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

Gear Position Sensor

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REMOVAL & INSTALLATION



See Figure 1

  1. Make sure the gear selector is in the N position.
  2.  
  3. Disconnect the battery cables and remove the battery.
  4.  
  5. Remove the battery tray.
  6.  
  7. Remove the air cleaner assembly and intake hose.
  8.  
  9. Remove the transmission cable from the rod arm.
  10.  
  11. Remove the selector lever.
  12.  
  13. Remove the dipstick pipe bracket.
  14.  
  15. Remove the position sensors mounting bolts and remove the sensor from the transaxle.
  16.  
  17. Disconnect the clamps and remove the connector from the transaxle.
  18.  

To install:
  1. Install the sensor and adjust using procedure outlined below.
  2.  
  3. Tighten the sensors mounting bolts.
  4.  
  5. Install the dipstick pipe bracket.
  6.  
  7. Install the selector lever.
  8.  
  9. Install the transmission cable onto the cable arm.
  10.  
  11. Install the air cleaner assembly and intake hose.
  12.  
  13. Install the battery tray.
  14.  
  15. Install the battery and connect the battery cables.
  16.  



Click image to see an enlarged view

Fig. Fig. 1: The gear position sensor is visible after the air cleaner is removed

ADJUSTMENT



  1. Make sure the gear selector is in the N position.
  2.  
  3. Disconnect the battery cables and remove the battery.
  4.  
  5. Remove the battery tray.
  6.  
  7. Remove the air cleaner assembly and intake hose.
  8.  
  9. Remove the transmission cable from the rod arm.
  10.  
  11. Remove the dipstick pipe bracket.
  12.  
  13. Install tool 5475 on the selector shaft and check that the indentation on the tool aligns with the mark on the sensor. If the sensor requires adjustment, perform the following:

    Remove the position sensor mounting bolts and the selector shaft nut.
     
    Rotate the sensor until the marks align.
     
    Tighten the sensor mounting bolts and the selector shaft nut.
     

  14.  

To install:
  1. Install the dipstick pipe bracket.
  2.  
  3. Install the selector lever.
  4.  
  5. Install the transmission cable onto the cable arm.
  6.  
  7. Install the air cleaner assembly and intake hose.
  8.  
  9. Install the battery tray.
  10.  
  11. Install the battery and connect the battery cables.
  12.  

 
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