Transmission, Installing
Transmission, installing
Special tools:
951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor
999 7057 Counterhold 999 7057 Counterhold
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.
Installation
Note! For tightening torques, see applicable specifications.
Installing the transmission
Before installing the transmission it is very important that the checks and cleaning have been carried out. See: Transmission, checking, B5244T5, M66 Component Tests and General Diagnostics.
Transfer the lock-up mechanism to the new gearbox.
Apply thread sealant 1161056 to the threads.
Tighten to 32 Nm.
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 the guide sleeves and guide pin for the starter motor align in the guide holes on the transmission.
Installing and tightening 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. Then tighten the screws crosswise.
Remove the fixture from the transmission.
Lifting the engine and transmission
Lift to slightly above horizontal position to make the rear engine mounting/pad more accessible
Note! Check that the connection on the hose for the heater is not trapped between the engine and firewall when the engine is lifted.
Raise the car.
Installing the rear engine mounting
Install:
- the rear engine mounting for the transmission to the engine mounting. Use 3 x M10 screws. Tighten.
Installing the bevel gear
Applies only to four wheel drive cars.
Note! Before installing the bevel gear the splined joint between the transmission and the bevel gear must be lubricated using grease.
Lubricate the splined joint between the transmission and the bevel gear. Use grease.
Check that the contact surfaces on the gearbox and the angle gear are clean.
Install the bevel gear. Use new screws. Tighten the screws alternately to light contact. Refer to applicable specifications.
Installing the left drive shaft on the transmission and the wheel spindle
Note! Ensure that the seal is in place on the drive shaft.
Press in the constant velocity joint housing firmly so that the snap ring engages in its groove in the transmission.
Pull the constant velocity joint to check that the drive shaft is secure.
Lubricate the drive shaft splines. Use a small amount of thin oil.
Locate the drive shaft in the wheel hub. Install a new screw loosely in the drive shaft.
Fitting the sub-frame to the body
Note! Use new screws. Lubricate the screw threads.
Lift the sub-frame until it is about 150 mm from the side member.
Secure the power steering pipe at the front edge of the upper side of the sub-frame. Use the rubber covered clamp. Install the screw loosely. Apply a small amount of soap solution so that it glides into the clamp easily.
Note! Ensure the following when lifting the sub-frame:
- that the brake pipe passes the bracket for the exhaust pipe
- that the ball joint pinion for the spring strut aligns in the control arm.
Install:
- the new screws and the support bracket at the rear edge
- the screws loosely in the bracket.
Applies only to cars with fuel driven parking heaters:
Tighten the sub-frame screws. Tighten to light contact.
Remove the mobile jack.
Installing the right-hand drive shaft to the gearbox, wheel spindle and link arm
Install the drive shaft and the cap for the pilot bearing. Use 2 x M8 screws. Tighten.
Lubricate the drive shaft splines. Use a small amount of thin oil.
Locate the drive shaft in the wheel hub. Install a new screw loosely in the drive shaft. Press down the control arm. Locate the spring strut in the ball joint pinion for the spring strut in the control arm.
Positioning the mobile jack lightly applied under the right side of the sub-frame
Install:
- new screws in the sub-frame
Note! Lubricate the screw threads.
- the screws loosely in the rear edge of the support plate.
Remove the mobile jack.
Tighten the sub-frame screws on both sides.
Tighten. See: Tightening torque [1][2]Specifications. Use: 951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor. Then tighten the 4 x M10 screws for the sub-frame brackets.
Fitting the screws for engine pads and the torque rod bracket in the gearbox
Install:
- new M10 lock nuts for the front and rear engine pads. Tighten
- the torque rod mounting on the transmission.
Note! Use new bolts.Tighten, see applicable specifications.
Installing the steering wheel shaft joint
Align the steering joint on the steering gear. Install the new steering shaft screw. Tighten. See Tightening torque [1][2]Specifications
Connect the cable to the stepper motor/solenoid. Check the tie rod position. See: Transmission, removing, B5244T5, M66 Transmission, Removing.
Installing the collision protection system over the steering gear
Applies only to right-hand drive cars.
Install the 2 x screws. Tighten.
Installing the crossmembers
Install:
- the front cross member and the brake pipe in their holders
- the middle cross member
Tighten all M8 screws.
Installing and tightening front suspension components
Install a new M12 lock nut for the ball joint pinion. Counterhold the ball joint pinion while tightening so that the ball joint boot cannot turn. Tighten. See: Tightening torque [1][2]Specifications
Tighten the drive shaft screw. Counterhold using a screwdriver in the brake disc vents. Tighten. See: Tightening torque [1][2]Specifications.
Use: 951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor
Install:
- the link for the anti-roll bar. Use a new M10 lock nut. Counterhold the ball joint pinion while tightening so that the ball joint boot cannot turn. Tighten. See: Tightening torque [1][2]Specifications
- the tie rod. Tighten. See: Tightening torque [1][2]Specifications
- The ABS line in the mounting in the spring strut
- the wing liner with support plate and nuts.
Checking and topping up oil
Check and top up with oil. See: Transmission fluid, replacing, B5244T5, M66 Service and Repair.
Installing the cable duct
Install:
- the cable duct on the sub-frame
- the ground cable to the sub-frame
- any additional heaters/parking heaters to the mounting in the sub-frame and the fuel lines to the mountings
- the front splash guard
- the splash guard under the engine
- the wheels. See Installing wheels Service and Repair.
Removing the lifting beams
Lower the car.
Remove the lifting beams and hooks from the engine.
Installing the coolant hose
Install the connector securing the engine coolant hose to the heater.
Remove the hose clips.
Installing the remaining screws for the transmission and starter motor
Install:
- the 3 x M10 screws, for the transmission/starter motor. Tighten
- the 2 x M10 screws for the transmission/starter motor. Tighten. See: Tightening torque [1][2]Specifications.
Installing components for the transmission
Install:
- the bracket for the engine coolant hose and cable harness
- the bracket for the cable harness clamp and the mounting for the heated oxygen sensor (HO2S) connector at the rear edge of the transmission
- the clamp for the cable harness at the rear edge of the engine
- the connector for the back-up lamp switch
- the mechanical transmission cables to the transmission. Adjust. See: Transmission cables, replacing, B5244T5, M66 Service and Repair.
- selector cables to levers.
Note! When working with the mechanical cables ensure that there is no cracking between the cable and sleeve.
Installing the service clips
Note! The automatic transmission has one gear selector cable while the manual transmission has two cables.
Ensure that the gear selector cable is locked in position before installing the blue clip. Press the clip into place as illustrated.
Check that the clip is positioned in the groove as illustrated.
Installing the clutch line
Install:
- the ground lead on the transmission and sub-frame
- the clamps for the cable harness on the transmission
- the clutch cable hose on the junction.
Remove the hose clip from the clutch cable hose.
Bleed the clutch. Only use Volvo original brake fluid.
Installing engine compartment components
Install:
- the engine stabilizer brace between the wheel arches. Use 4x M10 screws. Tighten
- 1 x M12 screw for the engine stabilizer brace/engine mounting. Tighten
- the air cleaner (ACL) housing to the intake manifold and connections. Hook the valve onto the air cleaner (ACL) housing
- the fresh air intake hose
- the cover on the side of the air cleaner (ACL) housing.
Fill with coolant. Carefully check while reaching operating temperature or test driving that the level remains the same and that there is no leakage.
Installing the battery lead
Connect the battery lead.
First read Battery, disconnecting Battery Disconnecting.