Transmission - Control System & Fluids: Other Volvo S60 I

Clutch Slave Cylinder, Replacing

Note. As the graphics in this service information are used for different model years and/or models, some variation may occur. However, the essential information in the graphics is always correct.

Removing the Gearbox

Remove the transmission according to TRANSMISSION, REMOVING .

Scheme 1381

Remove

1. the bolts, x3
2. the clutch cylinder.

Clean the contact surfaces in the clutch housing.

Check for any leakage from the gearbox.

To replace the primary shaft seal, see Input Shaft Seal .

Checking the Clutch Cylinder And the Throwout Bearing

Clean the clutch cylinder.

Check the wear, play and noise in the throwout bearing. There must be no deep grooves on the flat surface which presses onto the clutch.

Check the wear and sealing integrity of the cylinder and the protective bellows. The clutch cylinder and pipe are replaced as a complete unit.

Installing the Clutch Cylinder

Install

1. the clutch cylinder
2. the bolts, x3 (M6).

Finishing

Install the gearbox. See TRANSMISSION, INSTALLING .

Checking the Gear System

Problems that the customer may experience are hard shifts or slipping shifts. The following test-drive contains several different driving situations that may provoke these symptoms if the transmission is damaged.

Note. It is important that the transmission oil is above 70°C before the test-drive starts

Test 1

1. Driving at 100 km/h, 6th gear.
2. Perform a kickdown to 4th gear.
3. Let the transmission automatically shift up to 5th gear.
4. Let up the accelerator pedal and let the transmission shift up to 6th gear.

Test 2

1. Driving at 100 km/h, 6th gear.
2. Slight uphill grade, press accelerator pedal until you obtain shifting 6-5, not kickdown.

Test 3

1. Driving at 80 km/h.
2. Move the gear selector to position M and engage 6th gear.
3. Perform a kickdown and shift 6-5, 5-4, 4-3 at the same time.
4. Then upshift immediately to 6th gear.

Test 4

1. Stationary vehicle, engine running, parking brake applied, brake activated with left foot, gear selector in position R.
2. Press down the accelerator pedal (brake still activated). NOTE: Let up the accelerator pedal in case of noise or slipping.

Test 5

1. Stationary vehicle, engine running, parking brake applied, brake activated with left foot, gear selector in position D.
2. Press down the accelerator pedal (brake still activated). NOTE: Let up the accelerator pedal in case of noise or slipping.

If the symptoms hard shifts or slipping shifts arise during the test-drive, the transmission's control system must be replaced.

1. See «Control System, Replacing»(ref-445684-S16721112252012010600000)

Is the function OK?

1. YES Refer to «Fault-Tracing Information»(ref-445684-S33539298232012010600000) .
2. NO Refer to «Transmission Control System, Replacing»(ref-445684-S16721112252012010600000) .

Fault-Tracing Information

The automatic transmission's shifting quality may in some cases be dependent on the engine's function. If the automatic transmission's shifting quality is poor, troubleshoot the engine system as well.

Transmission Control System, Replacing

Note. The graphics in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the graphics is always correct.

Checking Transmission Oil Level

Scheme 1382

The difference between MAX and MIN volume is 0.5 liters. Check oil temperature in transmission.

At room temperature (+20°C) the oil level is near the MIN mark on the "cold area".

At room temperature (+20°C) and low oil level the oil barely reaches the dipstick.

The "cold range" (+40°C) is reached after approximately 15 minutes idling in the workshop, while the "hot range" (+80°C) is reached after approximately 30 minutes highway driving at an air temperature above +15°C.

Note. The check should be carried out at an oil temperature of +80°C.

1. Flat surface
2. Parking brake set
3. Foot brake applied
4. Engine idling
5. Move gear selector to position P.

Move the Gear Selector Through All Positions, Stopping In Each Position For Approximately 3 Seconds

Return gear selector to position P and wait 2 minutes before checking oil level.

The dipstick must be pushed down completely into the dipstick tube.

Top Up With Oil Through the Dipstick Pipe

Take account of the temperature when topping up with oil. See Preparations .

High Level (Overfilling)

Note. The transmission must not be operated if the oil level is too high due to overfilling. This can cause increased operating temperatures and oil leakage.

Scheme 1383

Undo the drain plug.

Allow some of the oil to drain out and reinstall the plug. Tighten to 40 Nm .

Check the level taking account of temperature. See Checking Oil Level .

The oil can also be sucked out through the dipstick pipe using an oil suction syringe with a narrow gauge hose.

Note. Strict cleanliness is important.

Checking For Coolant In Oil

This fault may be due to coolant that has leaked into the transaxle.

Inspect according to Checking For Coolant In the Oil

If coolant is detected in the transaxle oil, the transaxle, radiator and hoses between the radiator and transaxle must be replaced.

Other information

1. See «Gearbox, Removing»(ref-445710-S13887594142012010600000)

Was a fault detected?

1. YES Troubleshooting has been completed.
2. NO Refer to «Information»(ref-445684-S04425476702012010600000)

The fault should have been detected and remedied. As this is not the case fault-tracing has failed.

Exit fault-tracing for this diagnostic trouble code (DTC) or make another attempt.

Checking the Oil Temperature Sensor

See Connecting the Breakout Box

Note. Do not damage components and terminals when test measuring. Handle components and terminals carefully.

Check 1

Connect an ohmmeter between #A7 and #A8 on the breakout box.

Start the engine and run it at idle speed to raise the temperature of the transmission.

For resistance values see the table below.

A test measurement must be taken at all three temperatures. This is to establish if the resistance is correct or not.

Checking the Input And Output Speed Sensors For the Transmission

Note. The transmission control module (TCM) must not be connected.

Connect the breakout box. See Connecting the breakout box

Note. Do not damage components and terminals when test measuring. Handle components and terminals carefully.

Check 1

Connect an ohmmeter between the sensor terminals on the breakout box. Check the resistance. The resistance must be more than 1 Mohms but not infinite.

For transmission input speed sensor

1. terminal #12 and #13 on the breakout box

For transmission output speed sensor

1. terminal #19 and #20 on the breakout box

Note. Check the resistance using an ohmmeter which can measure resistances above 10 Mohms.

If the resistance is 0 ohms it means that the cables are short-circuited to each other or that the sensor is faulty.

If resistance is infinite it means that there is an open circuit in the circuit.

Check the wiring. Measure the resistance between a terminal and a ground point.

If the resistance is 0 ohms it means that the cable has a short-circuit to ground.

If resistance is infinite it means that there is an open circuit in the circuit.

Check 2

Connect a temporary voltage supply to

transmission input speed sensor

1. terminal #A12 on the breakout box

transmission output speed sensor

1. terminal #A19 on the breakout box

Connect a temporary ground terminal via a 100 ohms resistor and an ammeter/voltmeter to

transmission input speed sensor

1. terminal #A13 on the breakout box

transmission output speed sensor

1. terminal #A20 on the breakout box

Move the gear selector lever to gear position N . Raise the vehicle so that the drive wheels hang freely. Measure the current/voltage while spinning the wheels in the same direction. For values see the table below.

Connectors, Transmission, Disconnecting/Connecting (AW55-50 and AW50AWD)

Note. As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information is always correct.

Scheme 1384

A. Transmission input and output speed sensors.

B. Gear-shift position sensor.

D. Oil temperature sensor solenoids: SLU, SLT and SLS.

C. Solenoids S1 - S5.

Unhook the mounting with the connectors for the transmission from the bracket for the air cleaner (ACL) housing.

Separate the connectors.

Preparations

Remove the air cleaner housing ACL assembly with the intake pipe. Pull the air cleaner (ACL) housing from its mountings.