Transmission, Installing
Transmission, installing
Special tools:
998 5972 JACK 998 5972 Jack
999 5463 FIXTURE 999 5463 Fixture
999 5972 FIXTURE 999 5972 Fixture
Cleaning and lubricating the input shaft
The input shaft must be lubricated before a manual transmission is installed.
Checking before installing
Check that the transmission and engine mating surfaces are absolutely clean.
Also check that the guide sleeves on the engine are in place and fault free.
Lubricate the holes in the transmission (for the guide pins). Use a little grease.
Transmission, installing
Adjust for height and angle using the mobile jack and the transmission fixture.
Align the transmission against the engine.
Ensure that the transmission is guided straight in, in relation to the engine, and that no deviation occurs in the clutch driven plate center.
Note! Drive shaft.
Insert the screws. First tighten until they make contact. Then tighten the screws alternatingly to 50 Nm.
Caution! While tightening, check that the guide sleeves go into their guide holes in the transmission.
Remove the fixture and the mobile jack from the transmission.
Raise the engine/transmission to the horizontal position.
Install:
- screws of transmission/engine and starter motor/transmission. Tighten the retaining screws to 50 Nm.
- shift cables on mounting with clips (B) (press back the locking plate (A) on the clips before refitting).
Check that they are properly fastened.
- the shift cables to the gear selector arms on the transmission with washers and lock clips.
Lubricate the pins on the gear selector arms with a little grease, part no. 1161241-3.
- the connector for the back-up (reversing) light switch.
Mount the transmission mounting on the transmission and body
Make sure that the rubber of the mounting is correctly positioned.
Fit the mounting to the body mounting. Fit the screw and a new lock nut. Tighten hand-tight.
Raise the engine so that the 3 screws can be inserted. Tighten the screws to 50 Nm.
Remove the lifting hook and lifting brace.
Tighten the transmission mounting to the body. Tightening torque 98 Nm.
Raise the car.
Mounting brackets in the gearcase, installing
Install:
- front mounting bracket. Tightening torque 67 Nm.
- rear mounting bracket. Tightening torque 40 Nm.
- the dust excluder on the rear.
Drive shaft right-hand side, installing
Remove the special tool.
Install the drive shaft in the [1][2]differential and the support bearing in the bearing housing.
Install the drive shaft support bearing cap. Tightening torque 25 Nm.
Fit the wheel spindle to the spring strut. Install the screws and new lock nut finger-tight.
Caution! Make sure the sealing ring in the transmission and the drive shaft's rubber membrane are not damaged. Replace as necessary.
Longitudinal member, installing
Install the longitudinal member (A) and tighten to 69 Nm. Fit the two screws (B) through the engine pads.
Note! Position the engine pad rubber at the correct spot. See illustration (the front and rear engine pads are positioned on the member in the same manner).
Note! The screw of the front engine pad is longer.
Tighten the front engine pad nut (B) finger-tight. First tighten the rear engine pad nut to 59 Nm. Then tighten the front engine pad nut to 59 Nm.
Install the heat deflector plate on the rear bracket.
Front exhaust pipe, installing
Install the front exhaust pipe.
Transverse support member, installing
Install the member and retaining screws.
Tighten the screw on the right side first. Tighten the retaining screws to 50 Nm.
Drive shaft left-hand side, installing
- Clean the drive shaft and splines.
- Remove the special tool 999 5488 PLUGS 999 5488 Plugs from the transmission.
- Remove the screw from the pin/shock absorber.
- Insert the drive shaft in the transmission and press it to the stop.
- Fit the wheel spindle over the drive shaft splines and fit the nut.
- Fit the two screws on the pin/shock absorber.
Caution! Make sure that the rubber diaphragm and seals are not damaged. Replace as necessary.
Drive shaft left-hand side, checking
Carefully pull on the drive shaft joint to check that the drive shaft on the left-hand side is properly locked into the [1][2]differential.
Tighten the wheel spindle/spring strut nuts/screws to 90 Nm.
Install:
- The ABS cable to the mountings in the wheel housing and spring strut (both sides).
- the brake hose with mounting to the spring strut (both sides).
Check and fill transmission fluid
See Checking oil level, AW50-42 Checking Oil Level.
Protective covers and wheels, installing
Install:
- Protective cover in left-hand wheel housing.
- Protective covers beneath transmission/engine.
- Wheels, see Installing wheels, AW50-42 Installing Wheels.
- Tighten the drive shaft nut.
- Install the hub cap.
Attach the connecting pipe to the branching and bracket
- Replace the O-ring.
- Insert the pipe in the connection.
- Fit the locking pin.
- Position the hose in the bracket.
Bleed the clutch;
Note! Use only Volvo genuine brake fluid (Dot 4+).
Flywheel sensor, installing
- Clean the components.
- Install the sensor.
- Tighten the retaining screw.
Gear selector cables and clips on the transmission, installing
- Position the cable casing in the bracket and fit the screw and nut.
- Position the cables on the levers and fit the lock clips. Make sure they properly engage.
- Position the cable casing on the clutch pipe bracket and tighten.
Connect the transmission ground connection.
Clean the mating surface and connect the ground cable. Tighten to 40 Nm.
Engine compartment components, installing
Install:
- battery tray.
- air cleaner housing, see Replacing the air cleaner (ACL) Removal and Replacement.
Air intake hose
- Install the air intake hose in position.
- Connect the PCV hose and vacuum hose to the lower connections in the front edge.
- Connect the PCV hose and vacuum hose to the upper connections.
- Tighten the hose clips.
- Install the throttle body cover.
Install:
- battery,
Check the function.