only use Volvo Genuine parts brake fluid.
Installing the connector, gearbox lever and gearbox cables
Install:
- the connector for the reverse (reversing) light switch
- the outer gear selector lever and split pin
- the gear selector cables on the bracket mountings.
Caution! The outer mounting and outer selector cable are marked in yellow.
Lubricate the lugs on the gear selector lever using grease, P/N 1161241-3.
Install:
- the gear selector cables on the levers
- the two washers and the two clips.
Installing the ground strip and torque control arm / torque rod
Install:
- the ground strip in the bulkhead
- the screw and the nut for the torque control arm / torque rod.
Caution! Use a new screw and lock nut.
Tighten to 35 Nm . Angle-tighten 90° .
Aligning the hose for the charge air pipe. Tightening the clamp (turbocharged engines only)
Turn the intake manifold outwards as illustrated. Align the hose with the charge air pipe. Tighten the clamp.
Press the pipe up towards the throttle body (TB) with one hand. Tighten the clamp.
Connect the brake vacuum hose to the intake manifold using the clamp.
Install the hose between the pipe from the charge air cooler (CAC) and the outlet pipe from the turbocharger (TC).
Installing engine compartment components
Install:
- the expansion tank
- the screws securing the bracket for the air cleaner (ACL) housing
- the battery shelf
- the timer valve to the air cleaner (ACL) housing (turbocharged engines only)
- the air cleaner (ACL) housing with the intake manifold and connections
- the battery
- the hoses to the regulator valve. (Cars with EGR valve only).