Servicing - A/t: Other Volvo S60 I

Cold Transaxle

Transaxle fluid temperature should be approximately 105°F (40°C). This is the normal temperature for a transaxle that has been idling for about 15 minutes. Check fluid level on COLD side of the dipstick. Fluid level should be MINIMUM and MAXIMUM ridges. (Scheme 5) If fluid temperature is colder than specification, fluid level may be lower on the dipstick.

Warm Transaxle

Transaxle fluid temperature should be approximately 169°F (80°C). This is the normal temperature for a transaxle that has been driven for about 30 minutes. Check fluid level on HOT side of the dipstick. Fluid level should be MINIMUM and MAXIMUM ridges. If fluid temperature is above approximately 190°F (90°C), fluid level may be above the MAXIMUM ridge on the dipstick.

Checking Procedure

Park vehicle on level surface with engine at idle. Move gear selector through all gear positions. End in "P" position. Allow engine to idle in Park for 3 minutes. Check fluid level on dipstick. (Scheme 5) Ensure fluid level is correct for transaxle temperature. If needed, add additional fluid through dipstick tube. The space between the MINIMUM and MAXIMUM ridges corresponds to about.5 qt. (.5 L). DO NOT overfill transaxle.

Scheme 5

ON-VEHICLE REPAIRS

Note. Various components may be serviced without transaxle removal. For servicing of these components, see appropriate component under ADJUSTMENTS and/or REMOVAL & INSTALLATION . For additional information on testing electrical components, see appropriate DIAGNOSIS article.

GEARSHIFT CABLE

Note. See GEARSHIFT CABLE under REMOVAL & INSTALLATION.

PARK NEUTRAL POSITION SENSOR

Note. Park Neutral Position (PNP) sensor may also be known as gear shift position sensor.

1. Remove the air cleaner housing assembly with the intake pipe. (Scheme 6)
2. Remove the screws from the bracket for the gearshift cable. (Scheme 7) Detach the cable from the lever using tool (999 7077). (Scheme 8) Remove the cable from the bracket. Move the cable to one side. NOTE: When adjusting the PNP sensor, press the tool down to the flat surfaces below the thread on the shaft.
3. Check the setting of the PNP sensor. Remove the lever. Install Adjustment Tool (999 5475) on the gear shift linkage rod. (Scheme 9) Check that the shaft is in the "N" position. The groove on the tool must align with the marking on the PNP sensor. If adjustment is required, go to next step. If PNP sensor is adjusted correctly, go to step 5.
4. Remove the nut for the cable duct. Lift the cable duct away from the screw. Loosen the screws for the PNP sensor. (Scheme 10) Rotate the PNP sensor so that the mark on the switch aligns with the groove on the tool. Tighten the sensor bolts to specification. See «TORQUE SPECIFICATIONS»(ref-157395-S15252561672003081200000).
5. Remove the adjustment tool.
6. Install the following: Lever on the gear shift linkage rod. Cable on the lever. Bolts for the bracket.
7. Install the air cleaner housing assembly with the intake pipe and connector. (Scheme 6)

Scheme 6

Scheme 7

Scheme 8

Scheme 9

Scheme 10

Note. Gearshift cable may also be known as gear selector cable.

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Scheme 17

Scheme 18

1. Remove the air cleaner housing assembly with the intake pipe. (Scheme 6) Remove the left front wheel.
2. Remove the screws from the bracket for the gearshift cable. (Scheme 7). Detach the cable from the lever using tool (999 7077). (Scheme 8) Remove the cable from the bracket. Move the cable to one side.
3. Remove the center console. Slide the seat backwards and downwards. Fully apply the parking brake. Shift the gearshift lever to neutral.
4. Remove the pen holder. Unclip both sides using weatherstrip tools. (Scheme 11) Use care not to mark the edge of the dashboard. Carefully insert the weatherstrip tools between the dashboard panel and the short side of the pen holder.
5. Remove the side panel. Move the front seat to the rearmost position. Turn the clips a quarter turn using a washer or a coin. (Scheme 12) Slide the panel backwards. Remove the panel. Unsnap the nozzle.
6. Remove the selector panel. Move the gear selector to a rear position. Release the catches at the front edge. Lift the front edge of the panel. Lift up the panel.
7. Remove the coin holder/CD storage compartment in the rear center console locker. (Scheme 13) Pull the coin holder straight up. Detach the CD compartment by releasing the catch at the front edge. Lift straight up.
8. Remove the parking brake panel. Open the armrest hatch and the cover on the cup holder. Thread the boot over the parking brake lever. (Scheme 14)
9. Remove the rear ashtray. Open the ashtray so that it passes the hooks. Release the catches on one side using a screwdriver. (Scheme 15) Pull the same side straight out. Carry out the above procedure on the other side. Remove the connector.
10. Separate the cable harness at the rear edge of the center console. Loosen the 2 screws at the front edge of the center console and the 2 screws at the rear edge. (Scheme 16) Carefully lift the front edge of the center console. Then lift the rear edge and slide the center console over the parking brake.
11. Remove the gearshift cable from the gear selector assembly. Move the gear selector to "P" position.
12. Remove the catch for the cable on the gear selector. Remove the cable from the gear selector assembly using a screwdriver. (Scheme 17) Remove the cable.
13. Remove the 2 nuts for the transaxle cable grommet at the firewall (cowl). Remove the cable by pulling it inwards into the passenger compartment. (Scheme 18)

GEARSHIFT SHAFT SEAL

Note. Gearshift shaft may also be known as gear-shift linkage rod.

PARK/NEUTRAL POSITION SENSOR

Note. Park Neutral Position (PNP) sensor may also be known as gear shift position sensor.