Section 105 (Transmission - Installation (644 Body))
WARNING: This page is about a different car, the 2004 Volvo S40, 2003 Volvo S40, 2002 Volvo S40, 2001 Volvo S40, and 2000 Volvo S40. However, it is still accessible from the selected car via links, so may be relevant.
- Transmission
- Nut on the transmission oil return line for oil pipe bracket
- Transmission fluid, replacing (AW55-50)
- Transmission, installing (M56; turbocharged engines)
- Notes
- Cleaning and lubricating the input shaft
- Checking before installing
- Install the transmission
- Raise the engine/transmission to the horizontal position.
- Install the mounting on the transmission
- Install the brackets in the gearcase
- Install the right driveshaft.
- Install the support member under the engine.
- Fit the left-hand drive shaft
- Checking the left-hand side drive shaft
- Tighten the wheel spindle/spring strut nuts/screws to 90 Nm
- Attach the hose to the intercooler/charge air pipe
- Check the transmission fluid level. Install the protective plate and wheels.
- Attach the pipe to the branching and bracket. Install the branching clip.
- Attach and tighten the hose clip and retaining clamp to the charge air pipe.
- Install the engine compartment components
- Transmission, installing (M56; B4204S2)
- Notes
- Cleaning and lubricating the input shaft
- Checking before installing
- Transmission, installing
- Raise the engine/transmission to the horizontal position.
- Mount the transmission mounting on the transmission and body
- Mounting brackets in the gearcase, installing
- Drive shaft right-hand side, installing
- Longitudinal member, installing
- Front exhaust pipe, installing
- Transverse support member, installing
- Drive shaft left-hand side, installing
- Drive shaft left-hand side, checking
- Tighten the wheel spindle/spring strut nuts/screws to 90 Nm.
- Check and fill transmission fluid
- Protective covers and wheels, installing
- Attach the connecting pipe to the branching and bracket
- Flywheel sensor, installing
- Gear selector cables and clips on the transmission, installing
- Connect the transmission ground connection.
- Engine compartment components, installing
- Air intake hose
- Transmission, installing (AW55-50/51SN)
- Notes
- Checking before installing
- Adjust the position of the engine / transmission
- Install and tighten the screws for the transmission
- Install the torque converter screws
- Install the collision protection system over the steering gear (right-hand drive cars)
- Install the sub-frame components
- Lift up the engine and transmission to the horizontal position
- Install the rear engine mounting
- Install the sub-frame on the bodywork
- Install the left drive shaft on the transmission, the wheel spindle and the control arm
- Install the right drive shaft in the transmission, the wheel spindle and the control arm
- Install and tighten the sub-frame screws
- Install the oil pipe on the transmission
- Install and tighten the suspension components (both sides)
- Tighten the ball joint pinion
- Install new lock nuts on the steering gear
- Tighten the screw for the rear engine pad
- Reinstall the exhaust pipe
- Install the exhaust pipe on the turbocharger (TC)
- Install the screws for the bracket for the heated oxygen sensor (HO2S) cable
- Reinstall the front cross member
- Install the screw for the front engine pad and the torque rod mounting in the sub-frame
- Install the screw for the ground lead and the cable conduit
- Lower the car. Remove the lifting beam from the engine
- Install the remaining screws for the transmission and starter motor
- Install the dip stick pipe and the ground lead on the transmission
- Install the transmission cable on the transmission and the lever
- Install the charge air pipe on the charge air cooler (CAC). Connect the upper oil hose to the oil cooler
- Install the air cleaner (ACL) and the upper torque rod in the engine compartment
- Finishing work