Gearbox, fitting

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.

Special tools:

9512661

9995460

9995972

9995383

CAUTION: If the gearbox is not changed, the right-hand seal and O-ring should be changed, see Change the seal .

Position the gearbox against the engine

Fig 1: Identifying Support 9995972

Courtesy of VOLVO CARS OF NORTH AMERICA.

Position the gearbox in the assembly position on support 9995972 and secure it with the brackets.

Apply a little grease, part number 1161246-2, to the clutch shaft.

Grease the splines (RH drive shaft) on the gearbox using part number 1161035-9.

Press the gearbox towards the engine along the clutch plate splines, and press on the right-hand drive shaft onto the splines.

CAUTION: Fit the drive shaft so that the drilled holes for the locking pins are aligned.

NOTE: Position the starter motor on the adjustment bushing.

Secure the gearbox to the engine

Fig 2: Identifying Gearbox Retaining Bolts

Courtesy of VOLVO CARS OF NORTH AMERICA.

Thread the four retaining bolts and tighten to 50 Nm .

Remove the support 9995972 .

D4192T.

Press on the gearbox/engine mounting and secure with four bolts. Tightening torque 27 Nm .

Attach the gearbox mounting to the side of the body.

Fig 3: Identifying Gearbox Mounting Bolts

Courtesy of VOLVO CARS OF NORTH AMERICA.

Fit the mounting to the gearbox and secure with three bolts.

Use lifting hook 9995460 to lift the engine and fit the bolt to the chassis support.

Fit the three bolts and tighten to 45 Nm .

Lower the engine until the lifting brace no longer supports it.

Tighten the bolt on the side of the body to 98 Nm .

NOTE: Be careful of the hydraulic pipe to the clutch.

Diesel cars: Fit the fuel filter

Fig 4: Identifying Fuel Filter Nuts

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Position the fuel filter.

Fit the two nuts and tighten to 21 Nm .

Remove the lifting brace

Fig 5: Identifying Lifting Brace

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Remove the lifting hooks 9995460 , lifting brace 9995006 and support 9995383 .

Fit the retaining bolts to the top side of the gearbox

Fig 6: Identifying Gearbox Retaining Bolts

Courtesy of VOLVO CARS OF NORTH AMERICA.

Thread the bolts and tighten to 50 Nm .

Diesel cars:

Position the cable harness support on the gearbox and fit the bolt.

Tighten to 50 Nm .

Fit the starter motor

Fig 7: Identifying Starter Motor Bolts

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Position the starter motor and thread the three bolts.

Tighten the bolts to 50 Nm .

Fit the left-hand drive shaft

Fig 8: Identifying Left-Hand Drive Shaft Bolts

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Raise the car

Remove the protector from the tripod and opening in the gearbox.

Turn the steering wheel to the right to full lock.

Carefully fit the drive shaft into the differential.

Turn the steering wheel to the left and fit the lower adjustment bolt to the attachment point for the shock absorber/wheel axle.

Position the bellows.

Fit the three bolts and tighten to 25 Nm .

Secure the wheel axle to the shock absorber.

Fig 9: Identifying Wheel Axle And Shock Absorber

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Fit the upper bolt.

Tighten the two bolts to 90 Nm .

Insert the brake pipe into the support and fit the lock clip.

Fit the ABS line to the support.

Connect the lead to the reversing light switch

Fig 10: Identifying Reversing Light Switch

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Clean the connector first.

Connect the gearbox ground cable

Fig 11: Identifying Gearbox Ground Cable

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Clean the contact surfaces thoroughly.

Fit the cable and tighten to 40 Nm .

Diesel cars: Fit the intercooler

Fig 12: Identifying Intercooler Bolts

Courtesy of VOLVO CARS OF NORTH AMERICA.

Position the intercooler and thread the three bolts.

Tighten the bolts to 25 Nm .

Fit the right-hand drive shaft and speedometer cable to the gearbox

Fig 13: Removing Right Hand Drive Shaft From Transmission (MT)

Courtesy of VOLVO CARS OF NORTH AMERICA.

If the drilled hole in the end pointing towards the gearbox is at the bottom (down in the space between two splines), the equivalent hole in the half-shaft must be at the top (crown), and vice versa.

Fit the two new locking pins to the drive shaft.

CAUTION: Seal the holes for the locking pins with sealant, part number 1161058-1.

Fit a new O-ring to the speedometer cable and tighten.

Insert the wire fully into the housing and fit a circlip.

Fit the wheel

Fig 14: Identifying Wheel Installation

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Check that the contact surfaces of the brake disc and brake pads are clean.

Grease the central hub guide pin in front of the brake pad with corrosion inhibitor, part number 1161038-3.

Position the wheel and loosely tighten the bolts.

Then tighten diagonally opposite bolts alternately to 110 Nm .

When tightening with a percussion wrench, torque socket 9512661 must be used.

Retighten by hand.

CAUTION: Tighten in crosswise sequence to the correct tightening torque to avoid stresses in the brake disc.

Fit the hub cap.

Fit the gear selector rod

Fig 15: Identifying Gear Selector Rod And Bolt

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Grease moving parts with Volvo grease, part number 1161241-3.

Check the rubber parts.

Position the gear selector rod and thread the bolt.

Tighten the bolt to 16 Nm .

Fit the central longitudinal member

Fig 16: Central Front-Rear Member

Courtesy of VOLVO CARS OF NORTH AMERICA.

Fit the engine mounting to the engine support point.

Fit the two bolts (correct size).

Fit the four bolts:

front: long bolts
rear: short bolts.

Tighten the bolts to:

on body side, 69 Nm
on engine side, 52 Nm .

First, tighten the rear bolts and then the front bolts.

Fit the heat shield

Fig 17: Identifying Heat Shield Bolts

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Position the heat shield and thread the first bolt (A).

Fit the two other bolts.

Tighten the bolts to 10 Nm .

Fill the gearbox with oil

Fig 18: Identifying Gearbox Filled With Oil

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Position a receptacle to catch any spills.

Remove the filler/level plug.

Fill the gearbox with oil, part number 1161681, up to the edge of the filler orifice.

Fit a new seal to the filler/level plug

Fit the filler/level plug and tighten to 1.75 Nm .

Fit the left-hand engine cover

Fig 19: Identifying Left-Hand Engine Cover Bolts

Courtesy of VOLVO CARS OF NORTH AMERICA.

Position the engine cover.

Fit the three bolts in order as shown.

Tighten the bolts to 17 Nm .

Gas engine cars: Fit the front engine protector

Fig 20: Mudflap And Screw

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Position the engine cover.

Secure the engine protector with bolts and screws. Tighten to 10 Nm .

Fit the pulse sensor

Fig 21: Identifying Pulse Sensor Bolts

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Position the sensor and fit the two bolts.

Tighten the bolts to 20 Nm .

Fit the hydraulic clutch cylinder to the gearbox

Fig 22: Identifying Hydraulic Clutch Cylinder

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Position the hydraulic clutch cylinder and pipe.

NOTE: Depress the piston as far as possible.

Fit the bolt to the support.

Remove the lock clip from the clutch cylinder.

Fit the two bolts.

Tighten the bolts to 30 Nm .

Insert the hose into the support and fit the lock clip.

Diesel cars: Fit the intercooler hoses

Fig 23: Identifying Intercooler Hoses

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Fit the two hoses and tighten the hose clips.

Fit the air filter

Fig 24: Identifying Air Filter

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Fit the air filter in a twisting movement and press the guide pin into the support.

Thread the two bolts and tighten to 10 Nm .

Check the hatch for the gearbox in the front wing.

Fit the inlet air hose

Fig 25: Identifying Ventilation Hose And Connector

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CAUTION: Check that the throttle plate moves freely of the strip clamp.

Gas engine cars:

Connect the hose and secure with two hose clips.

Connect hose (D) at the rear.

Plug in the connector (C).

Connect the crankcase ventilation hose (B).

Fit the crankcase ventilation hose by (A).

Fit the preheater hose.

Diesel cars:

Fit the air hose and secure it with hose clips.

Connect the air temperature sensor.

Attach the ventilation hose (B) to the crankcase.

Fit

Cable to the negative battery terminal
Engine protection plate, tightening torque 11 Nm .
Diesel cars: engine protection plate on underside.

Check:

Start the engine and check the function of the clutch.