Section 66 (Transmission - Removal, Replacement And Installation - 2 Of 2)
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.
- Transmission, Automatic (Ambulance; 2001-2002)
- Installing the gearbox
- Notes
- Installation
- Notes
- Installing the gearbox
- Installing and tightening the screws to the gearbox
- Fitting the torque converter screws.
- Lifting the engine/gearbox
- Installing the rear engine mounting
- Installing the angle gear
- Installing the lower oil pipe to the gearbox
- Installing the left-hand drive shaft to the gearbox and the wheel spindle
- Fitting the sub-frame to the body
- Installing the right-hand drive shaft to the gearbox, wheel spindle and link arm
- Tightening the sub-frame screws (both sides)
- Fitting the screws for engine pads and the torque rod bracket in the gearbox
- Installing the steering wheel shaft joint
- Installing the collision protection system over the steering gear
- Installing the crossmembers
- Installing and tightening the front suspension components
- Installing the cable conduit
- Removing the lifting beam
- Installing the water hose
- Fitting the remaining screws to the gearbox/starter motor
- Installing the gear selector cables and oil line
- Installing the service clips
- Installing engine compartment components
- Finishing
- Replacing the gear-shift position sensor
- Replacing the sealing ring for the oil pump
- Sealing ring, gear shift linkage rod, replacing
- Notes
- Removing engine compartment components
- Removing the gear selector cable
- Removing the gear-shift position sensor from the gear shift linkage rod
- Replacing the sealing ring for the gear shift linkage rod
- Installing the gear-shift position sensor
- Adjusting the gear-shift position sensor
- Installing the gear-shift position sensor, continued
- Installing engine compartment components
- Checking diagnostic trouble codes (DTCs)
- Checking and adjusting the gear-shift position sensor
- Solenoid control system, replacing
- Transmission control module (TCM), replacing
- Transmission fluid, replacing
- Installing the gearbox
- Transmission, Automatic (Ambulance; 2003-2004)
- Cover brake cylinder B4 automatic transmission, replacing
- Gearbox, removing
- Installing the gearbox
- Replacing the gear-shift position sensor
- Replacing the sealing ring for the oil pump
- Sealing ring, gear shift linkage rod, replacing
- Solenoid control system, replacing
- Transmission control module (TCM), replacing
- Transmission fluid, replacing
- Transmission, Automatic (B5254T2, Aw50/51 AWD; 2004-2006)
- Connecting sleeve
- Cover brake cylinder B4 automatic transmission, replacing
- Replacing the gear-shift position sensor
- Notes
- Replacing the gear-shift position sensor
- Removing engine compartment components
- Removing the gear selector cable and connector
- Removing the gear-shift position sensor
- Installing the gear-shift position sensor
- Adjusting the gear-shift position sensor
- Installing the lever and the gear-shift position sensor
- Installing engine compartment components
- Checking diagnostic trouble codes (DTCs)
- Replacing the sealing ring for the oil pump
- Sealing ring, gear shift linkage rod, replacing
- Notes
- Removing engine compartment components
- Removing the gear selector cable
- Removing the gear-shift position sensor from the gear shift linkage rod
- Replacing the sealing ring for the gear shift linkage rod
- Installing the gear-shift position sensor
- Adjusting the gear-shift position sensor
- Installing the gear-shift position sensor, continued
- Installing engine compartment components
- Checking diagnostic trouble codes (DTCs)
- Solenoid control system, replacing
- Transmission control module (TCM), replacing
- Transmission fluid, replacing
- Transmission, installation
- Notes
- Installation
- Notes
- Installing the gearbox
- Installing and tightening the screws to the gearbox
- Fitting the torque converter screws.
- Lifting the engine/gearbox
- Installing the rear engine mounting
- Installing the angle gear
- Installing the lower oil pipe to the gearbox
- Installing the left-hand drive shaft to the gearbox and the wheel spindle
- Fitting the sub-frame to the body
- Installing the right-hand drive shaft to the gearbox, wheel spindle and link arm
- Tightening the sub-frame screws (both sides)
- Fitting the screws for engine pads and the torque rod bracket in the gearbox
- Installing the steering wheel shaft joint
- Installing the collision protection system over the steering gear
- Installing the crossmembers
- Installing and tightening the front suspension components
- Installing the cable conduit
- Removing the lifting beam
- Installing the water hose
- Fitting the remaining screws to the gearbox/starter motor
- Installing the gear selector cables and oil line
- Installing the service clips
- Installing engine compartment components
- Finishing
- Transmission, removing
- Notes
- Preparatory work
- Removal
- Disconnecting the battery lead
- Removing engine compartment components
- Removing components from the gearbox
- Removing the gearbox mounting screws
- Removing the coolant hose from the passenger compartment heater
- Installing the lifting beam and lifting hook on the engine lifting eyelet
- Removing the air baffle and splash guard under the engine
- Removing the screw for the cable duct
- Removing the cross members from the body
- Removing the screws and nuts for the engine pads, torque rod
- Measuring the position of the tie rod in the steering gear
- Exposing the steering shaft joint
- Removing front suspension components (both sides)
- Preparations when removing gearbox
- Preparations for lowering the sub-frame
- Removing the right-hand drive shaft
- Removing the left-hand drive shaft
- Lowering the sub-frame
- Removing bevel gear
- Removing the rear engine mounting
- Removing the screws from the torque converter
- Removing the oil pipe from the gearbox
- Lowering the engine and the gearbox
- Installing the fixture on the mobile jack and gearbox
- Removing all the screws for the gearbox and engine
- Removing the gearbox
- Transmission, Automatic (B5254T2, Aw55-50/51SN; 2004-2006)
- Cover brake cylinder B4 automatic transmission, replacing
- Replacing the gear-shift position sensor
- Replacing the sealing ring for the oil pump
- Sealing ring, gear shift linkage rod, replacing
- Solenoid control system, replacing
- Transmission control module (TCM), replacing
- Transmission fluid, replacing
- Transmission, installation
- Transmission, removing
- Transmission, Automatic (B6284T, 4T65EV-Gt; 1999-2001)
- Control system/valve housing, removing
- Notes
- Information before removal
- Removing the side cover
- Preparations for removing the valve housing
- Removing the cable harness
- Air vent housing
- Control system housing
- Removing the screws for the valve housing and pressure sensor
- Control system for cars of model year -2002
- Control system for cars of model year 2003-
- Removing and separating the valve housing
- Checking the markings and location of the gaskets
- Checking and reinstalling the balls in the valve housing
- Location of the control system housing balls
- Marking the location of the balls in relation to the distribution plate
- Marking the location of the control system balls in relation to the distribution plate
- Check the balls sealing against the distribution plate
- Installing new solenoids on the new valve housing
- Gasket / piston, accumulator, replacing
- Installing the control system / valve housing
- Transferring the balls to the new valve housing
- Checking the balls in the valve housing
- Installing new gaskets
- Replacing the seal on the pump shaft
- Installing the balls for the control system housing
- Installing the valve housing to the control system housing
- Installing the valve housing
- Transferring
- Control system for cars of model year -2002
- Tightening torques
- Control system for cars of model year 2003-
- Installing the oil pump
- Installing the cable harness
- Installing the side cover
- Filling with gearbox fluid
- Installing the gearbox side cover
- Notes
- Preparations
- Installing cover
- Lifting the engine and gearbox to the horizontal position
- Installing the oil pipes
- Installing the rear engine mounting
- Installing the screw for the rear engine pad through the steering gear
- Installing the collision protection system over the steering gear
- Installing the sub-frame on the bodywork
- Installing the left drive shaft on the gearbox, stub axle and control arm
- Installing and tightening the sub-frame screws
- Installing the screws for the bracket for the heated oxygen sensor (HO2S) cable
- Installing the front cross member
- Installing new lock nuts on the steering gear
- Installing the screw for the front engine pad and the torque rod mounting in the gearbox
- Installing the screws for the cable conduit and the ground lead bracket
- Installing and tightening front end components (both sides)
- Tightening the ball joint pinion
- Remove the lifting beam and the lifting hook from the engine and the car
- Installing all the charge air pipes
- Installing the connector
- Installing the upper torque rod
- Install the air cleaner (ACL) housing
- Filling the gearbox with fluid
- Refilling gearbox oil There are three different methods. Method 1
- Refilling gearbox oil Methods 2 and 3
- Check the coolant level in the expansion tank
- Installing the splash guards and the wing liner
- Checking the steering gear bearing in the boot at the bulkhead
- Installing the battery lead
- Test driving the car
- Installing the sealing ring and piston with O-ring for the front servo
- Installation
- Installing the piston and cover
- Installing front suspension components
- Installing the screw for the rear engine pad
- Installing the screws for the bracket for the heated oxygen sensor (HO2S) cable
- Installing the front cross member
- Installing new lock nuts on the steering gear
- Installing the screw for the front engine pad and the torque rod mounting in the transmission
- Tightening the ball joint pinion and the anti-roll bar link
- Installing the screws for the cable conduit and the ground lead bracket
- Remove the lifting beam and the lifting hook from the engine and the car
- Installing all the charge air pipes
- Finishing work
- Installation
- Piston / cover, back-up (reverse) servo, replacing
- Removing gearbox side cover
- Notes
- Disconnecting the battery lead
- Removing engine compartment components
- Removing the upper torque rod
- Collecting gearbox fluid
- Removing the charge air pipe and hose
- Removing the spark plugs cover
- Installing lifting fixture
- Removing the connector from the gearbox
- Installing the lifting beam and lifting hook on the engine lifting eyelet
- Disconnecting the front suspension components
- Removing the screws from the cable conduit and the parking heater. Removing the ground lead bracket from the sub-frame
- Removing the ball joint nut (left hand side)
- Removing the control arms for the anti-roll bar, the track rod and the screw from the drive shaft on the left hand side
- Removing the screws from the sub-frame support plates (both sides)
- Removing the pipe lines from the sub-frame
- Removing the stub axle from the control arm
- Pressing up the sub-frame on the right-hand side
- Removing the front cross member
- Removing the bracket for the heated oxygen sensor (HO2S) wiring
- Preparatory work for removing the stub axle on the left-hand side
- Removing the drive shaft from the stub axle (left-hand side)
- Removing the left drive shaft from the gearbox
- Removing the nuts and screws for the steering gear sub-frame
- Removing the collision protection system over the steering gear
- Lowering the sub-frame
- Removing the screw for the rear engine mounting
- Removing the rear engine mounting
- Preparations for removal of the gearbox side plate
- Removing the oil pipes from the gearbox
- Lowering the engine and gearbox
- Preparations for removal of the gearbox side cover
- Removing the gearbox side cover
- Finishing work
- Removing the sealing ring and piston with O-ring for the front servo
- Notes
- Removal
- Preparations
- Removing the spark plugs cover
- Installing lifting fixture
- Installing the lifting beam and lifting hook on the engine lifting eyelet
- Disconnecting the front suspension components
- Removing the screws for the cable conduit and ground lead bracket on the sub-frame
- Removing the nut for the ball joint pinion (left hand side)
- Removing the screws from the sub-frame support plates (both sides)
- Pressing up the sub-frame on the right-hand side
- Removing the nuts and screws for the steering gear sub-frame
- Removing the front cross member
- Removing the bracket for the heated oxygen sensor (HO2S) wiring
- Removing the screw for the rear engine mounting
- Preparatory work for removing the stub axle on the left-hand side
- Lowering the sub-frame
- Preparations for removing the servo cylinder
- Removing the cover
- Replacing the piston with O-ring and sealing ring
- Replacing differential housing cover
- Preparations
- Raise the car. Remove the splash guard under the engine
- Remove the right-hand drive shaft
- Remove the vehicle speed sensor (VSS) from the differential housing cover
- Remove the bracket between the transmission and the engine
- Remove the differential housing cover
- Check the bearing surface for the differential
- Install the spacer washer and the throw-out bearing on the differential
- Install the differential housing cover
- Install the bracket on the cylinder block
- Install the vehicle speed sensor (VSS)
- Install the right drive shaft
- Finishing work
- Check the oil level
- Oil level / temperature
- Replacing pressure sensor
- Replacing the gasket and O ring for the servo cylinder
- Replacing the oil pump
- Replacing the seal for the torque converter
- Solenoid for shifting 1-2 and 3-4, replace
- Solenoid for shifting 2-3, replace
- Solenoid lock-up function, replacing
- Solenoid, line pressure, replacing
- Transaxle, removing
- Notes
- Filling in Diagnostic and Check lists
- Disconnecting the battery lead
- Exposing the lower steering shaft
- Removing engine compartment components
- Removing the charge air hose and the hose clamp (turbocharged cars)
- Removing the gearbox cable from its mounting and the lever on the transaxle
- Removing the hose for the heater pipe
- Collecting transmission fluid
- Removing the screw from the sub-frame
- Removing the boost pressure pipe
- Removing the dipstick
- Installing the lifting fixture
- Removing the screws for the transmission and starter motor and the ground lead
- Removing components from the starter motor
- Removing the screws from the torque converter
- Installing the lifting beam and lifting hook on the engine lifting eyelet
- Disconnecting the front suspension components
- Removing the screws for the cable conduit and ground lead bracket on the sub-frame
- Removing the nut from the ball joint (both sides)
- Removing the control arms for the anti-roll bar, the track rod and the screw from the drive shaft on both sides
- Removing the screws from the sub-frame support plates (both sides)
- Removing stub axle from the control arm
- Pressing up the sub-frame on the right-hand side
- Removing the driveshaft from the wheel knuckle (right-hand side)
- Removing the cap for the drive shaft support bearing
- Removing the drive shaft
- Removing the drive shaft from the viscous coupling
- Removing the nuts and screws for the steering gear sub-frame
- Removing the front cross member
- Removing the centre and rear cross members
- Removing the bracket for the heated oxygen sensor (HO2S) wiring
- Preparatory work for removing the wheel knuckle on the left-hand side
- Removing the drive shaft from the wheel knuckle (left-hand side)
- Removing the left drive shaft from the gearbox
- Removing the collision protection system over the steering gear (right-hand drive cars)
- Removing the screw for the rear engine mounting
- Lowering the sub-frame
- Removing the rear engine pad
- Removing the rear engine mounting
- Removing the oil pipe from the gearbox
- Lowering the engine and transmission
- Removing the heated oxygen sensor (HO2S) connectors from the bracket on the transmission
- Preparations for removal of the transmission
- Installing the fixture on the mobile jack
- Aligning the fixture on the transmission
- Removing the transmission
- Flushing the oil cooler and oil hoses
- Transmission control module (TCM), replacing
- Transmission oil / oil filter, replacing
- Notes
- Conditions
- Remove the oil pan and the seal
- Remove the oil filter
- Install the oil filter
- Drain off the remaining oil in the torque converter and the oil cooler
- Remove the screw nipple on the oil return line from the connection. Counterhold in the transmission
- Install a plastic hose on the oil return line
- Finishing work
- Transmission, installing
- Notes
- When replacing with a new transmission
- Notes
- Checking before installing
- Adjusting the position of the transmission and engine
- Installing and tightening the screws for the transmission
- Installing the splash guard above the transmission
- Installing the heated oxygen sensor (HO2S) connectors on the bracket on the transmission
- Lifting the engine and transmission to the horizontal position
- Installing the oil pipe at the transmission
- Installing the rear engine mounting
- Installing the engine pad
- Installing the engine pad on the engine mounting
- Installing the sub-frame on the bodywork
- Installing the screw for the rear engine pad through the steering gear
- Installing the collision protection system over the steering gear
- Installing the left drive shaft on the transmission, wheel spindle and control arm
- Installing the drive shaft and the viscous coupling
- Installing the right-hand drive shaft on the transmission, wheel spindle and control arm
- Installing and tightening the sub-frame screws
- Installing the screws for the bracket for the heated oxygen sensor (HO2S) cable
- Installing the front cross member
- Installing new lock nuts on the steering gear
- Installing the screw for the front engine pad and the torque rod mounting in the transmission
- Installing the screws for the cable ducts and ground lead bracket
- Installing and tightening front end components (both sides)
- Tightening the ball joint pinion
- Remove the lifting beam and the lifting hook from the engine and the vehicle
- Installing the torque converter screws
- Installing the clamp for the oil pipe
- Installing the charge air hose
- Installing the screws in the transmission and engine
- Installing the starter motor
- Installing the dip stick pipe in the transmission
- Installing engine compartment components
- Installing the hose for the heater pipe
- Installing the gear selector cable on the transmission and lever
- Installing the upper torque rod
- Installing the air cleaner (ACL) housing
- Finishing work
- Filling the transmission with fluid
- Filling with transmission oil. There are 2 different methods. Method 1
- Filling with transmission oil. Method 2
- Check the coolant level in the expansion tank
- Installing the splash guards and the fender liner
- Assembling the upper and lower steering shaft
- Checking the steering gear bearing in the boot at the firewall
- Installing the battery lead
- Programming the transmission control module (TCM)
- Test driving the vehicle
- Control system/valve housing, removing
- Transmission, Automatic (B6294S, 4T65EV; B6294S, 4T65EV-Gt; 2000-2001)
- Control system/valve housing, removing
- Gasket / piston, accumulator, replacing
- Installing the control system / valve housing
- Installing the gearbox side cover
- Installing the sealing ring and piston with O-ring for the front servo
- Piston / cover, back-up (reverse) servo, replacing
- Removing gearbox side cover
- Removing the sealing ring and piston with O-ring for the front servo
- Replacing differential housing cover
- Replacing pressure sensor
- Replacing the gasket and O ring for the servo cylinder
- Replacing the oil pump
- Replacing the seal for the torque converter
- Solenoid for shifting 1-2 and 3-4, replace
- Solenoid for shifting 2-3, replace
- Solenoid lock-up function, replacing
- Solenoid, line pressure, replacing
- Transaxle, removing
- Transmission control module (TCM), replacing
- Transmission oil / oil filter, replacing
- Transmission, installing
- Transmission, Automatic (B6294S2, 4T65EV; 2003-2005)
- Control system/valve housing, removing
- Gasket / piston, accumulator, replacing
- Installing the control system / valve housing
- Installing the gearbox side cover
- Installing the sealing ring and piston with O-ring for the front servo
- Piston / cover, back-up (reverse) servo, replacing
- Removing gearbox side cover
- Removing the sealing ring and piston with O-ring for the front servo
- Replacing differential housing cover
- Replacing pressure sensor
- Replacing the gasket and O ring for the servo cylinder
- Replacing the oil pump
- Replacing the seal for the torque converter
- Solenoid for shifting 1-2 and 3-4, replace
- Solenoid for shifting 2-3, replace
- Solenoid lock-up function, replacing
- Solenoid, line pressure, replacing
- Transaxle, removing
- Transmission control module (TCM), replacing
- Transmission oil / oil filter, replacing
- Transmission, installing
- Transmission, Automatic (B6294S2, 4T65EV; B6294S2, 4T65EV-Gt; B6294T, 4T65EV-Gt; 2002)
- Control system/valve housing, removing
- Gasket / piston, accumulator, replacing
- Installing the control system / valve housing
- Installing the gearbox side cover
- Installing the sealing ring and piston with O-ring for the front servo
- Piston / cover, back-up (reverse) servo, replacing
- Removing gearbox side cover
- Removing the sealing ring and piston with O-ring for the front servo
- Replacing differential housing cover
- Replacing pressure sensor
- Replacing the gasket and O ring for the servo cylinder
- Replacing the oil pump
- Replacing the seal for the torque converter
- Solenoid for shifting 1-2 and 3-4, replace
- Solenoid for shifting 2-3, replace
- Solenoid lock-up function, replacing
- Solenoid, line pressure, replacing
- Transaxle, removing
- Transmission control module (TCM), replacing
- Transmission oil / oil filter, replacing
- Transmission, installing
- Transmission, Automatic (B6294S2, 4T65EV-Gt; B6294T, 4T65EV-Gt; 2003-2006)
- Control system/valve housing, removing
- Gasket / piston, accumulator, replacing
- Installing the control system / valve housing
- Installing the gearbox side cover
- Installing the sealing ring and piston with O-ring for the front servo
- Piston / cover, back-up (reverse) servo, replacing
- Removing gearbox side cover
- Removing the sealing ring and piston with O-ring for the front servo
- Replacing differential housing cover
- Replacing pressure sensor
- Replacing the gasket and O ring for the servo cylinder
- Replacing the oil pump
- Replacing the seal for the torque converter
- Solenoid for shifting 1-2 and 3-4, replace
- Solenoid for shifting 2-3, replace
- Solenoid lock-up function, replacing
- Solenoid, line pressure, replacing
- Transaxle, removing
- Transmission control module (TCM), replacing
- Transmission oil / oil filter, replacing
- Transmission, installing
- Transmission, Automatic (B6304S3, 4T65EV; 1999)
- Control system/valve housing, removing
- Gasket / piston, accumulator, replacing
- Installing the control system / valve housing
- Installing the gearbox side cover
- Installing the sealing ring and piston with O-ring for the front servo
- Piston / cover, back-up (reverse) servo, replacing
- Removing gearbox side cover
- Removing the sealing ring and piston with O-ring for the front servo
- Replacing differential housing cover
- Replacing pressure sensor
- Replacing the gasket and O ring for the servo cylinder
- Replacing the oil pump
- Replacing the seal for the torque converter
- Solenoid for shifting 1-2 and 3-4, replace
- Solenoid for shifting 2-3, replace
- Solenoid lock-up function, replacing
- Solenoid, line pressure, replacing
- Transaxle, removing
- Transmission control module (TCM), replacing
- Transmission oil / oil filter, replacing
- Transmission, installing
- Wiring (1999-2006)
- Wiring (B6284T, 4T65EV-Gt; 1999-2000)
- Wiring (B6294S, 4T65EV; B6294S, 4T65EV-Gt; 2000)
- Wiring (B6304S3, 4T65EV; 1999)