Home/Volvo/XC90/Volvo XC90 I (2002-2006)/Repair manual/Servicing - A/t (4T65AWD)/SUB-FRAME FRONT, REPLACING

Contents

Wiring diagrams Section: Servicing - A/t (4T65AWD)

OIL LEVEL, CHECKING

CHECKING THE OIL LEVEL

PREPARATIONS

OIL LEVEL / TEMPERATURE

Checking The Position Of The Gear Selector Lever

Check The Gearshifts In Manual Mode

Installing The Air Cleaner (ACL) Housing

Check

NOTE WHEN DISCONNECTING/CONNECTING THE BATTERY LEAD

Engine

PINION SEAL BEVEL GEAR, REPLACING

Preparatory Work

Removing The Nuts For The Bevel Gear Flange

Removing The Flange

Removing The Seal

Installing The Seal

Installing The Flange On The Pinion

Installing A New Nut In The Carrier

Filling And Checking Oil

Finishing

Install The New Boot

Reinstall The Panel On The Center Console

Installing The Gear Selector Knob And Boot

Removing The Center Console

Removing The Solenoid

Installing The Solenoid

Installing The Center Console

REMOVING CENTER TUNNEL CONSOLE

TOP PANEL GEARTRONIC, REPLACING

Removing The Top Panel

Removing The Gear Selector Knob

Removing And Transferring The Boot From The Top Panel

Installing The Boot

Installing The Top Panel

Installing The Gear Selector Knob And Lock Bracket

CABLE KEY INTERLOCK, REPLACING

Removing The Gear Selector Cable From The Ignition Switch

Removing The Gear Selector Cable From The Steering Column

Installing The Gearbox Cable

Initial Setting Of The Key Lock Cable (Adjusting)

Finishing Work

Detaching The Boot And Removing The Gear Selector Knob

Installing Gear Selector Knob And Boot

GEAR SELECTOR CABLES, REPLACING

Removing The Air Cleaner (ACL) Housing

Removing The Gear Selector Cable And Ball Joint

Removing The Left Front Wheel

Removing Side Panels

Removing The Gear Selector Cable

Removing The Gear Selector Cable At The Firewall

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

Locate The Grommet On The Studs

Feeding In The Gear Selector Cable From The Inside

Installing The Gear Selector Cable On The Gear Selector

Installing The Gear Selector Cable On The Transmission

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

Removing Centre Tunnel Console

Installing The Locking Sleeve For The Boot

Installing The Centre Tunnel Console

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 And Pressure Sensor

Removing And Separating The Valve Housing

Distribution Plate

Checking And Reinstalling The Balls In The Valve Housing

Check The Sealing Of The Balls 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

COVER DIFFERENTIAL, REPLACING

Removing The Bevel Gear/Chain Housing

Disconnecting The Pipe From The Turbocharger (TC)

Removing The Bracket For The Bevel Gear/Chain Housing

Removing The Transmission Output Speed Sensor From The Cover On The Transmission

Checking The Bearing Surface On The Differential

Installing The Spacer Washer And Throw-Out Bearing

Installing The Differential Housing Cover

Installing The Transmission Output Speed Sensor

Installing The Bracket For The Bevel Gear/Chain Housing

Installing The Pipe On The Turbocharger (TC)

Installing The Bevel Gear / Chain Housing

Filling The Cooling System

TRANSMISSION OIL / OIL FILTER, REPLACING

Install The Oil Filter

Install The Oil Pan

Install A Plastic Hose On The Oil Return Line

Fill The Transmission With Oil. There are two different methods. Method 1

Fill The Transmission With Oil. Method 2

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

Check The Oil Level

Check That There Is No Oil Leakage At The Pipe Couplings Or Oil Pan Install The Splashguard Under The Engine

Removing The Side Cover From The Transmission

Removing The Oil Pump

Removing The Oil Pump From The Pump Shaft

Installing The Side Cover On The Transmission

GASKET / PISTON ACCUMULATOR, REPLACING

Removing The Accumulator Housing From The Transmission

Removing The Pistons From The Accumulator Housing

Installing New Pistons For The Accumulator Housing

Installing The Accumulator Housing On The Transmission

GASKET/O RING SERVO CYLINDER, REPLACING

Removing The Servo Cylinder (2-1)

Replacing The Gasket, O-Ring And Strainer

Installing The Servo Cylinder On The Transmission

SIDE COVER TRANSMISSION, REMOVING

Disconnecting The Battery Lead

Removing Engine Compartment Components

Removing The Coolant Hose From The Passenger Compartment Heater

Disconnecting The Charge Air Pipe

Removing The Connector From The Transmission

Installing The Lifting Beams And Lifting Hooks On The Engine Lifting Lugs

Removing The Lower Steering Shaft From The Steering Shaft Joint

Removing Both The Front Wheels

Removing Components From The Sub-Frame

For Cars With Fuel Powered Parking Heaters

Removing The Cross Members From The Body

Removing The Front Cross Member

Removing Screws And Nuts From The Engine Pad And Engine Stabilizer Brace

Detaching The Power Steering Line

Removing Front Suspension Components On Both Sides

Disconnecting The Ball Joint Pinion From The Control Arm (Both Sides)

Unhooks The Control Arm From The Ball Joint Pinion (Both Sides)

Removing The Drive Shaft From The Wheel Hub (Both Sides)

Removing The Drive Shaft From The Transmission (Left-Hand Side)

Removing The Fender Liner And Support Plate

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

Lowering The Sub-Frame

Removing The Oil Pipe From The Transmission

Lowering The Engine And Transmission

SIDE COVER TRANSMISSION, INSTALLING

Checking The Gasket For The Side Cover

Installing Cover

Lifting The Engine And Transmission To The Horizontal Position

Installing Oil Pipes

Installing The Left Drive Shaft On The Transmission And The Wheel Spindle

Installing The Sub-Frame On The Bodywork

Installing The Drive Shaft On The Wheel Hub

Installing The Cross Members On The Bodywork

Installing The Front Mounting For The Exhaust Pipe And The Cross Member

Installing The Power Steering Line

Installing The Screws For The Engine Pads And Engine Stabilizer Brace

Installing Front Suspension Components (Both Sides)

Installing Components For The Fender Liner

Installing The Cable Duct

Removing The Lifting Beams

Installing The Lower Steering Shaft On The Steering Shaft Joint

Installing Steering Shaft/Firewall Boot

Installing The Coolant Hose

Installing The Connector On The Transmission

Installing Engine Compartment Components

Method 1

Method 2

Installing The Battery Lead

Check That There Is No Oil Leakage At

Installing The Front Splash Guard

SOLENOID LOCK-UP FUNCTION, REPLACING

Removing The Lock-Up Solenoid

Installing The Lock-Up Solenoid

Removing The Line Pressure Solenoid

Removing Solenoid S1

Installing Solenoid S1

Removing Solenoid S2

Installing Solenoid S2

Disconnecting The Pressure Sensor

Installing The Pressure Sensor

SEALING RING AND PISTON WITH O-RING FOR FRONT SERVO, REPLACING

Removing The Right Drive Shaft

Disconnecting The Steering Gear From The Engine Pad

Removing The Chain Housing Bracket

Removing The Screws For The Bevel Gear/Chain Housing

Removing The Servo Cylinder Cover

Removing The Piston From The Transmission

Replacing The Piston With O-Ring And Sealing Ring

SEALING RING AND PISTON WITH O-RING FOR FRONT SERVO, INSTALLING

Installing The Piston In The Transmission

Installing The Servo Cylinder Cover

Installing The Bracket

Installing The Steering Gear To The Engine Pad

Installing The Drive Shaft

SUB-FRAME FRONT, REPLACING

Preparation

Removing The Clamp For The Servo Pressure Hose

Removing The Right Engine Mounting

Removing The Splash Guard Under Engine

Removing The Skid Plate

Exposing The Sub-Frame

Removing The Drive Shaft

Removing The Sub-Frame

Transferring Components

Installing The Sub-Frame

Installing Removed Components

Installing The Skid Plate

Installing The Right-Hand Engine Mounting

Installing The Clamp For The Servo Pressure Hose

Removing Lifting Tools

Installing Wheels

All sections

SUB-FRAME FRONT, REPLACING Volvo XC90 I

Servicing - A/t (4T65AWD)

SUB-FRAME FRONT, REPLACING

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 in the illustrations is always correct.