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Servicing - A/t: Removal & Installation Volvo S60 I

Automatic Trans 4 illustrations ~762 words

REMOVAL & INSTALLATION

WARNINGVehicle is equipped with Supplemental Inflatable Restraint (SIR) system. When servicing vehicle, use care to avoid accidental air bag deployment. SIR system-related components are located in various locations throughout interior and exterior of vehicle, depending on application. Do not use electrical test equipment on or near these circuits. If necessary, deactivate SIR system before servicing components. See appropriate AIR BAG DEACTIVATION PROCEDURES article in GENERAL INFORMATION.
CAUTIONWhen battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.

Installation

Note. Take care not to damage the cable or sleeve by bending it excessively. Take care not to damage the cable boot.

Note. Be extremely careful when running the rubber bellow for the cable through the hole in the firewall. The cable must not be damaged.

Scheme 1

Scheme 1: Installation
Scheme 1: Installation

Scheme 2

Scheme 2
Scheme 2

Scheme 3

Scheme 3
Scheme 3
  1. Install the cable under the heater unit on left-hand side, down towards the hole. Feed a small amount of cable through the hole. see scheme 14 Locate the grommet on the studs. Install the nuts and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-157395-S15252561672003081200000).
  2. Feed the cable in from the inside. The cable must be routed past the steering gear and up to the transaxle bracket. Position the cable behind the steering gear and over the hydraulic pipes. (Scheme 1)
  3. Install the cable sleeve to the gear selector assembly. Install the cable to the gear selector and the catch. see scheme 13
  4. Install the center console in reverse order of disassembly. see scheme 12
  5. Install the gearshift cable on the transaxle. Move the gear selector to "P" position. Turn the lever on the transaxle to "P" position (the foremost position). (Scheme 2) Check that Park is engaged. Try to roll the car.
  6. Install the following: Lever on the gear shift linkage rod. Cable on the lever. Bolts for the bracket. see scheme 3 Tighten to specification.
  7. Check the shift positions. Turn ignition on. Shift the gear selector through all positions. Ensure that the letters and/or digits on the display on the combined instrument panel correspond to the shift positions on the top panel. (Scheme 3)
  8. Install the air cleaner housing assembly with the intake pipe and connector. see scheme 2 Install the front wheel.

Seal Replacement

  1. Remove the air cleaner housing assembly with the intake pipe. see scheme 2
  2. Remove the screws from the bracket for the gearshift cable. see scheme 3 Detach the cable from the lever using tool (999 7077). see scheme 4 Remove the cable from the bracket. Move the cable to one side.
  3. Remove the PNP sensor. Remove the following: Lever for the gear shift linkage rod. Nut, locking washer and rubber seal securing the gear-shift position sensor to the gear shift linkage rod. 2 bolts. see scheme 3 PNP sensor.
  4. Replace the sealing ring for the gearshift shaft. Remove the old sealing ring using a small rounded off screwdriver. (Scheme 4) Take care not to damage the rod. Apply A/T fluid on the new sealing ring. Install the ring using appropriate seal installer.
  5. Install the PNP sensor. Tighten the sensor screws lightly. Install the rubber washer, lock washer and the nut on the gear shift linkage rod connection. Tighten the nut. Lock the nut with the lock washer. Adjust the PNP sensor. See «PARK NEUTRAL POSITION SENSOR»(ref-157395-S15966739282003081200000) under ADJUSTMENTS.
  6. Carefully reinstall the cable on the lever pin and studs. see scheme 3 Ensure that neither the gear selector or lever change position. Install the nuts. Tighten alternately to specification. See «TORQUE SPECIFICATIONS»(ref-157395-S15252561672003081200000). Install the washer and the retaining clip on the lever. Install the cable in the clip on the connector bracket. Check adjustment. See «GEARSHIFT CABLE»(ref-157395-S41960181622003081200000) under ADJUSTMENTS.
  7. Install the air cleaner housing assembly with the intake pipe and connector. see scheme 2

Scheme 4

Scheme 4
Scheme 4

Removal

  1. Remove the air cleaner housing assembly with the intake pipe. see scheme 2
  2. Remove the screws from the bracket for the gearshift cable. see scheme 3. Detach the cable from the lever using tool (999 7077). see scheme 4 Remove the cable from the bracket. Move the cable to one side.
  3. Remove the PNP sensor. Remove the following: Lever for the gear shift linkage rod. Nut, locking washer and rubber seal securing the gear-shift position sensor to the gear shift linkage rod. 2 bolts. see scheme 3 PNP sensor.
  1. Install the PNP sensor. Tighten the sensor screws lightly. Install the rubber washer, lock washer and the nut on the gear shift linkage rod connection. Tighten the nut. Lock the nut with the lock washer. Adjust the PNP sensor. See «PARK NEUTRAL POSITION SENSOR»(ref-157395-S15966739282003081200000) under ADJUSTMENTS.
  2. Carefully reinstall the cable on the lever pin and studs. see scheme 3 Ensure that neither the gear selector or lever change position. Install the nuts. Tighten alternately to specification. See «TORQUE SPECIFICATIONS»(ref-157395-S15252561672003081200000). Install the washer and the retaining clip on the lever. Install the cable in the clip on the connector bracket. Check adjustment. See «GEARSHIFT CABLE»(ref-157395-S41960181622003081200000) under ADJUSTMENTS.
  3. Install the air cleaner housing assembly with the intake pipe and connector. see scheme 2

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