Removing the control system

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.

Fig 1: Identifying Control System Cover, Harness Clamp, Cooler Return Line And Screws

Courtesy of VOLVO CARS OF NORTH AMERICA.

Position a container under the transmission.

Remove the clamp for the cable harness on the control system cover. Disconnect the ground lead from the transmission. Tie up the cable harness and ground lead.

Disconnect the pipe/hose for the oil cooler from the transmission. Move the pipe to one side.

Fig 2: Identifying Removal Of Sealing Compound From Threads Using A Tap

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove the Torx TX40 screws for the control system cover.

Clean the sealing compound from the threads. Use tap M8 x 1.25.

Remove the cover. Use 9995477 . Carefully tap in the tool between the cover and the transmission to prevent deforming the sealing flange of the cover.

Clean gasket residue from the cover and transmission.

NOTE:

Ensure that no debris enters the transmission. Wash the cover thoroughly.

Fig 3: Locating Oil Temperature Sensor And Holder Screw

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove:

the connectors for the solenoid valves
the screw for the oil temperature sensor holder. Remove the sensor from the control system
the cable harness from the holder on the control system.

Remove the cable harness.

Fig 4: Identifying Control System Screws

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove:

the screws for the control system
the control system from the transmission.

NOTE:

Ensure that there are no cracks on the top of the lever for the gear selector slider.

The digits in the illustration specify the screw lengths.