Installing the transmission

WARNING: This page is about a different car, the 2002 Volvo C70, 2001 Volvo C70, 2000 Volvo C70, 1999 Volvo C70, and 1998 Volvo C70. However, it is still accessible from the selected car via links, so may be relevant.

Special tools:

9512050

Cleaning and lubricating the input shaft

The input shaft must be lubricated before a manual transmission is installed. See Input shaft, cleaning .

Checking the transmission

See Checking the gearbox .

Installing the transmission

Fig 1: Identifying Starter Motor Torx Screw

Courtesy of VOLVO CARS OF NORTH AMERICA.

Use the transmission fixture and the mobile jack to line up the transmission with the engine.

NOTE:

Ensure that the transmission comes straight in towards the engine without placing any stress on the center of the clutch driven plate.

Install the screws for the transmission / engine and the screw for the starter motor.

Tighten alternately until the transmission and the cylinder block are in contact all the way around. Torque tighten in the following order: M12 to 80 Nm . M8 to 25 Nm . Tighten the starter motor screws to 80 Nm .

Remove the transmission fixture and the mobile jack from the transmission.

Installing the lifting hook

Fig 2: Identifying Lifting Hook 9995460

Courtesy of VOLVO CARS OF NORTH AMERICA.

Screw in lifting hook 9995460 to the measurement noted earlier between the lifting beam and the valve cover. See Installing lifting tools .

Ensure that no cables or hoses are trapped.

Installing the rear engine mounting on the transmission

Fig 3: Identifying Rear Engine Mounting Screws

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install the mounting on the transmission (3 screws). Tighten the two rear screws. Tighten to 50 Nm . Remove the front screw again.

Install the engine pad splash guard using the screw for the mounting.

Press up the cover against the mounting. Tighten the screw. Tighten to 50 Nm .

Install the engine pad using a new nut

Fig 4: Identifying Hook 9995045

Courtesy of VOLVO CARS OF NORTH AMERICA.

Align the engine pad locating pin in the cover. Install the nut loosely.

Install the screw for the engine pad / steering gear. Do not tighten the screw.

Remove hook 9995045 .

Aligning the steering gear and the collision protection system in the sub-frame (right-hand drive cars only)

Fig 5: Identifying Distance Between Sub-Frame & Bodywork

Courtesy of VOLVO CARS OF NORTH AMERICA.

Raise the sub-frame so that it is 100 mm from the bodywork.

Locate the steering gear and the collision protection system in the sub-frame.

Install the left bearing and cap for the anti-roll bar. Tighten both the bearing caps. Tighten to 50 Nm .

Installing the sub-frame

See Installing the sub-frame .

Removing lifting tools

Fig 6: Identifying Lifting Hooks, Lifting Bar And Fender Edge Support

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove:

lifting hook 9995460 , lifting beam 9995006 and fender edge supports 9995033
the nuts for the exhaust manifold
lifting hook 9995638 .

Install the nuts for the exhaust manifold. Tighten to 25 Nm .

Installing the screws and nuts for the steering gear and the sub-frame

See Installing the screws and nuts for the steering gear and the sub-frame .

Installing the torque rod mounting

Fig 7: Identifying Torque Rod Mounting On Transmission Screws

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install:

the torque rod mounting on the transmission using new screws. Use bevel protractor 9512050 . Tighten to 35 Nm + 40°
the screws for the oil pipe brackets. Tighten to 25 Nm .

Check the oil level if necessary. Only use Volvo original transmission fluid (P/N 1161423-7).

Installing the right drive shaft on the transmission

See Installing the right drive shaft on the gearbox .

Installing the collision protection system (right-hand drive cars)

See Installing the collision protection system over the steering gear (right-hand drive cars only)

Installing the left drive shaft on the transmission

See Installing the left drive shaft on the gearbox .

Installing the drive shaft on the hub

See Installing the drive shaft on the hub .

Installing the ball joint on the wheel spindle

See Installing the ball joint on the stub axle .

Tightening the left drive shaft screw

See Tightening the drive shaft screw(s) .

Installing the ABS sensor

See Installing the ABS sensor .

Installing the cable conduit, hose and vacuum regulator

Fig 8: Identifying Cable Conduit, Charge Air Pipe Hose And Vacuum Regulator

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install:

the cable conduit on the sub-frame
the hose for the charge air pipe
the vacuum regulator on the sub-frame.

Tighten the clamp for the exhaust pipe. "Twist" the pipes when tightening.

Installing the splash guards and the wheels

Fig 9: Identifying Front Cover And Cover Under Engine

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install:

the front cover
the splash guard under the engine
the wheels. See Tightening the wheel studs .

Installing the transmission / engine and the torque control arm

Fig 10: Identifying Torque Control Arm/Torque Rod Screws And Transmission/Engine Screws

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install:

the 2 screws for the transmission / engine. Tighten to 80 Nm
the pipe for the crankcase ventilation loosely
the torque control arm. Use guide sleeves and new screws and nuts. Tighten the screws for the torque control arm to the transmission cover / engine. Tighten to 45 Nm + 90° . Tighten the screw for the torque control arm / torque rod. Tighten to 35 Nm + 90°
the screws for the crankcase ventilation pipe. Tighten to 25 Nm .

Tighten the nut for the rear engine pad. Tighten to 50 Nm .

Installing wiring and the quick-release coupling

See Installing wiring and the quick-release coupling .

Installing the connector and transmission lever and transmission cables

See Installing the connector, gearbox lever and gearbox cables .

Installing engine compartment components

Fig 11: Identifying Engine Cover, Battery, Air Cleaner (ACL) Housing And Charge Air Pipe Hose

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install:

the expansion tank
the screws securing the bracket for the air cleaner (ACL) housing
the battery shelf
the hose for the charge air pipe
the air cleaner (ACL) housing with the intake manifold and connections
the battery
the hoses for the control valve
the cover over the engine.