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

Manual Transmission Assembly

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REMOVAL & INSTALLATION



240
  1. Disconnect the negative battery cable.
  2.  
  3. At the firewall, disconnect the back-up light connector.
  4.  
  5. Raise the front of the vehicle and install jackstands.
  6.  
  7. From under the vehicle:
    1. Loosen the setscrew and drive out the pin for the shifter rod.
    2.  
    3. Disconnect the shift lever from the rod.
    4.  

  8.  
  9. From inside the vehicle:
    1. Remove the shifter.
    2.  

  10.  
  11. Disconnect the clutch cable and return spring at the fork.
  12.  
  13. Disconnect the exhaust pipe bracket(s) from the flywheel cover.
  14.  
  15. Remove the oil pan splash guard.
  16.  
  17. Using a floor jack and a block of wood, support the engine beneath the oil pan.
  18.  
  19. Remove the transmission support crossmember.
  20.  
  21. Disconnect the driveshaft.
  22.  
  23. Disconnect the speedometer cable.
  24.  
  25. If so equipped, disconnect the overdrive wire.
  26.  
  27. Remove the starter retaining bolts and pull the starter free of the flywheel housing. Leave the starter wiring connected and secure the starter out of the way.
  28.  


CAUTION
The transmission is heavy. Support its weight with a second jack or hoist before removing. Do not allow the transmission to hang partially removed on the shaft.

  1. Support the transmission using another floor jack.
  2.  
  3. Remove the flywheel bell housing-to-engine bolts and remove the transmission by pulling it straight back.
  4.  

To install:
  1. Prior to installation, inspect the condition of the clutch and throwout bearing. Replace the bearing if it is scored or has been noisy in operation.
  2.  
  3. After reinstalling the transmission, tighten the mounting bolts to 30 ft. lbs. (41 Nm).
  4.  
  5. Secure the starter to the bell housing.
  6.  
  7. Fill the transmission with fluid to the proper level.
  8.  
  9. Connect the driveshaft, the speedometer cable and if necessary, the overdrive wiring.
  10.  
  11. Reinstall the transmission cross member. When secure, remove the jack from beneath the engine.
  12.  
  13. Replace the splash guard and attach the exhaust bracket to the bell housing.
  14.  
  15. Reconnect the clutch cable and return spring to the fork.
  16.  
  17. Install the shifter.
  18.  
  19. Under the vehicle: Connect the shifter rod to the shift lever. Don't forget to tighten the setscrew.
  20.  
  21. Connect the back-up light wiring.
  22.  
  23. Lower the vehicle.
  24.  
  25. Connect the negative battery cable.
  26.  

700 Series Vehicles
  1. If possible, support the engine with a hoist or support apparatus such as Volvo tool 5006 or equivalent. The purpose of supporting the rear of the engine is to prevent damage to the fan, radiator or front engine mounts by limiting the downward travel of the engine when the transmission crossmember is removed. If no lifting apparatus is available, place a jack with a protective wooden block beneath the engine oil pan. Do not place the jack under the flywheel (clutch) housing.
  2.  
  3. Disconnect the battery ground cable.
  4.  
  5. Remove the ashtray and holder assembly.
  6.  
  7. Remove the trim box around the gear shift lever.
  8.  
  9. Disconnect the shift lever cover from the floor.
  10.  
  11. Remove the snapring at the base of the shift lever.
  12.  
  13. Raise the vehicle and safely support it.
  14.  
  15. From underneath the vehicle, disconnect the gear shift rod at the gear shift lever.
  16.  
  17. Remove the lock screw, and press out the pivot pin.
  18.  
  19. Push up on the shift lever, and pull it up and out of the vehicle.
  20.  
  21. Matchmark the driveshaft and transmission flanges for later assembly.
  22.  
  23. Disconnect the driveshaft from the transmission.
  24.  
  25. Separate the exhaust pipe at the joint under the vehicle.
  26.  
  27. Detach the bracket from the front end of the exhaust pipe (near the bend).
  28.  
  29. Unbolt the transmission crossmember; at the same time, detach it from the rear support (rubber bushing).
  30.  
  31. Remove the rear support from the transmission.
  32.  
  33. Lower the transmission, as required.
  34.  
  35. Tag and disconnect the electrical connectors from the overdrive, back-up light connector and the solenoid.
  36.  
  37. Cut the plastic clamp at the gear shift assembly from the wiring harness.
  38.  
  39. Remove the starter motor retaining bolts.
  40.  
  41. Remove the cover plate under the bell housing and the cover plate from the other starter motor opening, as required.
  42.  
  43. Remove the slave cylinder from the bell housing and upper bolts holding the bell housing.
  44.  


CAUTION
The transmission is heavy. Support its weight with a second jack or hoist before removing. Do not allow the transmission to hang partially removed on the shaft.

  1. Place a transmission jack or a hydraulic floor jack underneath the transmission so that the transmission is resting on the jack pad. If possible, have another person steadying and guiding the transmission on the jack as it is lowered.
  2.  
  3. Remove the lower bolts holding the bell housing, and lower the transmission a few inches as you roll it back so the input shaft will clear. Stop the jack and make sure all wires and linkage are disconnected, then lower the transmission the rest of the way.
  4.  

To install:
  1. When installing the transmission, make sure the release bearing is correctly positioned in the shift fork, and that the input shaft is aligned in the clutch disc.
  2.  
  3. Install the upper bolts in the bell housing.
  4.  
  5. Raise the end of the transmission and attach the gear lever.
  6.  
  7. Attach the slave cylinder or clutch cable to its mounts.
  8.  
  9. Reinstall the starter motor.
  10.  
  11. Remount the gear lever to the transmission. Secure the connectors for the back-up lights, the solenoid and (on M46) the overdrive unit.
  12.  
  13. Replace the transmission crossmember.
  14.  
  15. Set the engine back to its normal position.
  16.  
  17. Tighten the exhaust pipe joint, attach its bracket and attach the gear shift rod to the gear shift lever.
  18.  
  19. Install and tighten the driveshaft.
  20.  
  21. Refill the transmission with the proper amount of fluid.
  22.  
  23. Connect the gear shift rod to the gear shift lever.
  24.  
  25. Inside the vehicle, mount and secure the shifter assembly.
  26.  
  27. Double check all installation items, paying particular attention to loose hoses or hanging wires, untightened nuts, poor routing of hoses and wires (too tight or rubbing) and tools left in the work area.
  28.  
  29. Lower the vehicle.
  30.  
  31. Install the ashtray, interior trim and shifter boot.
  32.  
  33. Connect the negative battery cable.
  34.  

 
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