Installing The Gearbox: Installation

WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2006 Volvo S80, 2005 Volvo S80, 2004 Volvo S80, 2003 Volvo S80, and 2002 Volvo S80. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

For tightening torques, see: Tightening torque .

Installing the gearbox

Fig 1: Adjusting Height & Angle Using Mobile Jack And Gearbox Fixture

Courtesy of VOLVO CARS OF NORTH AMERICA.

Before installing the transmission it is very important that the checks and cleaning have been carried out. See: Transmission, preparations before installing .

Adjust for height and angle using the mobile jack and the gearbox fixture.

Align the gearbox against the engine.

NOTE:

Make sure that the gearbox goes straight in relation to the engine and that the guide sleeves and locating pin for the starter motor fit into the guide holes on the gearbox.

Installing and tightening the screws to the gearbox

Fig 2: Gearbox And Engine Screws

Courtesy of VOLVO CARS OF NORTH AMERICA.

Fit the screws, 7 x M10, to the gearbox/engine.

First tighten alternately and crosswise with light contact, while checking that the gearbox and engine are in contact all the way around.

Following which, tighten the screws with light contact crosswise to the gearbox/engine. Tighten.

Remove the fixture from the gearbox.

Fitting the torque converter screws.

Fig 3: Identifying Torque Converter Screws

Courtesy of VOLVO CARS OF NORTH AMERICA.

NOTE:

Use new screws, Torx TX50.

Align the torque converter to the carrier plate, by means of pulling round the engine with the nut to the crankshaft pulley and turning the torque converter.

Fit all screws, 6, loosely. Insert the screws as far as the screw heads sit against the carrier plate. Tighten in accordance with: Summary of tightening torques for specific components .

NOTE:

Remove the socket wrench from the crankshaft.

Lifting the engine/gearbox

Fig 4: Identifying Engine/Gearbox Lifted

Courtesy of VOLVO CARS OF NORTH AMERICA.

Lift up the engine/gearbox. Check that the engine/gearbox is in horizontal position.

Raise the vehicle.

Installing the rear engine mounting

Fig 5: Identifying Rear Engine Mounting

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install:

the rear engine mounting, 3 x M10, to the gear box. Tighten
the screw to the engine pad/steering gear loosely.

Installing the angle gear

NOTE:

Only applies to vehicles with four-wheel drive AWD

Fig 6: Angle Gear Screws

Courtesy of VOLVO CARS OF NORTH AMERICA.

NOTE:

Before installing the angle gear the splined joint between the gearbox and the angle gear must be lubricated with grease in accordance with: Splines greasing .

Check that the contact surfaces on the gearbox and the angle gear are clean.

Fit the angle gear. Tighten the screws, M10, alternately to light contact. Tighten.

Installing the lower oil pipe to the gearbox

Fig 7: Gearbox Oil Pipe And Screws

Courtesy of VOLVO CARS OF NORTH AMERICA.

Use a new O-ring.

Install:

the oil pipe. Tighten the lower screw, 1 x M6.
the upper screw (oil pipe/dipstick pipe). Tighten in accordance with: Summary of tightening torques for specific components .
a tie strap to the cable harness/oil pipe
the ground cable to the engine.

Installing the left-hand drive shaft to the gearbox and the wheel spindle

Fig 8: Constant Velocity Joint Housing At Transmission

Courtesy of VOLVO CARS OF NORTH AMERICA.

NOTE:

Check that the seal is fitted on the drive shaft.

Fit the drive shaft joint sealing ring in accordance with: Seal CV joint housing, replacing .

Press the drive shaft joint in so that the lock ring engages its groove in the gearbox. Check by pulling in the joint housing.

Locate the drive shaft in the wheel hub. Install a new screw loosely in the drive shaft.

Fitting the subframe to the body

Fig 9: Identifying Sub-Frame And Screws

Courtesy of VOLVO CARS OF NORTH AMERICA.

NOTE:

Use new screws. Lubricate the screws' threads.

Applies to certain models.

Raise the subframe so that it remains approx. 150 mm before reaching the side member.

Secure the servo line with the rubber clamp in the front on the top of the frame. Fit the screw loosely.

NOTE:

When the subframe is raised, make sure that the spring strut ball joint pin aligns in the link arm.

Install:

the new screws and the support bracket at the back
the bracket screws loosely.

Tighten the subframe screws to light contact.

Remove the mobile jack.

Installing the right-hand drive shaft to the gearbox, wheel spindle and link arm

Fig 10: Bearing Cap And Drive Shaft Support Bearing

Courtesy of VOLVO CARS OF NORTH AMERICA.

Fit the bearing cap to the drive shaft support bearing, 2 x M8.

Tighten.

NOTE:

Make sure that the seal is fitted on the drive shaft.

Fit the drive shaft joint sealing ring in accordance with: Seal CV joint housing, replacing .

Align the drive shaft in the wheel hub. Fit a new screw loosely in the drive shaft.

Press the link arm down and align the spring strut ball joint pin in the link arm.

Position the mobile jack under the right-hand side of the subframe with light contact. Remove both subframe screws.

Install:

new screws in the subframe

NOTE:

Lubricate the screws' threads.

the screws loosely in the support plate at the rear.

Tighten the subframe screws to light contact.

Remove the mobile jack.

Tightening the subframe screws (both sides)

Fig 11: Identifying Sub-Frame And Bolts

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install the four subframe screws together with the subframe brackets and engine heater where appropriate.

Tighten to: Tightening torque . First tighten the screws on the left-hand side of the subframe followed by those on the right.

Tighten the bracket screws M10.

Tighten the screws, 4 x M10, to the subframe brackets.

Fitting the screws for engine pads and the torque rod bracket in the gearbox

Fig 12: Engine Pads And Screws

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install:

the screws, M10, to the front and rear engine pads. Tighten

NOTE:

Use new screws.

the torque rod bracket to the transmission. Tighten. See Summary of tightening torques for specific components .

Installing the steering wheel shaft joint

Fig 13: Identifying Screw For Joint Between Steering Gear And Steering Shaft

Courtesy of VOLVO CARS OF NORTH AMERICA.

Align the steering wheel shaft joint on the steering gear.

Fit a new steering wheel shaft screw. Tighten in accordance with: Summary of tightening torques for specific components .

Connect the cable to the stepper motor/solenoid.

Check the position of the tie rod in the steering gear in accordance with Measuring the position of the tie rod in the steering gear .

Installing the crossmembers

Fig 14: Cross Members

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install:

the front crossmember and the brake pipe in their holders
the other 2 crossmembers.

Tighten all M8 screws.

Installing and tightening the front suspension components

Fig 15: Front Suspension Components

Courtesy of VOLVO CARS OF NORTH AMERICA.

Fit the nut to the ball joint pin. Counterhold the ball joint pin while tightening so that the gaiter does not turn. Use a new nut, M12.

Tighten, see: Summary of tightening torques for specific components .

Tighten the drive shaft screw. Use a new screw. Counterhold with a screwdriver in the brake disc. Tighten in accordance with: Summary of tightening torques for specific components . Use: 9512050 .

Fit on the left-hand side:

the link to the anti-roll bar. Counterhold the ball joint pin while tightening so that the gaiter does not turn. Use a new lock nut. Tighten in accordance with: Summary of tightening torques for specific components .
the tie rod. Tighten in accordance with: Summary of tightening torques for specific components .

Install:

the ABS line to the bracket in the spring strut
the wing liner with support plate and nuts.

Installing the cable conduit

Fig 16: Fuel Line For Heater And Sub-Frame

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install:

the cable duct to the subframe
the ground cable to the subframe
auxiliary heater/parking heater to the bracket in the subframe and the fuel line to the brackets (if fitted to the vehicle)
the front splash guard
the splash guard under the engine
the wheels. See Installing wheels .

Removing the lifting beam

Fig 17: Identifying Lifting Beam And Lifting Hook Installed On Engine Lifting Eyelet

Courtesy of VOLVO CARS OF NORTH AMERICA.

Lower the vehicle.

Remove the lifting beams and lifting hooks from the engine.

Installing the water hose

Fig 18: Coolant Hose In Passenger Compartment

Courtesy of VOLVO CARS OF NORTH AMERICA.

Fit the water hose quick attachment to the heater.

Remove the hose clips.

Fitting the remaining screws to the gearbox/starter motor

Fig 19: Cable Harness Clamp Screws

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install:

the screws, 3 x M10, to the gearbox/engine. Tighten
the screws for the starter motor. Tighten. See: Summary of tightening torques for specific components
the bracket to the coolant hose-cable harness
the bracket to the cable harness clamp and the bracket for the heated oxygen sensor (HO2S) connectors in the rear edge of the gearbox
the clamp to the cable harness at the rear edge of the engine
the bracket for the air cleaner (ACL), 2 x M10. Tighten (Applies only to B5254T4).

Installing the gear selector cables and oil line

Fig 20: Gear Selector Cables And Oil Line

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install:

the ground cable with bracket to the subframe
the oil pipe to the gearbox
the gear selector cables with the bracket, 2 x M8. Tighten.

Connect the cable to the lever. Connect the gearbox connector and the bracket to the air cleaner (ACL) housing bracket.

Press the cable harness bracket onto the control system cover.

CAUTION:

Check that the gearbox air bleed hose/valve is not trapped. Risk of overpressure in the gearbox.

Installing service clips

Fig 21: Gear Selector Cable And Clip

Courtesy of VOLVO CARS OF NORTH AMERICA.

Ensure that the gear selector cable is engaged before fitting the blue clip. Press the clip into position as illustrated.

Fig 22: Clip Positioned In Groove

Courtesy of VOLVO CARS OF NORTH AMERICA.

Check that the clip is positioned in the groove as illustrated.

Installing engine compartment components

Fig 23: Air Cleaner Housing, Hoses And Electrical Terminals

Courtesy of VOLVO CARS OF NORTH AMERICA.

Applies only to turbocharged engines, fit:

the control valve to the fan cover
the charge air pipe over the engine
the air cleaner (ACL) housing assembly with the intake manifold and connections
the cover at the side of the air cleaner (ACL) housing (Applies only to B5254T4)
the ground cable to the bracket on the engine (certain variants)
the upper torque rod between the wheel housings. Tighten the screws, M10
the screw, M12, to position rod/engine mounting. Tighten.

Fig 24: Engine Compartment Covers

Courtesy of VOLVO CARS OF NORTH AMERICA.

Fig 25: Air Cleaner Housing, Vacuum Hoses And Ground Strap

Courtesy of VOLVO CARS OF NORTH AMERICA.

Applies only to naturally aspirated engines, fit:

the air cleaner (ACL) housing with the intake manifold and preheating hose
the vacuum hoses, 2, from the intake manifold to the control valves
the ground cable to the bracket on the engine (certain variants)
the upper torque rod between the wheel housings. Tighten the screws, M10
the screw, 1 x M12, to the torque rod/engine mounting. Tighten.