Transmission - Removal & Installation - A/t: Application Volvo S80 I

APPLICATION

TRANSAXLE APPLICATION

Scheme 3

Scheme 4

Scheme 5

Scheme 6

Scheme 7

Scheme 8

Scheme 9

Scheme 10

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Scheme 17

Scheme 18

Scheme 19

Scheme 20

Scheme 21

Scheme 22

Scheme 23

Scheme 24

Scheme 25

Scheme 26

Scheme 27

Scheme 28

Scheme 29

Scheme 30

Scheme 31

Scheme 32

Scheme 33

Scheme 34

1. Disconnect the battery leads.
2. Set the front wheels to the straight ahead position. Lock the steering wheel. Remove the upper bolt on the lower steering shaft. Expose the lower steering shaft from the upper steering shaft. (Scheme 3) Press up the upper steering shaft slightly for better access.
3. Remove the air cleaner housing. Pull the air intake backwards (towards the engine) so that it disconnects from it's mounting under the front cover plate. Disconnect the hose clamp for the air hose. Remove all the air hoses and connectors from the air cleaner. Remove the air cleaner housing front it's mountings. (Scheme 4) Pull it straight up.
4. On turbocharged models, carefully heat around the pipe at the charge air cooler (CAC). Use a hot air gun. Loosen and remove the pipe. (Scheme 5)
5. On all models, remove the upper torque rod. (Scheme 6) Remove the bolt for the oil hose clamp on the cross member mounting (right-hand side).
6. Remove the following: Plastic covers over the spring strut mountings (if applicable). Bolts. Bolt and nut for the engine mounting.
7. On turbocharged models, remove the charge air hose and the hose clamp. Undo the hose clamp at the twin pipe. Remove the hose from the twin pipe. (Scheme 7)
8. On all models, remove the transaxle cable from its mounting and the lever on the transaxle. Using appropriate pry bar, detach the ball joint for the gear selector cable from the lever.
9. Remove the gear selector cable from the bracket. Press the catch under the gear selector cable. Pull the gear selector cable out of the bracket.
10. Remove the connector from the transaxle (press the connector together). Pull it from the transaxle. Hang the gear selector cable from a tie strap around the brake pipes.
11. Remove the hose for the heater pipe. Disconnect the hose from the heater pipes at the firewall so that the pipe in the heater unit is not damaged when lowering the engine (the rubber hose is short). (Scheme 9)
12. Twist the catch on the hose connection. Pull the quick-release connector straight out. A small amount of water should run out. Tie the hose up.
13. Disconnect the ground strip.
14. Remove the dipstick from the dip stick pipe. Remove the oil using an oil suction device. Remove the bolt for the dip stick pipe by the engine mounting.
15. Remove the bolt from the sub-frame. Loosen the bolt for the clamp holding the oil pipe to the power steering. (Scheme 10)
16. Remove the boost pressure pipe. (Scheme 11) Loosen the upper bolt for the dipstick pipe. Loosen the bolt for the clamp around the turbocharger pipe. Open the clamp so that it is released from the turbocharger. Pull the turbocharger pipe from the turbocharger (push the pipe to one side).
17. Remove the following engine compartment components: Lower bolt for the dip stick pipe. Nut for the engine pad. Bolt for the splash guard plate (by the engine mounting).
18. Cut off the 4 tie straps holding the cable harness on the bracket. Disconnect the speed sensor connector.
19. Remove the dipstick. Pull the pipe straight upward out of the transaxle. Ensure that the "O" ring stays in place on the pipe.
20. Installing the lifting fixture bracket (999 7018) on the left hand side of the engine at the 2 bolts. Lock the fixture using the catch. (Scheme 12)
21. Remove the following: 3 bolts for the transaxle/engine. (Scheme 13) Bolt for the ignition setting sender (lift up the ignition setting sender). 2 bolts for the starter motor. Remove the starter motor. Ground lead bolt under the starter motor. Bolt for the clamp holding the positive cable on the engine.
22. Tie the hoses and the cable harness to the intake manifold.
23. Remove the nut for the positive cable and the switch on the starter motor. Remove the bolt at the bracket for the starter motor. (Scheme 14)
24. Remove the bolts from the torque converter. Loosen and remove the bolts in the cut-out between the engine and the transaxle from below. (Scheme 15) Turn the engine using a boltdriver in the cut-out under the transaxle.
25. Installing the lifting beam and lifting hook on the engine lifting eyelet. Position the stand for lifting beam (999 5716) on the upper wheel arch members. Position the lifting beam directly above the engine lifting eyes on both sides. (Scheme 16) Connect lifting hook (999 5460). Tighten to light contact.
26. Raise the car. Position the front lift arms so that they do not obstruct the sub-frame support plates.
27. Remove the front wheels. Remove the splash guard under the engine. Remove both the bolts for the front splash guard. Remove the cover. Press in the catches at the front edge of the cover. (Scheme 17) Pull the cover backwards.
28. Remove the bolts for the cable conduit and ground lead bracket on the sub-frame. Remove the bolt for the front engine pad. (Scheme 18) Remove the bolt for the torque rod in the transaxle.
29. On models equipped with parking heaters, remove the nuts for the heater from the sub-frame. Hang the heater on the left front fender.
30. On all models, remove the nut for the lower ball joint and control arm. Clean the exposed threads outside the nut. Use rust solvent before removing the nut. Using Torx TX 40 socket, hold the ball joint pinion when removing the nut. (Scheme 19)
31. Remove the control arms for the anti-roll bar, the tie rod and the bolt from the axle shaft on both sides. (Scheme 20) Remove the link for the anti-roll bar up at the spring strut. Hold using Torx 30 socket. Ensure the rubber boot is not be twisted. Remove the tie rod from the wheel spindle. Remove the nut for the axle shaft.
32. Remove the bolts from the sub-frame support plates (both sides). (Scheme 21) Position screw jack stand (light contact) under the right-hand side of the sub-frame. Loosen both the sub-frame bolts approximately 5 turns. Lower the sub-frame so that it rests on the screws and the screw jack.
33. Remove the wheel spindle from the control arm. Pry the control arm with a crowbar. (Scheme 22) At the same time, lift the wheel spindle off the control arm. Install socket (999 5562) on the wheel spindle ball joint. Do not damage the rubber bellow for the ball joint.
34. Press up the sub-frame on the right-hand side. Tighten the sub-frame bolts to light contact, then loosen the bolts approximately 4-5 turns. Move the screw jack to the left hand side.
35. Remove the axle shaft from the wheel spindle (right-hand side). See appropriate AXLE SHAFTS article in DRIVELINE/AXLES. Remove the axle shaft from the wheel spindle (right-hand side). Take hold of the axle shaft. (Scheme 23) Pull it down towards the control arm so that it does not tension.
36. Pull the brake disc outwards. At the same time, pull on the constant velocity joint towards the transmission so that the axle shaft loosens. Allow the axle shaft to lie on the control arm. Some models have a rubber seal on the constant velocity joint (both sides). Use care not to damage the seal.
37. Remove the cap for the axle shaft support bearing. (Scheme 24) Remove the bolts for the bearing cap.
38. Unhook the servo pipe and the evaporator pipe from the holders on the right-hand side of the sub-frame. Unhook the servo pipe from the clip on the sub-frame.
39. Take hold of the inner constant velocity joint. Pull the axle shaft straight out of the transmission. Remove the axle shaft from the viscous coupling using pry bar. See appropriate AXLE SHAFTS article in DRIVELINE/AXLES.
40. Remove the nuts and the bolts from the steering gear sub-frame. (Scheme 25)
41. Remove the front cross member. Drill out the pop rivets for the heat deflector. Remove the following: 4 bolts by the front cross member. (Scheme 26) Bolts for the exhaust pipe mounting in the front crossmember. Brake pipe from its holder in the crossmember.
42. Remove the center and rear crossmembers. (Scheme 27) Loosen the bolts for the crossmembers. Remove the 2 bolts for each member. Let them hang down.
43. Remove the bracket for the heated oxygen sensor (HO2S) wiring. Remove the bolts for the bracket in the sub-frame holding the heated oxygen sensor (HO2S) cable. (Scheme 28) Push the bracket to one side. Disconnect the connectors from the sub-frame. Disconnect the heated oxygen sensor (HO2S) wiring from the sub-frame.
44. Position jack stand under the sub-frame. Remove the sub-frame bolts. Lower the sub-frame so that the left ball joint detaches. Install socket (999 5562) on the wheel spindle ball joint.
45. Remove the axle shaft from the wheel spindle (left-hand side). Take hold of the axle shaft. Pull it down towards the control arm so that it does not tension.
46. Pull the brake disc outwards. At the same time, pull on the constant velocity joint towards the transaxle so that the axle shaft loosens. Allow the left axle shaft to lie on the control arm. Some models have a rubber seal on the constant velocity joint (both sides). Use care not to damage the seal.
47. Remove the left axle shaft from the transaxle. See appropriate AXLE SHAFTS article in DRIVELINE/AXLES. CAUTION: The steering shaft must not slide out of the rubber boot.
48. Lower the sub-frame approximately 5.5" (140 mm). Hang the steering gear from a tie strap. (Scheme 29) Carefully lower the sub-frame. Let it hang free. Ensure that the bolts for the steering gear on the left side release from the frame.
49. Remove the engine pad on the left side between the bodywork and the three-way catalytic converter. (Scheme 30)
50. Remove the rear engine mounting. Loosen the 4 bolts for the engine mounting. (Scheme 31) Twist out and remove the engine mounting.
51. Remove and cap off the oil pipes from the transaxle. Remove the nuts from the brackets for the oil pipes. Remove the bolt nipples. (Scheme 32) Hold at the connections. Pull out the oil pipes. Move the oil pipes to one side. Lower the car. CAUTION: Ensure that the engine mounting is not against the exhaust boot and is not trapped.
52. Lower the engine/transaxle on the left-hand side using the hook. Lower the engine so that the distance between the upper edge of the mounting bracket and the spark plug cover is approximately 13.75" (350 mm).
53. Raise the car. Remove the heated oxygen sensor (HO2S) connectors from the bracket on the transaxle. (Scheme 33) Disconnect the connectors from the bracket. Remove the nut on the bracket and the clamp holding the wiring.
54. Remove the 2 nuts for the fender liner. Angle out and tie up the fender liner to the lifting beam using a retaining strap. (Scheme 34) Remove the ABS line from the spring strut.
55. Locate appropriate transmission jack with fixture on the transaxle.
56. Remove the 2 bolts (on the bracket) at the cover for the differential housing. Remove the 2 bolts positioned furthest in and highest up at the engine/transaxle. Remove the remaining 4 bolts for the engine/transaxle.
57. Pull the transaxle straight out in relation to the engine. Lower the transaxle slightly when it is being removed so that it will go past the side member. Continue pulling the transaxle straight out. Ensure that the torque converter is also removed.

Scheme 35

Scheme 36

Scheme 37

1. Ensure that the transaxle and engine mating surfaces are clean. Check that the guide sleeves towards the engine are in position and are free of faults. Lubricate the holes in the transaxle (for the guide pins).
2. Adjust height and angle with the screw jack and the transaxle fixture. Locate the transaxle on the engine. Ensure that the transaxle goes straight in relation to the engine and that the torque converter is in the correct location. If necessary, turn the engine so that the stator shaft is correctly aligned in the torque converter.
3. Install all 6 bolts for the transaxle and engine. Check that the entire transaxle is in contact with the engine. Tighten the transaxle/engine bolts in crisscross patter. Tighten to bolts to specification. See «TORQUE SPECIFICATIONS»(ref-156407-S05499048902003071600000).
4. Remove the transmission jack and fixture from the transaxle. Install the 2 bolts on the bracket at the cover for the differential housing.
5. Install the splash guard above the transaxle. Slide the splash guard up and secure it with a bolt at the right axle shaft. (Scheme 35) Illustration shows the splash guard when the three-way catalytic converter (TWC) is not in position.
6. Install the heated oxygen sensor (HO2S) connectors to the bracket on the transaxle. (Scheme 33) Connect the connectors. Secure the connectors on the bracket. Install the clamp with the wiring on the transaxle. Lower the car.
7. Lift up the engine and transaxle to the horizontal position. Install the oil pipes on the transaxle. (Scheme 32) Tighten the bolt nipples to specification. See «TORQUE SPECIFICATIONS»(ref-156407-S05499048902003071600000). Tighten the nuts at the bracket.
8. Install the rear engine mounting. Install the rear engine mounting on the transaxle. Install the 4 bolts for the engine mounting. (Scheme 31)
9. Install the engine cover. Insert the engine pad between the bodywork and the three-way catalytic converter. (Scheme 30) Secure the heat shield on the engine pad so that it is against the three-way catalytic converter.
10. Install the engine pad on the engine mounting. Take out the nut, a short extension bar and a socket. Insert the nut into the socket so that it remains in place. Insert the extension bar up to the collision protection system using your left hand. (Scheme 36) Move up the engine pad to the engine mounting. Place the nut on the engine pad. Tighten the nut from above.
11. Install the sub-frame on the bodywork. Lubricate the NEW bolt threads. When the sub-frame is raised, ensure that the bolts for the steering gear locate in the frame. Remove the hook/straps. Use the bolt jack to lift the frame towards the bodywork until the frame is approximately 3.9" (10 cm) from the bodywork.
12. Install the bolt for the rear engine pad through the steering gear.
13. Install the right axle shaft on the transaxle, wheel spindle and control arm. See appropriate AXLE SHAFTS article in DRIVELINE/AXLES. Ensure that the rubber seal is in position on the constant velocity joint.
14. Align the axle shaft in the wheel arch. Install the bolt loosely in the axle shaft. Install the jack stand under the sub-frame. Remove both the sub-frame bolts. Lower the sub-frame approximately 3.9" (10 cm). Install the wheel spindle on the control arm. Install the lock nut loosely.
15. Lift the sub-frame to the bodywork. Install the bolts for the frame. Press the evaporator cable and the oil pipe into place in the sub-frame clips.
16. Install and tighten the sub-frame bolts. (Scheme 37) Install the bolts for the support bracket. First tighten the frame bolts to 77 ft. lbs. (105 Nm). Tighten bolts an additional 120°. Then tighten the frame bracket bolts to specification. See «TORQUE SPECIFICATIONS»(ref-156407-S05499048902003071600000).
17. On models equipped with parking heaters, install the parking heater in the bracket.
18. Install the bolts for the bracket for the heated oxygen sensor (HO2S) cable. Install the bolts for the bracket. (Scheme 28) Install the connectors in the sub-frame. Connect the connectors.
19. Install the front cross member. Install the bolts for the exhaust pipe mounting. Install the brake pipe in its holders. Install the bolts for the cross member. (Scheme 26) Secure the heat deflector using rivets (early version).
20. Install NEW lock nuts on the steering gear. Tighten the nuts and bolts. (Scheme 25) Tighten the bolt and the clamp for the oil pipe.
21. Install the bolt for the front engine pad. Install the torque rod mounting on the transaxle. Install the bolts for the cable conduit and the ground lead bracket. (Scheme 18)
22. Reinstall the fuel line in the clips on the sub-frame.
23. Install and tighten front end components (both sides). Install NEW nut for the tie rod. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-156407-S05499048902003071600000).
24. Tighten the axle shaft nut. See appropriate AXLE SHAFTS article in DRIVELINE/AXLES.
25. Install NEW nut for the anti-roll bar link at the spring strut. Hold the ball joint pinion when tightening the anti-roll bar link so that the ball joint boot cannot turn.
26. Tightening the ball joint pinion. Hold the ball joint pinion while tightening so that the ball joint boot cannot turn. (Scheme 19)
27. Remove the lifting beam and the lifting hook from the engine and the car. Lower the car. Remove the lifting fixture from the motor. Install the ground strap.
28. Install NEW torque converter bolts. (Scheme 15) Install all 6 bolts loosely. Tighten the bolts until the heads are in contact with the carrier plate, then tighten to specification. See «TORQUE SPECIFICATIONS»(ref-156407-S05499048902003071600000).
29. Install the clamp for the oil pipe. Install the bolt and clamp.
30. Install the charge air hose. Reinstall the rubber hose for the delivery pipe. Tighten the hose clamp.
31. Install the 3 bolts for the transaxle and engine. (Scheme 13) Install the ignition setting sender and the bolt. Install the bolt for the clamp for the positive cable.
32. Install the starter motor. Install the positive cables and the connector. Install the nut for the positive cables. (Scheme 14) Install the bolt for the bracket.
33. Install the dip stick pipe in the transaxle using a new rubber seal. Apply petroleum jelly on the rubber seal. Carefully check that the rubber seal is correctly positioned in the transaxle.
34. Install the bolt for the splash guard. Install the engine pad. Install the turbo pipe to the turbocharger. Tighten the clamp. Install the lower bolt for the oil pipe. Install the upper bolt for the oil pipe. Install the connector. Install the tie strap around the electrical wiring.
35. Install the hose for the heater pipe. Install the hose on the heater pipe in the firewall. (Scheme 9) Press the radiator hose quick-release connector into place on the heater pipe. Check installation by pulling on the hose.
36. Install the transaxle cable on the transaxle and the lever. Install the ball joint for the gear selector cable on the lever. Install the gear selector cable in the bracket. Install the connector for the transaxle. Press the connector into place properly. Install the connector for the ABS unit.
37. Install the engine stabilizer brace. (Scheme 6) Tighten the mounting bolts to specification. See «TORQUE SPECIFICATIONS»(ref-156407-S05499048902003071600000). Install the bolt and a new nut for the engine mounting. Install the plastic guard over the spring strut (if applicable). Tighten the bolts.
38. Install engine compartment components. Install the integrated relay/fusebox in the bracket.
39. Install the air cleaner housing. (Scheme 4) Connect all the air hoses and connectors to the air cleaner housing. Tighten the hose clamp. Fold the air intake in under the front cover plate. Locate it in its mounting and press it into place. The positioning of the air intake can be seen through an oblong hole in the front cover plate.
40. Fill transaxle with fluid. See appropriate SERVICING article.
41. Check the coolant level in the expansion tank. Top up with water and coolant as necessary (when the engine is at operating temperature). Raise the car. Check that there is no oil leakage at the transaxle or at the dipstick.
42. Install the ABS cable on the mounting. Install the front splash guard under the engine. (Scheme 17) Install the nut for the left fender liner. Install the front wheels. Lower the car.
43. Assemble the upper and lower steering shaft. (Scheme 3) Pull the upper steering shaft down. Assemble the upper steering shaft with the lower steering shaft. Install NEW bolt and the nut. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-156407-S05499048902003071600000).
44. Check the steering gear bearing in the boot at the firewall. Check that the steering gear bearing in the boot has not detached from the boot. (Scheme 38) Press the bearing back down into the boot. Check that the rubber boot is positioned correctly in the body. Adjust if necessary. Lift up the outer section of the rubber boot.
45. Install the battery leads.

Scheme 38