Home/Volvo/S80/Volvo S80 I (1998-2003)/Repair manual/Transmission - Servicing - A/t (4T65EV)/Method 1

Contents

Wiring diagrams Section: Transmission - Servicing - A/t (4T65EV)

OIL LEVEL, CHECKING

CHECKING THE OIL LEVEL

Preparations

Oil Level/Temperature

Installing The Oil Plug

Further Filling

Connecting Components To The Vacuum Extractor

Detaching & Installing The Upper Oil Hose & Pipe

Filling With Oil

Connecting The Vacuum Extractor

Removing & Installing The Existing Oil Hoses

Adjusting Cables With 7 mm Sleeve

Checking The Position Of The Gear Selector Lever

Check The Shifting In Manual Position

Check

Note Before Disconnecting The Battery Lead

Note Before Connecting The Battery Lead

Initializing The Upper Electronic Module (UEM)

Engine

ACCUMULATOR, GASKET/PISTON, REPLACING

Removing The Accumulator Housing From The Transmission

Removing The Pistons From The Accumulator Housing

Installing New Pistons On The Accumulator Housing

Installing The Accumulator Housing On The Transmission

Finishing

Install The New Boot

Reinstall The Panel On The Center Console

Install The Gear Selector Knob & The Boot

Disconnect The Cable From The Ignition Switch

Install The Cable

Connect The Cable To The Gear Selector Mounting

Initial Setting Of The Key Lock Cable (Adjusting)

Finishing Work

CONTROL SYSTEM/VALVE HOUSING, REMOVING

Removing The Side Cover

Preparations For Removing The Valve Housing

Air Vent Housing

Control System Housing

Removing The Screws For The Valve Housing & Pressure Sensor

Removing & Separating The Valve Housing

Distribution Plate

Checking & Reinstalling The Balls In The Valve Housing

Check The Balls Sealing Against The Distribution Plate

Check The Sealing Of The Balls Against The Control System Housing

Installing New Solenoids On The New Valve Housing

CONTROL SYSTEM/VALVE HOUSING, INSTALLING

Transferring The Balls To The New Valve Housing

Transferring

Checking The Balls In The Valve Housing

Installing New Gaskets

Replacing The Seal On The Pump Shaft

Installing The Balls For The Control System Housing

Installing The Valve Housing

Installing The Oil Pump

Installing The Side Cover

Check The Bearing Surface For The Differential

Install The Spacer Washer & The Throw-Out Bearing On The Differential

Install The Differential Housing Cover

Install The Bracket On The Cylinder Block

Install The Vehicle Speed Sensor (VSS)

Install The Right Drive Shaft

Fill The Transmission With Oil

Check The Oil Level

Install The Gear Selector Cable From The Inside Of The Passenger Compartment

Locate The Grommet On The Studs

Feed The Gear Selector Cable In From The Inside

Position The Gear Selector Cable Behind The Steering Gear

Install The Gear Selector Cable On The Gear Selector

Install The Gear Selector Cable On The Transmission

Install The Gear Selector Knob

Removing The Boot From The Gear Selector Knob

Removing The Lock Bracket From The Gear Selector Knob

Installing The Gear Selector Knob

Installing The Lock Bracket On The Gear Selector Knob

Installing The Top Panel

Transfer The Solenoid With The Connector

Install The Top Panel & Boot

Install The Center Console

Fold The Top Panel With The Boot Away From The Gear Selector Lever

Install The Locking Sleeve For The Boot

Install The Centre Console

OIL PUMP

Removing The Transmission Side Cover

Removing Oil Pump

Removing The Oil Pump From The Pump Shaft

Installing The Side Cover On The Transmission

Separate The Panel & Top Panel

Pull Up Front Edge Of The Bracket

Preparations For Removing The Center Console

Install The Panel & Connector

Reinstall The Side Panels

Disconnecting The Pressure Sensor

Installing The Pressure Sensor

Installing The Transmission Side Cover

Removing The Spark Plugs Cover

Applies Only To Turbocharged Engines

Installing Lifting Fixture

Installing The Lifting Beam & Lifting Hook On The Engine Lifting Eyelet

Disconnecting The Front Suspension Components

Removing The Screws For The Cable Conduit & Ground Lead Bracket On The Sub-Frame

Removing The Nut For The Ball Joint Pinion (Left Hand Side)

Removing The Screws From The Sub-Frame Support Plates (Both Sides)

Pressing Up The Sub-Frame On The Right-Hand Side

Removing The Front Cross Member

Removing The Screw For The Rear Engine Mounting

Preparatory Work For Removing The Wheel Spindle On The Left-Hand Side

Lowering The Sub-Frame

Preparations For Removing The Servo Cylinder

Removing The Cover

Replacing The Piston With O-Ring & Sealing Ring

Installing The Piston & Cover

Installing Front Suspension Components

Installing The Screw For The Rear Engine Pad

Installing The Screws For The Bracket For The Heated Oxygen Sensor (HO2S) Cable

Installing The Front Cross Member

Installing New Lock Nuts On The Steering Gear

Installing The Screws For The Cable Conduit & The Ground Lead Bracket

Applies Only To Turbocharged Cars

Checking The Steering Gear Bearing In The Boot At The Firewall

SERVO CYLINDER, GASKET & O-RING, REPLACING

Removing The Servo Cylinder (2-1)

Replacing The Gasket, O-Ring & Strainer

Installing The Servo Cylinder On The Transmission

Removing The Center Console

Removing The Solenoid

Installing The Solenoid

Installing The Center Console

SOLENOID LOCK-UP FUNCTION, REPLACING

Preparatory Work

Removing The Lock-Up Solenoid

Installing The Lock-Up Solenoid

Side Cover, Transmission, Removing

Removing The Line Pressure Solenoid

Removing Solenoid S1

Installing Solenoid S1

Removing Solenoid S2

Installing Solenoid S2

Removing The Boot From The Gear Selector

Removing The Gear Selector Knob

Installing The Boot On The Gear Selector

Removing The Boot From The Top Panel

Installing The Boot On The Top Panel

Removing The Top Panel

Removing & Transferring The Boot From The Top Panel

Installing The Boot

Installing The Gear Selector Knob & Lock Bracket

Install The Oil Filter

Install The Oil Pan

Install A Plastic Hose On The Oil Return Line

When Filling (Select Method 1 Or 2)

Install The Oil Return Line On The Transmission

Lower The Car

Pour The Rest Of The Oil Into The Transmission

Install The Splashguard Under The Engine

Disconnecting The Battery Lead

Removing The Air Cleaner (ACL) Housing

Removing The Charge Air Pipe & Hose

Removing The Connector From The Transmission

Removing The Screws From The Cable Conduit & The Parking Heater, Removing The Ground Lead Bracket From The Sub-Frame

Applies Only To Cars With Parking Heaters

Removing The Ball Joint Nut (Left Hand Side)

Removing The Control Arms For The Anti-Roll Bar, The Tie Rod & The Screw From The Drive Shaft On The Left Hand Side

Removing The Pipe Lines From The Sub-Frame

Removing The Wheel Spindle From The Control Arm

Removing The Drive Shaft From The Wheel Spindle (Left-Hand Side)

Removing The Left Drive Shaft From The Transmission

Removing The Nuts & Screws For The Steering Gear Sub-Frame

Removing The Oil Pipes From The Transmission

Lowering The Engine & Transmission

TRANSMISSION SIDE COVER, INSTALLING

Installing Cover

Lifting The Engine & Transmission To The Horizontal Position

Installing The Oil Pipes

Installing The Rear Engine Mounting

Installing The Screw For The Rear Engine Pad Through The Steering Gear

Installing The Sub-Frame On The Bodywork

Installing The Left Drive Shaft On The Transmission, Wheel Spindle & Control Arm

Cars With Parking Heaters

Installing The Connector

Installing The Air Cleaner (ACL) Housing

Method 1

Method 2

Method 3

Check The Coolant Level In The Expansion Tank

Check That There Is No Oil Leakage At

Installing The Splash Guards & The Fender Liner

Checking The Steering Gear Bearing In The Gaiter At The Firewall

Installing The Battery Lead

All sections

Method 1 Volvo S80 I

Transmission - Servicing - A/t (4T65EV)

Method 1

Note. Filling with 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.