Side cover transmission, removing: Removal

Disconnecting the battery lead

Remove the battery lead. See Battery, disconnecting .

Removing engine compartment components

Fig 1: Identifying Engine Compartment Components

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove:

the engine stabilizer brace between the suspension turrets and the engine
the air cleaner (ACL) housing assembly with the intake pipe.

Unhook the turbocharger (TC) control valve from the air cleaner (ACL) housing. Pull the air cleaner (ACL) housing out of its mountings.

Draining oil

Fig 2: Identifying Dip Stick Pipe & Oil Suction Device

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Use an oil suction unit.

Remove the dip stick. Ensure that the suction pipe reaches down into the transmission.

Extract all the fluid, approximately 6 liters.

Removing the coolant hose from the passenger compartment heater

Fig 3: Identifying Clamped Coolant Hoses

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Clamp the hoses with hose clips.

Place some paper under the inner hose connection to collect any spilled coolant.

Turn the quick-release connector (the inner of the 2 hoses) slightly in the direction of the arrow so that the lock opens. At the same time, pull the coolant hose straight out of the coolant pipe.

NOTE:

Tie the hose up to the engine so that it does not fall down and trap the hose connector against the firewall during installation.

Disconnecting the charge air pipe

Fig 4: Identifying Heating Around Pipe At Charge Air Cooler

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Detach the charge air pipe from the charge air cooler (CAC).

Carefully heat around the pipe at the charge air cooler (CAC). Use a hot air gun. Loosen and remove the pipe.

Removing the connector from the transmission

Fig 5: Identifying Gearbox And Connector

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Remove:

the screw for the clamp holding the positive cable on the engine
the connector from the transmission (press the connector together). Pull it from the transmission.

Installing the lifting beams and lifting hooks on the engine lifting lugs

Fig 6: Identifying Engine Lift Installed

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NOTE:

The front lifting beam must be equipped with fixture kit 9997070 as illustrated.

Position lifting beams 9995716 on the wheel arch and directly above the engine lifting eyelets on the left and right-hand sides.

Connect the lifting hooks 9995460 on the engine lifting lugs.

On the right-hand side of the engine, the hook must have a clearance of 10 mm .

On the left-hand side of the engine, lifting lug 9997018 must be used. Connect the tool to the 2 screws at the rear edge of the engine together with lifting hook 9995460 .

Tighten to light contact on the left hand side.

Removing the lower steering shaft from the steering shaft joint

Fig 7: Identifying Removing Lower Steering Shaft From Steering Shaft Joint

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Detach the boot from the firewall and slide it up on the steering shaft.

Turn the steering wheel so that the screw for the steering shaft joint is accessible but with the wheels as straight forward as possible.

Remove the ignition key. Do not turn the steering wheel now.

Remove the screw from the steering shaft joint and slide up the lower steering shaft.

Raise the car.

Fig 8: Identifying Steering Shaft Joint Screw

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Removing both the front wheels

Fig 9: Identifying Front Splash Guard

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Remove:

both the front wheels
the front protective panel. See Sub-frame front, replacing
the splash guard under the engine.

Removing components from the sub-frame

Fig 10: Identifying Cable Duct

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove the screw for the cable duct. Unhook the cable duct from the sub-frame.

For cars with fuel powered parking heaters:

Remove the 2 screws for the heater.

Unhook the heater from the mounting. Leaving it hanging in its upper mounting.

Detach the fuel line for the heater from the holders on the sub-frame.

Removing the cross members from the body

Fig 11: Locating Cross Members And Bolts

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Slacken off the 2 screws in the center bearing/member for the propeller shaft

Remove:

the screws for the support for the center bearing. Let the propeller shaft rest against the exhaust pipe
one of the screws and slacken off the other for the rear member. Turn the member to the side so that the exhaust pipe is exposed.

Removing the front cross member

Fig 12: Locating Front Cross Member And Bolts

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Remove:

the clamp for the heated oxygen sensors (HO2S) from the member
the member. Remove the brake pipe from the mountings in the member
the connector for the heated oxygen sensors (HO2S) in the sub-frame
the rubber mountings from the exhaust pipe and the mounting on the sub-frame.

Removing screws and nuts from the engine pad and engine stabilizer brace

Fig 13: Identifying Engine Pads And Engine Stabilizer Brace Bolts

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Remove:

the screws for the front and rear engine pads
the screws for the engine stabilizer brace.

Detaching the power steering line

Fig 14: Locating Power Steering Line

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Remove:

the screw for the clamp for the power steering line at the front edge of the top of the sub-frame. The screw can be accessed from the front if the cable duct is lifted up
the screw for the clamp for the power steering line on the right-hand side at the rear edge of the frame.

Unhook the servo and the evaporator lines from the holders on the right-hand side of the sub-frame.

For cars with fuel powered parking heaters

Unhook the fuel line from the holders.

Removing front suspension components on both sides

Fig 15: Identifying Front Suspension Components

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Remove:

the soundproofing over the drive shaft (applies to certain versions)
the screw for the drive shaft. Counterhold using a screwdriver in the brake disc vents. Tap in the end of the drive shaft approximately 20 mm into the wheel hub
the link from the anti-roll bar. Counterhold using a Torx wrench in the ball joint pinion to prevent the boot from turning
the nut for the ball joint / link arm. Clean the exposed threads outside the nut. Spray using rust solvent before removing the nut
the nut for the tie rod from the wheel spindle.

Fig 16: Identifying Length Of Track Rod In Relation To Steering Gear Housing

Courtesy of VOLVO CARS OF NORTH AMERICA.

NOTE:

Before detaching the tie rod, measure and note the distance as illustrated.

Disconnecting the ball joint pinion from the control arm (both sides)

Fig 17: Identifying Disconnecting Ball Joint Pinion From Control Arm Using 999 7062

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Use tool 9997062 .

Install cap nut 9997062 on the ball joint pinion. Tighten the nut against the control arm. Then slacken off 1 to 2 turns so that there is clearance between the cap nut and the control arm.

Position puller 9997062 on the control arm and detach the ball joint from the control arm.

Remove the tools.

Unhooks the control arm from the ball joint pinion (both sides)

Fig 18: Identifying Unhooking Control Arm From Ball Joint Pinion

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Use lifting lug 9995085 and a longer jimmy bar or the handle of jimmy bar 9995462 .

Position the lifting lug hook in the cast countersink on the control arm. Position a jimmy bar or handle of the jimmy bar through the lug on the hook and against the control arm as illustrated.

Press the control arm down and slide the wheel spindle to one side while installing protective socket 9995562 on the ball joint pinion. Hold it in place with the nut for the ball joint.

Removing the drive shaft from the wheel hub (both sides)

Fig 19: Identifying Removing Drive Shaft From Wheel Hub

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Hold the control arm as above to facilitate removal of the drive shaft joint from the hub.

Release the control arm to the rest position.

Removing the drive shaft from the transmission (left-hand side)

Fig 20: Identifying Drive Shaft & Transmission

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Use counterhold 9995462 modified according to the Workshop Guide Bulletin.

Do not damage the drive shaft seal when removing the end of the drive shaft from the transmission.

Remove the drive shaft.

Hold the spring struts back on both side using a tensioning strap to give more space.

Removing the fender liner and support plate

Fig 21: Identifying Fender Liner Tied Up To Lifting Beam Using Retaining Strap

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Remove the 2 nuts from the fender liner and the support plate.

Angle out and tie up the fender liner to the lifting beam. Use a retaining strap.

NOTE:

Do not damage the front fender.

Removing the screws from the sub-frame support plates (both sides)

Fig 22: Identifying Screws And Sub-Frame Support Plates

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Remove the screws from the sub-frame support plates (both sides).

Position mobile jack 9985972 with universal plate 9995972 , so that the plate is in light contact under the right-hand side of the sub-frame. Slacken off the screws for the sub-frame on the right hand side. Ensure that the nuts are still secured by at least 5 threads.

Remove the jack.

Lowering the sub-frame

Fig 23: Identifying Mobile Jack & Sub-Frame

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Position the mobile jack lightly applied under the left side of the sub-frame. Remove the sub-frame screws.

NOTE:

Ensure the following when lowering the sub-frame:

the steering shaft joint on the steering gear runs freely in the bodywork grommet
that the brake pipe does not catch in the bracket for the exhaust pipe mounting.

Remove the mobile jack and let the frame hang loose.

Removing the oil pipe from the transmission

Fig 24: Identifying Transmission Oil Pipes

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NOTE:

Plug the oil pipes so that no dirt gets in.

Remove the nuts from the brackets for the oil pipes.

Remove the connection nuts from the pipes (counterhold at the connections). Pull out the oil pipes.

Move the oil pipes to one side.

Lowering the engine and transmission

Fig 25: Identifying Lowering Engine And Transmission

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Lower:

the engine and transmission on the left-hand side. Ensure that no cables and hoses are trapped or stretched while lowering
as much as the lifting hook allows, check through the hole in the lifting hook to see when the stop becomes visible.

Preparations for removal of the transmission side cover

Fig 26: Identifying Gearbox Side Cover

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Remove the gear selector cable from its clips on the side member.

Blow clean thoroughly around the cover.

Collect the oil spill when the side cover has been removed.

Remove the nut for the clamp and bracket holding the wiring. Cut off the tie straps holding the cable harness above the bracket. Move the wiring to one side. Remove the screw from the bracket. Unhook the bracket.

Remove all the screws from the side cover. Note the location of the different types of screws.

Removing the side cover

Fig 27: Identifying Removing/Installing Gearbox Side Cover

Courtesy of VOLVO CARS OF NORTH AMERICA.

Pull out the side cover slightly from the transmission. Angle out the cover at the front on the left side quite a lot.

Pull the cover backwards to the steering gear. Pull out the cover at the bottom edge so that the upper section passes the side member. Keep the seal between the side cover and the transmission.