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

Automatic Transmission Assembly

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REMOVAL & INSTALLATION




CAUTION
If the vehicle has been driven within the last 3-5 hours, the transmission oil can be scalding hot. Use extreme care when draining the oil or handling components.

Except 240 and 960

See Figure 1

  1. Disconnect the battery ground cable.
  2.  
  3. Place the gear selector in the P position.
  4.  
  5. Disconnect the kickdown cable at the throttle pulley on the engine.
  6.  
  7. Disconnect the oil filler tube at the oil pan, and drain the transmission oil.
  8.  


CAUTION
The oil will be scalding hot if the vehicle was recently driven.

  1. Disconnect the control rod at the transmission lever, and disconnect the reaction rod at the transmission housing.
  2.  
  3. On the AW71 transmission, disconnect the wire at the solenoid (slightly to the rear of the transmission-to-driveshaft flange).
  4.  
  5. Matchmark the transmission-to-driveshaft flange and unbolt the driveshaft.
  6.  
  7. Place a jack or transmission dolly under the transmission and support the unit. Remember that the transmission will be heavier at the front end than the rear.
  8.  
  9. Remove the transmission crossmember assembly.
  10.  
  11. Disconnect the exhaust pipe at the joint and remove the exhaust pipe bracket from the exhaust pipe.
  12.  
  13. Remove the rear engine mount with the exhaust pipe bracket.
  14.  
  15. Remove the starter motor.
  16.  
  17. Remove the cover plate at the torque converter housing.
  18.  
  19. Disconnect the oil cooler lines at the transmission.
  20.  
  21. Remove the upper bolts at the torque converter cover.
  22.  
  23. Remove the oil filler tube.
  24.  

It is helpful to have another person steadying and guiding the transmission during the removal process.

  1. Remove the lower bell housing bolts.
  2.  
  3. Remove the bolts retaining the torque converter to the drive plate.
  4.  
  5. Pry the torque converter back from the drive plate with a small prybar.
  6.  
  7. Slowly lower the transmission as you pull it back to clear the input shaft.
  8.  


WARNING
Do not tilt the transmission forward, or the torque converter may slide off.

To install:
  1. When reinstalling, install the two lower bolts in the casing as soon as the transmission is in place. For the B280 engine, adjust the panel between the starter motor and torque converter casing, and install the bolts for the starter.
  2.  
  3. Mount the oil filler tube at the oil pan, but do not tighten the nut.
  4.  
  5. Install the tube bracket and the two upper bolts in the converter casing.
  6.  
  7. Tighten the nut for the oil tube to 65 ft. lbs. (88 Nm).
  8.  
  9. Install the bolts for the coupling flange; hand-tighten the bolts first, then tighten in a crisscross pattern to 32 ft. lbs. (44 Nm).
  10.  
  11. Reinstall the rear engine mount with the exhaust pipe bracket and reconnect the exhaust system.
  12.  
  13. Reinstall the transmission crossmember; when it is securely bolted in place, the supporting jack may be removed.
  14.  
  15. Reinstall the driveshaft.
  16.  
  17. Making sure that both the transmission linkage and the shift selector in the vehicle are in the P position, attach the actuator rod and the reaction rod.
  18.  
  19. Adjust the shift linkage as necessary.
  20.  
  21. Lower the vehicle.
  22.  
  23. On AW71 models, install and connect the wiring to the solenoid valve.
  24.  
  25. Connect the kickdown cable at the throttle pulley. Adjust the cable if necessary.
  26.  
  27. Fill the transmission with oil.
  28.  
  29. Connect the negative battery cable.
  30.  
  31. Apply the parking brake. Start the engine and allow to idle. Move the selector lever through all gear positions.
  32.  
  33. Place the selector lever in P . Wait 2 minutes and check the fluid level. Top up, as required.
  34.  



Click image to see an enlarged view

Fig. Fig. 1: Remove the transmission using a suitable holding fixture

240
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the dipstick and filler pipe clamp.
  4.  
  5. Remove the bracket and throttle cable from the dashboard and throttle control.
  6.  
  7. Disconnect the exhaust pipe at the manifold flange.
  8.  
  9. Raise and support the vehicle.
  10.  
  11. Drain the fluid into a clean container.
  12.  
  13. Disconnect the driveshaft from the transmission flange.
  14.  
  15. Disconnect the selector lever controls (shift linkage) and the pan reinforcing bracket.
  16.  
  17. Remove the converter attaching bolts.
  18.  
  19. Support the transmission with a jack or a transmission dolly and holding fixture.
  20.  
  21. Remove the rear crossmember.
  22.  
  23. Disconnect the exhaust pipe brackets and remove the speedometer cable from the case.
  24.  
  25. Remove the filler pipe.
  26.  
  27. Install a wooden block between the engine and firewall; lower the jack until the engine contacts the block.
  28.  
  29. Make sure no tension is put on the battery cable.
  30.  
  31. Disconnect all electrical wiring at the transmission case.
  32.  
  33. Disconnect the starter cable and remove the starter.
  34.  
  35. Remove the converter housing bolts.
  36.  
  37. Pull the transmission backwards to clear the guide pins.
  38.  
  39. Lower and remove the transmission assembly from the vehicle.
  40.  

To install:
  1. When reinstalling, load the transmission straight onto the engine and install the converter housing bolts.
  2.  
  3. Tighten the converter-to-drive plate bolts to 35 ft. lbs. (48 Nm).
  4.  
  5. Install the starter and connect its cable; hook up all other wiring to the transmission case.
  6.  
  7. Using the jack, elevate the transmission and engine into their proper position.
  8.  
  9. Install the speedometer cable and the filler pipe.
  10.  
  11. Reconnect the exhaust pipe and the rear engine mount brackets.
  12.  
  13. Install the rear crossmember and tighten its bolts to 18 ft. lbs. (25 Nm). When the crossmember is secure, the jack may be removed.
  14.  
  15. Install the converter attaching bolts.
  16.  
  17. Connect the selector lever controls and the pan reinforcing bracket.
  18.  
  19. Connect the driveshaft to the transmission flange.
  20.  
  21. Lower the vehicle.
  22.  
  23. Reconnect the exhaust pipe at the manifold flange.
  24.  
  25. Reinstall the bracket and throttle cable and adjust if necessary.
  26.  
  27. Install the dipstick and filler pipe.
  28.  
  29. Reconnect the negative battery cable.
  30.  
  31. Fill the transmission to the proper level with fluid.
  32.  
  33. Apply the parking brake. Start the engine and allow to idle. Move the selector lever through all gear positions.
  34.  
  35. Place the selector lever in P . Wait 2 minutes and check the fluid level. Top up, as required.
  36.  

960
  1. Disconnect the negative battery cable.
  2.  
  3. Support the engine using the special tools (5006, 5033, 5115, 5429 and 5186, or their equivalents).
  4.  
  5. Remove the preheater pipe under the engine. Be careful not to damage the O-ring.
  6.  
  7. Disconnect the front section of the exhaust pipe.
  8.  
  9. Disconnect the transmission cooler lines and plug the openings.
  10.  
  11. Unfasten the 3 transmission connectors.
  12.  
  13. Disconnect the oxygen sensor lead from the transmission unit and support member.
  14.  
  15. Matchmark the driveshaft coupling halves to aid during re-assemble.
  16.  
  17. Disconnect the driveshaft.
  18.  
  19. Remove the clips between the gear selector lever and control rod/reaction arm. Withdraw the rods from the mounting.
  20.  
  21. Disconnect the transmission support member from the transmission bump stop and side members.
  22.  
  23. Position a service jack beneath the transmission.
  24.  
  25. Carefully lower the transmission.
  26.  
  27. Remove the torque converter-to-flexplate retaining bolts.
  28.  
  29. Remove the transmission housing bolts.
  30.  
  31. Separate the torque converter from the flexplate and lower the transmission.
  32.  

To install:
  1. Lift the transmission into position, while aligning the torque converter with the flexplate.
  2.  
  3. Install the transmission housing mounting bolts.
  4.  
  5. Install the torque converter retaining bolts and tighten alternately to 22 ft. lbs. (30 Nm).
  6.  
  7. Raise the transmission and secure the support member. Tighten to 37 ft. lbs. (50 Nm).
  8.  
  9. Install the gear selector lever.
  10.  
  11. Install the locking clips.
  12.  
  13. Connect the transmission oil cooler lines.
  14.  
  15. Connect the transmission connectors and oxygen sensor lead.
  16.  
  17. Connect the driveshaft. Check to ensure the matchmarks are aligned.
  18.  
  19. Lubricate the O-ring and install the preheater pipe.
  20.  
  21. Install the front exhaust pipe.
  22.  
  23. Remove the engine support tools.
  24.  
  25. Reconnect the negative battery cable.
  26.  
  27. Fill the transmission to the proper level with the appropriate fluid.
  28.  
  29. Apply the parking brake. Start the engine and allow to idle. Move the selector lever through all gear positions.
  30.  
  31. Place the selector lever in P . Wait 2 minutes and check the fluid level. Top up, as required.
  32.  

ADJUSTMENTS



Before performing any adjustments, the following checks should be made: Check that the engine can be started, only with the selector lever in position P and with the brake pedal depressed. The selector lever should stand vertically when in the P position. Check that the back-up lights illuminate only when the selector lever is in the R position. On AW 70/71/72 transmissions, check that the clearance from position D towards N is the same or smaller than the clearance between position 3 towards 2 . On the AW 30-40 transmission, check that there is a noticeable play from position D towards N ; however, that play should not be greater than the play from position 3 towards L .

Shift Control
AW 70/71/72 Transmissions

See Figure 2

  1. Set the selector lever in position P . Loosen the retaining nuts for the shift control rod A and retaining arm B.
  2.  
  3. Check that the lever on the transmission is at position P (first step seen from the rear). Turn the transmission output shaft until it locks.
  4.  
  5. Set the lever in the vertical position on the shift control rod, or just facing forward; tighten the nut. Push the retaining arm lightly to the rear until slight resistance is felt. Temporarily tighten the retaining nut to 42 inch lbs. (5 Nm).
  6.  
  7. Check that the clearance from position D towards N is the same or smaller than the clearance between position 3 towards 2 .
  8.  
  9. If incorrect:
    1. If the gear selector lever is stiff in position D , move the connecting rod 5 / 64 inch (2mm) to the rear.
    2.  
    3. If the gear selector lever is stiff in position 3 , move the connecting rod 1 / 8 inch (3mm) to the front.
    4.  

  10.  
  11. When the adjustment is correct, tighten the retaining nut to 13-17 ft. lbs. (17-23 Nm).
  12.  
  13. After adjustment, check that the engine can be started, only with the selector lever in position P and with the brake pedal depressed. The back-up lights should illuminate only when the selector lever is in the R position.
  14.  



Click image to see an enlarged view

Fig. Fig. 2: Adjusting the shift control on AW 70/71/72 transmissions

AW 30/40 Transmission

See Figure 3

  1. Place the selector lever in position P .
  2.  
  3. Loosen the nuts on the control rod and reaction strut.
  4.  
  5. Make sure the selector link arm on the transmission is in position P (rearmost gear position).
  6.  
  7. Make sure the gear lever arm A is vertical (or slightly forward) and tighten the nut.
  8.  
  9. Press the reaction arm B gently backwards until slight resistance is felt. Tighten the nut approximately 48 inch lbs. (5 Nm).
  10.  
  11. Check that the play from position D towards N ; is the same as the play from position 3 towards L .
  12.  
  13. If incorrect:
    1. If there is no play in position D , move the reaction arm backwards approximately 0.08 inches (2mm).
    2.  
    3. If there is no play in position 3 , move the reaction arm forwards approximately 0.12 inches (3mm).
    4.  

  14.  
  15. When the adjustment is correct, tighten the retaining nut to 13-17 ft. lbs. (17-23 Nm).
  16.  
  17. After adjustment, check that the engine can be started, only with the selector lever in positions P or N . The back-up lights should illuminate only when the selector lever is in the R position.
  18.  



Click image to see an enlarged view

Fig. Fig. 3: Adjusting the shift control on AW 30/40 transmissions

Kickdown Cable/Throttle Linkage
AW 70/71/72 Transmissions

See Figure 4

  1. Check that the wire is tensioned at idle setting, without tensioning against the throttle pulley, and that it is in the pulley groove and runs smoothly.
  2.  
  3. Pull the wire out approximately 0.39 inch (10mm) and release suddenly. A mechanical click should be heard from the throttle cam, when it reaches the standby setting. Adjust with the wire tensioner.
    1. If no clicking is heard, the wire is too firmly tensioned.
    2.  
    3. If no kickdown can be obtained, the wire is too slack.
    4.  

  4.  
  5. Check the cable sheath adjustment with the throttle pedal in the vehicle depressed, not by actuating the linkage by hand. When depressing the throttle pedal fully, the distance from the cable sheath to the clip should be 2.02 inches (51.5mm), but 1.98-2.06 inches (50.4-52.6mm) is permitted. If required, adjust the distance on the cable sheath.
  6.  



Click image to see an enlarged view

Fig. Fig. 4: Adjustment of the kick-down cable on AW 70/71/72 transmissions

 
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