Transmission, Installing
Transmission, installing
Special tools:
999 7089 Adjustment tool 999 7089 Adjustment Tool
Note! As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information is always correct.
Preparatory work
Transferring components
Move the ball catch to the new gear box.
Apply the thread lock 1161056 to the threads.
Tighten to 32 Nm.
When replacing the transmission, the transmission cable bracket must be transferred to the new transmission.
Installation
Note! For tightening torques, see Specifications. [1][2]Manual Transmission/Transaxle
Cleaning and lubricating the input shaft
The input shaft must be lubricated before a manual transmission is installed. See: Input shaft, cleaning Input Shaft, Cleaning.
Checking before installing
Check that the transmission and engine mating surfaces are absolutely clean.
Also check that the guide sleeves towards the engine are in position and are free of faults. Lubricate the holes in the transmission (for the guide pins). Use a little grease.
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 engine mounting
Install the mounting for the transmission. Use 4 M10 screws and 1 M8 screw. Tighten.
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.
Remove the lifting beams and the lifting hook.
Installing the screws in the transmission / engine
Install:
- the 4 x M10 screws for the transmission and engine. Tighten
- the starter motor.
Installing the clutch line
Use a new O-ring for the clutch line. Install the clutch line. Lock using the locking pin.
Remove the pedal jack (if applicable). Lift up the clutch pedal. Bleed the clutch.
Installing the bracket
Install:
- the bracket holder
- the bracket and the coolant hose.
Installing the gear selector cable
Note! Ensure that the cable and sleeve do not crack or break.
Install:
- the connector for the back-up lamp switch
- the transmission cables to the bracket and levers. Adjust the transmission cable. See: 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 using 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 4 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 new M16 screws, together with the brackets and their 4 M8 screws.
Tighten the M16 screws. See: Tightening torque [1][2]Manual Transmission/Transaxle.
Tighten the 4 M8 screws for the brackets. Tighten.
Install the rubber mountings for the exhaust pipe mounting.
Installing the screws, continued
Tighten the front M12 screws to the subframe. See: Tightening torque Tightening Torque.
Install new screws for the steering gear and sub-frame loosely.
Tightening is performed later from the engine compartment.
Finishing
Installing the bevel gear
Install the bevel gear. See: Bevel gear Bevel Gear.
Installing the left drive shaft
Install the left-hand drive shaft. See: Driveshaft left, M56, M66 AWD, M66, MMT6, MTX75 Driveshaft Left.
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 lead
Install:
- the box for the battery
- the battery negative lead. See: Battery Disconnecting
Check the brake fluid
Check the brake fluid level. Use only Volvo Genuine parts brake fluid (Volvo DOT 4+) when topping up.