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

Manual Transaxle Assembly

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REMOVAL & INSTALLATION



850
  1. With all four wheels on the ground, loosen the front axle shaft locknuts.
  2.  
  3. Place the transaxle in N and set the parking brake.
  4.  
  5. Disconnect and remove the battery, air cleaner air intake ducts.
  6.  
  7. Remove the battery tray.
  8.  
  9. On turbocharged models, disconnect the timing valve from air cleaner and the turbocharger air duct clamp and hose.
  10.  
  11. Disconnect the gear selector cables from the brackets and lever.
  12.  
  13. Remove the selector link plate after tapping out the lock pin.
  14.  
  15. Detach the back-up light switch connector.
  16.  
  17. On turbocharged models remove the control pulley cover.
  18.  
  19. Disconnect the turbocharger inlet pipe and tie it back out of the way.
  20.  
  21. Disconnect the upper coolant hose to the engine oil cooler.
  22.  
  23. Disconnect the clutch slave cylinder and remove the clip.
  24.  
  25. Remove the ground strap from the transaxle.
  26.  
  27. Loosen the rear engine mount and splash guard nut.
  28.  
  29. Remove the bolts connecting the engine, transaxle and starter.
  30.  
  31. Disconnect the transaxle ground strap.
  32.  
  33. Disconnect the ground strap from the firewall.
  34.  
  35. Remove the torque arm bolt.
  36.  
  37. Secure the engine from above with an engine support that rests on the inner edges of the engine compartment.
  38.  
  39. Lift the engine up slightly to take weight off the engine mounts.
  40.  
  41. Raise and safely support the vehicle and remove the wheels.
  42.  
  43. Disconnect the ABS sensor from the left side axle shaft, but do not unfasten the connector.
  44.  
  45. Drain the gear oil from the transaxle.
  46.  
  47. Disconnect all brackets for the front brake lines and ABS wiring for both sides of the vehicle.
  48.  
  49. Remove the plastic inner fender liners on both sides.
  50.  
  51. Remove and discard the axle shaft locknuts.
  52.  
  53. Separate the ball joint from control arm, being careful not to damage the boots.
  54.  
  55. Disconnect the sway bar links on both sides.
  56.  
  57. Remove the mounting screws holding the cable to the front of the subframe and disconnect the cable from the subframe.
  58.  
  59. Disconnect the carbon canister hoses.
  60.  
  61. Disconnect the exhaust pipe clamp behind the catalytic converter.
  62.  
  63. Remove the left and right halfshafts.
  64.  

Be careful not to damage the transaxle seal.

  1. Install seal plugs in the transaxle.
  2.  
  3. Loosen the two right side subframe-to-body bolts approximately 1 / 2 in. (15mm).
  4.  
  5. Remove the subframe-to-body bolts on the left side.
  6.  

Make sure the steering gear bolts come out of the subframe and the control arm is free of the axle shaft boot on the right side.

  1. Remove the jack and let the frame hang down from the right side bolts.
  2.  
  3. Tie the left side of the steering gear to the left side frame rail for support.
  4.  
  5. Remove the steering gear engine mount bolt and nut at the top of the mount and remove.
  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, as well as 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.
  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. Remove the seven remaining transaxle-to-engine bolts. Pull the gearbox away from the engine. Lower the jack and move the transaxle away.
  2.  

To install:
  1. Secure the throwout bearing fork to the transaxle.
  2.  
  3. Make sure the mating surfaces on the transaxle and engine are clean and that the dowel pins are in place on the engine.
  4.  

Do not grease the primary shaft or throwout bearing sleeve. Make sure there are no breaks in the clutch plate.

  1. Lift the transaxle into place and mate to the engine.
  2.  
  3. Install the seven bolts securing the engine and transaxle and tighten them a little at a time to draw the transaxle into place. Tighten the bolts to 37 ft. lbs. (50 Nm) and remove the transaxle jack.
  4.  
  5. Lift the engine and transaxle up until the distance between the engine support beam and spark plug cover is 0.20 in. (5mm).
  6.  
  7. Install the rear transaxle mount and bolts.
  8.  
  9. Tighten the rear two bolts to 37 ft. lbs. (50 Nm), then remove the front bolt.
  10.  
  11. Install the cover.
  12.  
  13. Install the engine mount by fitting its guide pin into the cover.
  14.  
  15. Install a new nut and hand-tighten.
  16.  
  17. Install the steering rack engine mount bolt, but do not tighten.
  18.  
  19. Remove the support for the steering gear.
  20.  
  21. Reconnect the oxygen sensor wiring and clamps on the cover.
  22.  
  23. Install the vehicle speed sensor connector and wiring and connect the transaxle ground strap.
  24.  
  25. Install the subframe using new 4 x M14 bolts and apply grease to the threads.
  26.  
  27. Starting on the left side, lift the frame with a jack.
  28.  
  29. Mount the support brackets on both sides.
  30.  
  31. Tighten the frame bolts to 78 ft. lbs. (105 Nm), then tighten an additional 120°.
  32.  
  33. Tighten the bracket bolts to 37 ft. lbs. (50 Nm).
  34.  
  35. Remove the jack and repeat the procedure for the right side.
  36.  
  37. Remove the engine support tool and lifting eyelet from engine.
  38.  
  39. Tighten the engine mount nut to 37 ft. lbs. (50 Nm).
  40.  
  41. Install five new nuts on the steering rack and tighten them to 37 ft. lbs. (50 Nm).
  42.  
  43. Install the front engine mount nut, then tighten the front and rear bolts to 37 ft. lbs. (50 Nm).
  44.  
  45. Install the torque rod mount on the transaxle using new bolts. On earlier vehicles equipped with M18 bolts, tighten the bolts to 13 ft. lbs. (18 Nm) and then an additional 90 degrees. On later models with M10 bolts, tighten to 26 ft. lbs. (35 Nm) and then an additional 40 degrees.
  46.  
  47. Install the oil line bracket bolts and tighten to 19 ft. lbs. (25 Nm).
  48.  
  49. Tighten the exhaust pipe clamp while rocking the pipe back and forth to seat it properly.
  50.  
  51. Install the right and left halfshafts.
  52.  

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. Connect the brake line and ABS cable bracket on both sides.
  4.  
  5. Install the ABS sensor on the axle shaft and clean if needed.
  6.  
  7. Tighten the sensor to 7.4 ft. lbs. (10 Nm).
  8.  
  9. Attach the cable pipe and carbon canister to the subframe.
  10.  
  11. Install the front splash guard.
  12.  
  13. Install the wheels.
  14.  
  15. Install the starter and tighten the bolts to 30 ft. lbs. (40 Nm).
  16.  
  17. Connect the cable conduit and oxygen sensor connectors.
  18.  
  19. Install the dipstick tube with a new O-ring and tighten the bolt to 19 ft. lbs. (25 Nm).
  20.  
  21. Connect the slave cylinder and clips.
  22.  
  23. Fasten the back-up light switch connector.
  24.  
  25. Position the shift lever plate and secure with the lock pin.
  26.  
  27. Install the cables and lubricate the levers, cables, washers and clips with grease.
  28.  
  29. Connect ground strip to the firewall.
  30.  
  31. Install a new bolt and nut for the extension arm and torque rod.
  32.  
  33. Connect the oil cooler hose to the cooler, if equipped.
  34.  
  35. Lower the vehicle.
  36.  
  37. Install the throttle body and cover over control pulley.
  38.  
  39. Connect the intake manifold to the turbocharger.
  40.  
  41. Install the coolant expansion tank, battery tray, air cleaner and connectors.
  42.  
  43. Connect the control valve to air cleaner on turbocharged models.
  44.  
  45. Install the battery and attach leads.
  46.  
  47. Tighten the axle shaft nut to 89 ft. lbs. (120 Nm), then tighten an additional 60 degrees. Lock the axle shaft nut by notching its flange into the axle shaft groove.
  48.  
  49. Fill the transaxle with the specified amount of oil.
  50.  
  51. Reinstall the plug.
  52.  
  53. Check the function of the clutch before driving.
  54.  

 
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