Operation CHARM: Car repair manuals for everyone.

Transmission Replace



Transmission Replacement
Special tools: 9995006, 9995033, 9995185, 9995244, 9995429, 9995460, 9995972, 9985300, 9985972, 9988670

- Disconnect battery ground lead.





- Install lifting lug 999 5429 at rear of engine
- Place support 999 5033 on fender edges and lifting yoke 999 5006 on support.
- Relieve transmission mounting with lifting hook 999 5460. Earlier type of lifting hook 5460 may be also be used in combination with hook 999 5185.
- Disconnect braided ground lead between engine and chassis.





- Remove splashguard under engine.





- Remove preheat pipe, retain 0-ring.





- Remove lateral strut (applies only to certain markets).





- Disconnect HO2S lead
- Open connector at starter motor.
- Cut off cable ties carefully.
- Remove cable clip on torque converter housing.
- Open clips on transmission and remove two clips on transmission support member.





- Remove connectors (three) from bracket on torque converter housing.
- Remove connectors (three) from bracket on torque converter housing.
- Push connectors lengthwise on bracket, front and rear connectors backward and middle connector forward.
- Open all connectors.





- Remove front exhaust pipe.





- Disconnect propeller shaft from transmission using socket 999 5244.
- Disconnect control rod and reaction strut from gear selector link on transmission by removing snap rings and washers.

NOTE: Reaction strut is not installed on later models.





- Remove heat shield.
- Disconnect oil cooler pipes from transmission using wrench 998 5300. Use wrench to hold unions at transmission end.
- Use container to collect fluid spillage, if any. Plug pipe ends.





- Remove transmission support member.





- Lower rear of engine as far as possible.

NOTE: Ensure that no sensors, wiring or hoses become caught between engine and firewall.





- Remove torque converter bolts (Torx Tx 40).
- Turn engine using 14 mm wrench fitted to one of vibration damper bolts.





- Position assembly hoist and universal fixture 999 5972 under transmission, with fixture in light contact with housing.
- Ensure that support arms are bearing against transmission and are tightened.





- Separate transmission from engine.
- Remove torque converter housings bolts.

NOTE: Bolt beside engine oil dipstick tube may remain in cylinder block.





- Lower transmission on hoist.
- Push transmission backward, pressing simultaneously against torque converter.

NOTE: Ensure that transmission is tilted backward throughout operation to prevent torque converter falling out.





- Inspect carrier plate on engine to ensure component is free of damage and cracks.
- Inspect guide surface on torque converter centering pin.
- Inspect centering pin mating surface on crankshaft.
- Remove defects, if any, with fine emery cloth.
- Flush oil pipes and cooler with fresh Dexron II E or Ford Mercon fluid.
- Use fluid filler pump. Plug pipe ends.





- Transfer gear selector control rod and reaction strut to new transmission.
- Grease torque converter centering pin lightly.

NOTE: Reaction strut is not installed on some models.





- Ensure that torque converter is in position.
- Place straight steel edge against torque converter housing. Measure distance between edge and torque converter mounting bosses.
- Distance should be approx. 14 mm when torque converter is in rearmost position i.e. bottoms against oil pump.





- Install transmission.
- Ensure that transmission is tilted backward slightly and fit to engine.
- Install torque converter housing bolts.
- Tighten bolts in starter motor to 40 Nm (30 ft lb) and other bolts to 48 Nm (36 ft lb).
- Move torque converter forward towards carrier plate by hand.





- Install torque converter using new bolts.
- Turn engine using one of vibration damper bolts.
- Install all bolts loosely, tightening sufficiently for heads to meet carrier plate.
- Tighten finally to 30 Nm (22 ft lb) using Torx TX 40 socket.

NOTE: Remember to remove wrench from vibration damper.





- Install transmission support member.
Tighten mounting bolts (four) alternately. Tighten transmission bump stop nut.
- Remove hoist and fixture.





- Connect control rod and torque strut to gear selector link on transmission.
- Ensure that snap rings are seated in grooves.

NOTE: Reaction strut is not installed on some models.





- Reconnect propeller shaft to transmission using new bolts and nuts.
- Tighten diagonally to 50 Nm (37 ft lb).





- Install oil cooler pipes.
- Install pipes using wrench 998 5300. Use wrench to counterhold unions at transmission end when tightening pipe nuts.
- Install heat shield.





- Install exhaust pipe. Tighten flange fastenings alternately.
- Ensure that rear joint taper is seated correctly before tightening clamp.





- Install HO2S lead in clips on transmission support member and torque converter housing.
- Reconnect HO2S and transmission connectors. Ensure that connector locking tabs are securely engaged.
- Install connectors on bracket. Secure wiring with cable ties.





NOTE: The following point applies only to certain markets:

- Install lateral strut.





- Install preheat pipe.
- Lubricate 0-ring lightly with Vaseline.





- Install splashguard under engine.





- Remove lifting hook(s), lifting yoke, supports and lifting lug from engine.





Check gear mechanism adjustment

NOTE: Illustration shows earlier version. Reaction strut is not installed on later version.





- Check and adjust fluid level.

NOTE: The gear box must be filled with ATF fluid that complies with the specifications for both Dexron II E and Ford Mercon alternatively Dexron III and Ford Mercon.

CAUTION: Since fluid and transmission are both cold, and engine is switched off, correct fluid level will be only a few mm on the dipstick.

NOTE: (Fluid temperature in transmission may be checked with Volvo ST in test mode 5 - code 1-1-5.)





- Reconnect battery ground lead
- Erase DTCs, if any, in OBD memory.
- Switch on ignition.
- Connect DLC test lead to socket No.1.
- Press DLC test button for more than 5 seconds. Release button.
- LED should light after 3 seconds.
- Press button again for more than 5 seconds.
- Release button. LED should go out.
- Check that DTCs are erased by pressing test button once for more than 1 second (but not more than 3 seconds).
- If code 1-1-1 is displayed, DTCs are erased.





Test drive car in all three driving modes





- Check fluid level when transmission has reached working temperature.
- Gear selector should be in position P with engine idling.
- Dipstick is accessible from engine compartment using long handle with 1/2" drive inserted in top. Turn dipstick through quarter turn to release latching spring and remove.
- After test drive, check that no DTCs have been recorded as described in above.