Transmission, Installing
Transmission, installing
Note! 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.
Note! For tightening torques see: Tightening torque Tightening Torque , Tightening torque [1][2]Manual Transmission/Transaxle, Tightening torque [1][2]Specifications
Preparatory work
Moving components
When replacing the transmission, the transmission cable bracket must be transferred to the new transmission.
Transfer of the rear light switch
Moving the rear light switch. Refer to: Back-up lamp switch, replacing Service and Repair
Gearbox, check before installing
Check the transmission. See: Transmission, checking .
Installation
Installing the transmission
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 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. Tighten.
Remove the fixture from the transmission.
Installing back-up (reversing) lamp switch
Install the back-up lamp switch.
Installing bracket and screws between engine/transmission
Install:
- the 3 x M12 screws for the engine mounting bracket
- the starter motor, 3 screws. See Tightening torque Tightening Torque
- the 3 x M10 screws between engine and transmission.
Lifting the engine and the transmission
Lift the engine/transmission. Align the mounting against the transmission in the engine pad.
Install the M14 screw for the engine mounting. Tighten. See: Tightening torque [1][2]Manual Transmission/Transaxle.
Remove the lifting beams and the lifting hook.
Installing the bracket
Install the 3 x M8 screws on the bracket for the gear selector cables.
Installing the clutch line
Use a new gasket for the clutch line. Install the clutch line and lock using the locking pin.
Remove the pedal jack (if applicable) and lift the clutch pedal. Bleed the clutch.
Installing the bracket
Install:
- the bracket holder
- the bracket and the coolant hose.
Installing the transmission cable
Note! Ensure that the cable and sleeve do not crack or break.
Install the transmission cables on the bracket and the levers.
Fitting service clips
Note! The automatic transmission has one shift cable while the manual transmission has two shift cables.
Make sure that the shift cable is locked in position before fitting the blue clip. Press the clip into place as illustrated.
Check that the clip is positioned in the groove as illustrated.
Adjust the gear cables according to: Transmission cable, adjusting Adjustments.
Installing the air cleaner (ACL) module
Install the air cleaner (ACL) module. See: Air filter module Service and Repair.
Installing components
Install:
- the ground lead on the transmission
- the torque rod mounting to the transmission, 3 x M10. Tighten.
Installing the sub-frame
Secure the sub-frame against the fixture plate. Use 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 anti-roll bar. Use four 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 4 x M8 screws.
Tighten the M16 screws. See: Tightening torque Tightening Torque. Loosely tighten the 4 x M8 screws to the brackets.
Install:
- the screw for the lower torque rod mounting. Use a new screw. Tighten. See: Tightening torque Tightening Torque
- the rubber mountings for the exhaust pipe mounting
- the heated oxygen sensor (HO2S) cable harness to the sub-frame and to the tab on the torque rod mounting in the transmission.
Installing the screws, continued
Tighten the front M12 screws to the sub-frame. See: Tightening torque Tightening Torque.
Install new screws for the steering gear / sub-frame loosely. Tightening is performed later from the engine compartment.
Finishing
Installing drive shafts
Install the drive shafts. See: Driveshaft left, M56, M66 AWD, M66, MMT6, MTX75 Driveshaft Left Driveshaft left Driveshaft Left and Drive shaft right Drive Shaft Right.
Checking the transmission fluid level
Top up the transmission with fluid if necessary. See: Transaxle oil 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
Install:
- the box for the battery
- the battery
- the battery leads.
Check the brake fluid
Check the brake fluid level.
Use only Volvo Genuine parts brake fluid (Volvo DOT 4+) when topping up.