Control System/Valve Housing, Removing
Control system/valve housing, removing
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! Read through the instructions before beginning to work.
Information before removal
When replacing the valve housing, the distribution plate and all 6 balls (if undamaged) should be transferred to the new valve housing. There are many screws of different lengths. It is important that the different screws are not mixed up. Checks are carried out when replacing the valve housing.
The new valve housing does not have any solenoids installed. The solenoids are loose in the kit and must be installed separately.
Removing the side cover
Remove the side cover. See Removing gearbox side cover Removing Gearbox Side Cover.
Preparations for removing the valve housing
Remove the cable harness. See Cable harness, control system, transmission, replacing Service and Repair.
Remove the oil pump. See Replacing the oil pump Service and Repair.
Air vent housing
The valve housing consists of:
- the valve housing (300)
Gaskets:
- 1 marked C (369)
- 1 marked V (371).
- distribution plate (370)
- guide sleeve (410).
There are six balls in the valve housing. 4 small (372) and 2 larger (373).
When separating the valve housing from the control system housing: The gaskets and plate must remain in the valve housing so that the balls do not fall out of their seats in the valve housing.
There are two small strainers (382) on the distribution plate.
2 plastic plugs (368) hold the gasket and plate in place.
Control system housing
There are 4 more balls in the control system housing. The balls will fall out when the valve housing is removed. Collect the balls in a clean container (the balls will be reinstalled later). There are 2 balls which do not fall out when the valve housing is removed (these are in the control system, C1 and C2).
Removing the screws for the valve housing and pressure sensor
1. Pressure switch -2002
2. Pressure switch 2003-
Caution! The screws are of different lengths. It is important that the screws are installed in the right place.
Control system for cars of model year -2002
Remove the following screws:
- 3 screws numbered 374 (64 mm)
- 3 screws numbered 375 (60 mm)
- 1 screw numbered 376 (30 mm). Retain the guide sleeve on the screw or in the valve housing
- 3 screws numbered 378 (55 mm)
- 1 screws numbered 379 (15 mm)
- 1 screws numbered 380 (10 mm)
- 1 screw numbered 384 (85 mm).
Leave the screws numbered 377 (45 mm) in position for the time being.
Control system for cars of model year 2003-
Remove the following screws:
- 3 screws numbered 374 (64 mm)
- 2 screws numbered 375 (60 mm)
- 1 screw numbered 376 (30 mm). Retain the guide sleeve on the screw or in the valve housing.
- 4 screws numbered 378 (55 mm)
- 1 screws numbered 379 (15 mm)
- 1 screws numbered 380 (10 mm)
- 1 pc. number 384 (85 mm)
Leave the screws numbered 377 (45 mm) in position for the time being.
Removing and separating the valve housing
Note! Do not damage the 2 small strainers on the distribution plate. The valve housing must not be twisted during removal.
Position a clean container underneath the gearbox.
Slacken off the 2 Torx screws numbered 377. Press the valve housing against the control system housing.
Grip the valve housing (diagonally). Pull it straight out a little (ensure that the gaskets and distribution plate move with it). Continue to withdraw the valve housing so that fingers can be inserted to hold the gaskets and distribution plate in position in the valve housing.
Pull the valve housing out from the control system housing until 4 balls fall out.
Note! The oil pump shaft follows slightly.
Place the valve housing on a bench with the gaskets upwards.
Note! Do not damage the 2 small strainers on the distribution plate.
Take the balls out of the container. Wipe the balls dry. Check that the balls are round and smooth. Replace any defective balls.
Checking the markings and location of the gaskets
The gaskets are marked C and V.
Gasket C is against the control system housing.
Gasket V is against the valve housing.
Distribution plate
Remove the locking pin (368) (can be reused).
Lift up the distribution plate together with gasket C.
Note! Do not damage the 2 small strainers on the distribution plate.
Lift out gasket V.
Checking and reinstalling the balls in the valve housing
2 large balls (373).
4 smaller balls (372).
Inspect one ball at a time. Ensure that there is no dirt on the ball and that the surface are smooth and shiny.
Check the four balls in the control system housing. Follow the same procedure as above.
Location of the control system housing balls
Ball (372) A (1) is located between 2 existing balls in the housing (C1 and C2).
Ball (372) A (2) is located next to the hole.
Balls (372) B (1-2) are located in a seat with a holder to the right to prevent the ball moving to the side.
Installing the balls, see Marking the location of the control system balls in relation to the distribution plate.
Marking the location of the balls in relation to the distribution plate
Position the distribution plate on the valve housing (strainers upwards) so that the balls can be seen. Mark the position of each ball beside the hole using a marker pen.
Turn the distribution plate and find each respective marking. Mark the hole. Check this side of the plate for leakage. See Check the balls sealing against the distribution plate.
Marking the location of the control system balls in relation to the distribution plate
Install the balls in the housing. Use Volvo Genuine parts petroleum jelly (P/N 116 1151-40).
Identify where the balls are to be located. Press petroleum jelly into the relevant holes and position the balls (the petroleum jelly ensures that the balls stay in the housing). To mark the position of the balls in relation to the distribution plate, see Marking the location of the balls in relation to the distribution plate.
Check the balls sealing against the distribution plate
Note! Check that the balls are round and smooth. Replace any defective balls.
Feel the holes for the balls. Check that there is not a rough lip around the hole.
Turn each ball in turn in their hole (to remove dirt or burring).
Place the ball in the hole. Press the ball and turn the ball in the hole to see that the ball seals and that the holes in the plate are not oval.
Check the sealing of the balls against the control system housing
Carry out the same check as above for the 4 balls in the control system housing.
Remove the balls. Wipe off the petroleum jelly.
Installing new solenoids on the new valve housing
Install the solenoids in the relevant positions on the valve housing.
Note! Make sure that the solenoids are secure.