Transmission - Installation: Other Volvo S60 I

Transaxle, Installing

Special tools

9512050

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

Note. For tightening torques, see: Tightening torque .

Installing the Transmission

Before installing the transmission it is very important that the checks and cleaning have been carried out. See TRANSMISSION, PREPARATIONS BEFORE INSTALLING .

Scheme 1708

Adjust height and angle with the mobile jack and the transmission fixture.

Locate the transmission on the engine.

Note. Make sure that the gearbox goes straight in relation to the engine and that the guide sleeves and locating pin for the starter motor fit into the guide holes on the gearbox.

Scheme 1709

Install the 6 M10 screws securing the transmission to the engine.

First tighten alternately and crosswise to light contact.

At the same time, check that the whole of the transmission is in contact with the engine.

Then tighten the screws to light contact crosswise to the transmission/engine. Tighten.

Remove the fixture from the transmission.

Scheme 1710

Note. Use new screws, Torx TX50.

Align the torque converter to the carrier plate, by turning the engine with the nut for the crankshaft's belt pulley and turning the torque converter.

Install all 6 screws, loosely. Tighten in the screws so that the screw heads almost have contact with carrier plate. Tighten according. to: Summary Of Tightening Torques For Specific Components .

Note. Remove the socket wrench from the crankshaft.

Scheme 1711

Lift up the engine/gearbox. Check that the engine/gearbox is in horizontal position.

Raise the vehicle.

Scheme 1712

Install

1. the rear engine mounting, 3 x M10, to the gear box. Tighten
2. the screw for the engine pad, loosely.

Scheme 1713

Note. Before installing the bevel gear, the splined joint between the transmission and the bevel gear must be lubricated with grease.

Lubricate the splined joint between the transmission and the bevel gear. Use grease. See Splines Greasing .

Check that the contact surfaces on the gearbox and the angle gear are clean.

Install the charge-air pipe with hose to the turbocharger.

Install the bevel gear and tighten the 7 M10 screws.

Scheme 1714

Reinstall the bracket and tighten the 4 M10 screws.

Scheme 1715

Install the charge air pipe on the engine and the hose on the turbocharger (TC).

Scheme 1716

Use new O-rings.

Install the oil pipes. Tighten according. to Summary Of Tightening Torques For Specific Components .

Scheme 1717

Press in the constant velocity joint housing firmly so that the snap ring engages in its groove in the transmission.

Check by pulling in the joint housing.

Locate the drive shaft in the wheel hub. Install a new screw loosely in the drive shaft.

Scheme 1718

Note. Use new screws. Lubricate the screw's threads.

Applies to certain models.

Lift up the sub-frame until it is about 150 mm from the side member.

Secure the power steering pipe at the front edge of the upper side of the sub-frame using the rubber covered clamp. Install the screw. Finger tighten.

Note. When the subframe is raised, make sure that the screws for the steering gear locate in the frame. Make sure that the ball joint pinion for the spring strut is aligned in the control arm.

Install

1. the new screws and the support bracket at the rear edge
2. the bracket screws loosely.

Tighten the sub-frame screws to light contact.

Remove the mobile jack

Scheme 1719

Fit the bearing cap to the drive shaft support bearing, 2x M8.

Tighten.

Locate the drive shaft in the wheel hub. Install a new screw loosely in the drive shaft.

Depress the control arm and align the spring strut ball joint pinion in the control arm.

Position the mobile jack lightly applied under the right side of the sub-frame.

Remove both the sub-frame screws.

Install

1. new screws in the sub-frame NOTE: Lubricate the screws' threads.
2. the screws loosely in the support plate at the rear.

Tighten the sub-frame screws to light contact.

Remove the mobile jack

Scheme 1720

First tighten the sub-frame's screws on the left side, then on the right according. to

Use: 9512050 .

Then tighten the 4 pieces. M10 screws for the sub-frame brackets.

Scheme 1721

Install

1. the screws, M10, to the front and rear engine pads. Tighten.

Note. Use new screws.

1. the torque rod mounting on the transmission.

Tighten according to Tightening torque

Scheme 1722

Align the steering wheel shaft joint on the steering gear.

Install a new steering wheel shaft screw. Tighten according. to: Tightening torque .

Connect the cable to the stepper motor/solenoid.

Check the position of the tie rod in the steering gear according. to: Transmission, removing

Scheme 1723

Note. Applies only to right-hand drive vehicles.

Fit the screws, 2 x M12. Tighten.

Scheme 1724

Install

1. the front crossmember and the brake pipe in their holders
2. the rear cross member

Tighten all M8 screws.

Scheme 1725

Fit the nut to the ball joint pin. Counterhold the ball joint pin while tightening so that the gaiter does not turn. Use a new nut, M12.

Tighten according to Summary of tightening torques for specific components

Tighten the drive shaft screw. Use a new screw.

Counterhold the brake disc with a screwdriver. Tighten according. to: Summary of tightening torques for specific components

Use: 9512050 .

Fit on the left-hand side

1. the link to the anti-roll bar. Counterhold the ball joint pin while tightening so that the gaiter does not turn. Use a new lock nut. Tighten according. to: «Summary of tightening torques for specific components»(ref-415459-S09555248762011081500000)
2. the tie rod. Tighten. See: «Summary of tightening torques for specific components»(ref-415458-S18638818192011081500000)
3. the ABS line to the bracket in the spring strut
4. the wing liner with support plate and nuts.

Scheme 1726

Install

1. auxiliary heater/parking heater to the bracket in the sub-frame and the fuel line to the brackets (if fitted to the vehicle)
2. the front splash guard
3. the splash guard under the engine
4. the wheels. See «Installing wheels»(ref-415307-S16574462602011081500000) .

Scheme 1727

Lower the vehicle.

Remove the lifting beams and hooks from the engine.

Scheme 1728

Install the heater.

Scheme 1729

Install

1. the 4 pieces M10 screws for the transaxle/engine. Tighten
2. the 2 pieces. M10 screws, for the transmission/starter motor. Tighten.

Scheme 1730

Install

1. the gear selector cable
2. the cable bracket to the transmission
3. the connection for the Transmission control module (TCM)
4. the ground lead
5. clamp for the coolant hoses (applies to vehicles with fuel heater)

Scheme 1731

Install

1. the hose between the inlet pipe and charge-air cooler to the inlet pipe
2. the nut that holds the inlet pipe.

Scheme 1732

Install

1. the exhaust gas recirculation (EGR) module. See «EGR Mixer/Gasket, Replacing»(ref-445721-S29711790062012010600000)
2. the torque rod. See «Brake Fluid Reservoir, Replacing»(ref-445687-S41446732372012010600000)

Installing the Battery Cable

Connect the battery lead. First read Battery, Disconnecting

Check

Carry out checks after working on the transmission. See TRANSMISSION REPLACEMENT, POST-CHECKING .

Note. This step is only necessary when installing a new component.

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