Volvo 240/740/760/780/940/960 1990-1998

Automatic Transaxle Assembly

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REMOVAL & INSTALLATION



850, C70, S70 and V70 Models

See Figures 1 and 2

  1. Pull the steering wheel adjustment lever out and adjust the wheel in and up as far as it will go. Then lock it in position.
  2.  
  3. Put the transaxle gear selector in N and set the parking brake.
  4.  
  5. Disconnect and remove the battery and air cleaner assembly.
  6.  
  7. Remove the battery tray.
  8.  
  9. On turbo models, disconnect the control valve from air cleaner and the air charge manifold clamp and hose. Also remove the turbocharger air cleaner intake.
  10.  
  11. Detach the transaxle cable and connector from the transaxle. Be careful not to damage the rubber seal.
  12.  
  13. Remove the wiring harness and ground from the control system cover.
  14.  
  15. On early models, disconnect the transaxle vent hose.
  16.  
  17. On later models, disconnect the wiring and oxygen sensor from the transaxle brackets.
  18.  
  19. Disconnect the transaxle cooling lines from the quick disconnects and drain the transmission fluid.
  20.  
  21. Remove the dipstick and tube.
  22.  
  23. On vehicles with an EGR valve, disconnect the hoses to the valve.
  24.  
  25. On turbo models, remove the cover over the control pulley, then disconnect the intake to the throttle body and pull it to one side so that the throttle body is free. Seal all oil connections to prevent dirt from entering.
  26.  
  27. Remove the bolts connecting the engine and transaxle and starter.
  28.  
  29. Disconnect the transaxle ground strap.
  30.  
  31. Lift off the radiator overflow tank and let it hang.
  32.  
  33. Remove the torque rod extension arm bolt and swing it out of the way.
  34.  

It will be necessary to support the engine from above and still be able raise and lower the car.

  1. Install lifting yoke 999-5534 or equivalent in place of the torque rod extension arm.
  2.  
  3. Install support tool 999-5033 on the inside fender rail, lifting beam support 999-5006 or equivalent placing the beam directly over the eyelet for the lifting yoke.
  4.  
  5. Install the lifting hook 999-5460 or equivalent and pull it up slightly until the load is taken off of the engine mounts. Measure the distance between the beam and spark plug cover and make note of it.
  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Remove the front wheels.
  10.  
  11. Disconnect the ABS sensor from the left side axle shaft but do not disconnect.
  12.  
  13. Disconnect all brackets for the brake lines and ABS wiring on both sides.
  14.  
  15. Remove the plastic inner fender wells on both sides.
  16.  
  17. Remove the transfer case (V70 AWD models only).
  18.  
  19. Remove the left and right side halfshafts.
  20.  
  21. Install a seal plug in the transaxle.
  22.  
  23. Remove all the splash guards.
  24.  
  25. Separate the ball joints from the control arms, being careful not to damage the boots.
  26.  
  27. Disconnect the sway bar links on both sides.
  28.  
  29. Remove the subframe cable mounting screws and disconnect them from the subframe.
  30.  
  31. Disconnect the carbon canister and hoses from the subframe. Cut the wire tie and hang the holder on the body.
  32.  
  33. Disconnect the exhaust pipe clamp behind the catalytic converter.
  34.  
  35. Remove the oil line bracket screws and torque rod holder mounting screws.
  36.  
  37. Back the engine mounting/steering gear bolt off one turn.
  38.  
  39. Remove the five steering gear mounting nuts in the subframe.
  40.  
  41. Position a jack under the left-hand side of the subframe so that it is barely touching.
  42.  
  43. Remove the subframe bracket bolts on the body. Back the 15mm bolts between the frame and body on the right-hand side several turns. Remove the bolts from the left.
  44.  

Make sure the steering gear bolts come out of the subframe.

  1. Remove the jack and let the frame hang down from the right side bolts.
  2.  
  3. Secure the end of the right side driveshaft on the oil lines.
  4.  
  5. Remove the steering gear engine mount bolt and nut at the top of the engine mount and remove the mount.
  6.  

Make sure the steering gear is properly secured so the lower steering shaft does not slide out of the steering column.

  1. Disconnect the oxygen sensor wiring clamps from the cover and the connector and wiring to the vehicle speed sensor.
  2.  
  3. Remove the cover at the back of the engine and the mount from the transaxle.
  4.  
  5. Lower the engine and transaxle with the lifting hook until the distance between the beam and spark plug cover is 12.6 in. (320mm).
  6.  


WARNING
If the engine is lowered too far, the exhaust pipe will be crushed against the steering rack. Be careful not to pinch any wiring or hoses and be sure that the engine dipstick tube is free of the fan.

  1. Install transaxle fixture 5463 on the transaxle jack or equivalent, using the torque rod mounting bolts to hold it in place. At the same time, fit support plate tool 5463-1 or equivalent and raise the jack so that it is making light contact.
  2.  
  3. Remove the six torque converter bolts using a TX50 Torx® socket.
  4.  
  5. Remove the lower plastic nut and fold out the inner fender well on the right-hand side.
  6.  
  7. Then turn the crankshaft with a socket and ratchet.
  8.  
  9. Remove the seven bolts between the engine and transaxle.
  10.  
  11. Remove the torque converter bolts from the flywheel.
  12.  
  13. Remove the transaxle making sure the torque converter comes out with it and does not slip off the shaft. Use the hole in the torque converter cover to press the torque converter in to keep it from sliding off.
  14.  


WARNING
Do not pry against carrier plate rim, as damage may result.

To install:
  1. Flush the oil lines with clean transmission fluid.
  2.  
  3. Install the line and hose on the transaxle using new O-rings on the quick-connectors.
  4.  
  5. Install the hose on the upper transaxle cooler line catch pan under the return line.
  6.  
  7. Inspect all components before installing.
  8.  
  9. Apply a small amount of grease to the torque converter guide pin and install, making sure the converter is all the way into the transaxle. The distance between the cover and converter bolt flange should be 0.55 in. (14mm).
  10.  
  11. Install the transaxle securing in place with the seven bolts between the engine and transaxle. Tighten them to 37 ft. lbs. (50 Nm).
  12.  
  13. Install new torque converter bolts and tighten to 22 ft. lbs. (30 Nm) using a TX50 Torx® socket.
  14.  

Remove the socket from the crankshaft.

  1. Install the rear transaxle mount and three bolts. Tighten the rear two bolts to 37 ft. lbs. (50 Nm), then remove the front bolt.
  2.  
  3. Install the cover against the mount and tighten the bolt to 37 ft. lbs. (50 Nm).
  4.  
  5. Install the engine mount guide pin into the cover. Install a new nut and hand-tighten.
  6.  
  7. Install the steering rack engine mount bolt, but do not tighten.
  8.  
  9. Reconnect the oxygen sensor.
  10.  
  11. Install the vehicle speed sensor connector and connect the transaxle ground strap.
  12.  
  13. Install the subframe using new bolts. Apply grease to the threads.
  14.  
  15. Starting on the left, lift the frame with a transaxle jack. Mount the support brackets on both sides.
  16.  
  17. Tighten the frame bolts to 78 ft. lbs. (105 Nm) plus an additional 120 degrees.
  18.  
  19. Tighten the bracket bolts to 37 ft. lbs. (50 Nm).
  20.  
  21. Remove the jack and repeat the procedure for the right side.
  22.  
  23. Install five new nuts on the steering rack and tighten them to 37 ft. lbs. (50 Nm).
  24.  
  25. Install the front engine mount nut, then tighten the front and rear bolts to 37 ft. lbs. (50 Nm).
  26.  
  27. Install the torque rod mount on the transaxle using new bolts, tighten the M18 bolts (early models) to 13 ft. lbs. (18 Nm) plus an additional 90 degrees or M10 bolts (later models) to 26 ft. lbs. (35 Nm) plus an additional 40 degrees.
  28.  
  29. Install the transfer case (if equipped).
  30.  
  31. Install the right and left halfshafts.
  32.  

Make sure the transaxle axle seal and axle boot are not damaged.

  1. Connect the control arms to the ball joints using new nuts.
  2.  
  3. Install the sway bar link using new nuts and tighten to 37 ft. lbs. (50 Nm).
  4.  
  5. Attach the cable pipe and carbon filter container to the subframe. Tie the hoses with a strip clamp on the subframe.
  6.  
  7. Install engine splash guard on early models.
  8.  
  9. Install the front splash guard by pressing in the guides and installing the screws.
  10.  
  11. Install the five transaxle bolts on top side and tighten to 37 ft. lbs. (50 Nm).
  12.  
  13. Install the starter.
  14.  
  15. Connect the cable conduit and oxygen sensor connectors.
  16.  
  17. Install the dipstick tube with a new O-ring and tighten to 19 ft. lbs. (25 Nm).
  18.  
  19. Connect the wiring harness, ground lead, transaxle connectors.
  20.  
  21. Connect the transaxle vent and EGR hoses.
  22.  
  23. Attach the transaxle cable and adjust.
  24.  
  25. Connect the ground strip to the firewall.
  26.  
  27. Install a new bolt and nut for the extension arm and torque rod.
  28.  
  29. Tighten early model M8 bolts to 13 ft. lbs. (18 Nm) plus an additional 120 degrees. Tighten later model M10 bolts to 26 ft. lbs. (35 Nm) plus an additional 90 degrees.
  30.  
  31. Install the remaining components.
  32.  
  33. Fill the transaxle with fluid.
  34.  
  35. Check the fluid level after the engine has reached normal operating temperature to assure that it is correct.
  36.  



Click image to see an enlarged view

Fig. Fig. 1: Remove the bell housing bolts, and use a T50 Torx® bit to remove the torque converter bolts



Click image to see an enlarged view

Fig. Fig. 2: Use a suitable stand to support the transaxle before removing

ADJUSTMENTS



Throttle Linkage/Kickdown Switch

See Figures 3 and 4

  1. Remove the throttle pulley cover.
  2.  
  3. Remove the clip from the kickdown cable.
  4.  
  5. Install a 0.14 inch (3.5mm) spacer between the throttle pulley stop and the bracket stop.
  6.  
  7. Install the clip into the cable making sure it is firmly against the bracket.
  8.  
  9. Adjust until the cable is under light tension.
  10.  
  11. Remove the locking clip.
  12.  
  13. Remove the spacer.
  14.  
  15. Reinstall the locking clip.
  16.  
  17. Install the pulley cover.
  18.  



Click image to see an enlarged view

Fig. Fig. 3: Remove the throttle pulley cover and cable clip in order to adjust the throttle cable



Click image to see an enlarged view

Fig. Fig. 4: Install a 3.5mm spacer between the throttle pulley stop and the bracket stop, then adjust the cable

 
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