Transmission - Replacing: Maintenance Volvo S60 I

Cleaning and lubricating the input shaft

The input shaft must be lubricated before a manual transmission is installed. See Input shaft, cleaning .

Scheme 1499

Check that the transmission and engine mating surfaces are absolutely clean.

Check that the guide sleeves towards the engine are in position and are free of faults.

Lubricate the holes in the transmission (for the guide pins and the starter motor). Use a little grease.

Scheme 1500

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

Locate the transmission on the engine.

Ensure that the transmission goes straight in, in relation to the engine, and that no deviation occurs in the clutch driven plate center.

Guide the transmission cover onto the guide sleeves on the engine and the starter motor.

Scheme 1501

Install the 6 screws for the transmission - engine.

Tighten the screws alternately and crosswise to light contact.

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

Following which, tighten the M10 screws crosswise.

Remove the fixture from the transmission.

Lower the car.

Scheme 1502

Install

1. the 4 x M10 screws for the transmission/engine
2. the M10 screws for the starter motor.

Position the coolant hose inside the hose for the EGR cooler.

Scheme 1503

Lift the engine and transmission to slightly above horizontal for better access when installing the engine pad on the engine mounting.

Raise the car.

Scheme 1504

Install

1. the rear engine mounting and the engine pad together with the heat deflector plate. Hold the engine pad limiter (cable) in place during installation. Use a tie strap
2. the 3 x M10 screws for the engine mounting
3. the screw for the steering gear - engine pad loosely.

Check, and if necessary align, the bearing for the steering shaft in the boot when installing the steering gear. See Installing the gearbox .

Scheme 1505

Install the charge air pipe and the hose, M7, on the turbocharger (TC) and engine.

Scheme 1506

Note. Replace the sealing ring if it is damaged or worn.

Clean around the constant velocity joint before installing the sealing ring.

Carefully install the sealing ring. Ensure that the sealing ring is correctly positioned on the drive shaft.

Scheme 1507

Note. Ensure that the seal is in place on the drive shaft.

Install the sealing ring for the constant velocity joint housing. See Installing the sealing ring for the CV joint housing on the wheel spindle .

Press in the constant velocity joint housing firmly so that the snap ring engages in its groove in the transmission. Pull the constant velocity joint to check that the drive shaft is secure.

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

Scheme 1508

Start on the left-hand side.

Raise the subframe with the mobile jack 9985972 .

Locate the steering gear screws in the subframe.

Install the subframe and support bracket screws, start on the left-hand side followed by the right. See appropriate service information for torque specifications.

Move the mobile jack to the right-hand side. Remove the existing screws and repeat the operation.

Scheme 1509

Install the cap for the support bearing for the drive shaft. Tighten.

Note. Ensure that the seal is in place on the drive shaft.

Install the sealing ring for the constant velocity joint housing. See Installing the sealing ring for the CV joint housing on the wheel spindle .

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 under the right-hand side of the sub-frame with light contact. Remove both sub-frame screws.

Scheme 1510

Install

1. the screws for the front/rear engine pad. Tighten the front and rear screw
2. the torque rod bracket to the transmission. Tighten. See appropriate service information for torque specifications. NOTE: Use new screws.

Scheme 1511

Applies only to right-hand drive cars

Install both the screws. Tighten.

Scheme 1512

Align the steering joint on the steering gear. Install the new steering shaft screw. Tighten. See Tightening torque .

Connect the cable to the stepper motor/solenoid.

Scheme 1513

Check the tie rod position according to the measurement noted earlier.

Scheme 1514

Use oil of the right grade.

Fill with transmission oil, Volume 2.1 liters.

Tighten the filling plug. See Tightening torque .

Scheme 1515

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

Tighten the drive shaft screw. Use a new screw.

Counterhold using a crow bar in the brake disc.

Install

1. the link for the anti-roll bar. Counterhold the ball joint pinion while tightening so that the ball joint boot cannot turn. Use a new lock nut. Tighten. See
2. the nut for the steering arm.
3. the ABS line in the mounting in the spring strut
4. the fender liner with the support plate and nuts and the soundproofing over the drive shaft.

Scheme 1516

Install

1. the cable duct to the sub-frame, M6
2. the additional heater / parking heater on the mounting in the sub-frame
3. the fuel line in the holders in the sub-frame
4. the splash guard under the engine
5. the wheels. See «Installing wheels»(ref-415307-S16574462602011081500000) .

Scheme 1517

Install

1. catalytic converter bracket, M8
2. rubber mounting for the bracket
3. front member
4. bracket pipe in the holders
5. screws on the frame and rear cross members, M8.

Filling the transmission with fluid

Note. Oil grade: Only ATF-oil Dexron III (with G-license). Transmission oil, Volvo part no. 116 1521-8 (1 liter), 116 1621-6 (4 liters).

Note. Filling oil: Start by filling with 5.5 liters of oil.

Scheme 1518

Note. Filling oil: Start by filling with 5.5 liters of oil.

Fill the transmission with oil. Use a funnel with a plastic hose. Fill through the dipstick pipe.

Clear up any oil spillage under the dip stick pipe.

Scheme 1519

Note. Filling oil: Start by filling with 5.5 liters of oil.

Use a converted five liter plastic can (see the illustration).

This method avoids oil spillage. It also provides a more regular flow when filling.

To check the oil level , see: Oil level, checking .

Note. After replacing the transmission, the transmission's adaption as well as the counter for "Transmission oil, change" shall be reset. Use VIDA Vehicle communication to reset the adaption and the counter.

Scheme 1520

Top up with water and coolant as necessary (when the engine is at operating temperature).

Check the level in the servo oil reservoir and top up if necessary.

Raise the vehicle.

Check that there is no oil leakage at the transmission, the dip stick or at the steering gear.

Scheme 1521

Install

1. The ABS-cable on the mounting
2. the splash guard under the engine
3. the front splash guard
4. the nut for the left fender liner.

Lower the vehicle

Scheme 1522

Check that tie rod is in the same position as when it was removed.

Install

1. the wheels. See: «Installing wheels»(ref-415307-S16574462602011081500000) .

Lower the vehicle.

Scheme 1523

Install the steering shaft joint on the steering gear and steering shaft.

Install a new screw. Tighten.

Scheme 1524

Check that the steering gear bearing in the boot has not detached from the boot.

If it has become detached apply a little grease to the edge of the boot (around the hole). Press the bearing back down into the boot. See arrow in illustration.

Scheme 1525

Reinstall the steering shaft boot and snap ring.

Fold back the carpet.

Draining coolant

Remove

1. the front splash guard
2. the splash guard under the engine
3. the front wheels.

Position a container under the radiator. Drain off the coolant by opening the nipple on the radiator and the cylinder block. Close the nipples.

Remove

1. the front splash guard
2. the splash guard under the engine
3. the front wheels.

Position a container under the radiator. Drain off the coolant by opening the nipple on the radiator and the cylinder block. Close the nipples.