Volvo Cars 1999-05

Transaxle Removal & Installation

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  1. Drain the transaxle fluid.
  2.  


NOTE
Leave the key in the ignition switch.

  1. Remove or disconnect the following:

    Negative battery cable
     
    Battery box
     
    Front wheels
     
    Engine splash guard
     
    Halfshafts
     
    Anti-roll bar
     
    Steering gear and hang securely out of the way
     
    Sub-frame
     
    Transmission ground lead
     
    Torque rod mounting
     
    Air intake assembly
     
    Transmission cables
     
    Coolant hose bracket
     
    Clutch cable
     
    Gear selector cable bracket
     

  2.  
  3. Install lifting beam 999-7103 and lifting hook 999-7102 to the engine.
  4.  
  5. Remove the left hand engine mount and lower the engine slightly.
  6.  
  7. Remove or disconnect the following:

    Engine mount bracket
     
    Starter motor
     
    Top three mounting bolts between the engine and the transmission
     
    Reverse lamp switch
     

  8.  
  9. Install transaxle fixture 999 5463 on transaxle jack, using the torque rod mounting bolts to hold it in place. At the same time, fit tool 999 5463-2 support plate and raise the jack so that it is making light contact.
  10.  
  11. Remove the remaining mounting bolts between the engine and transmission.
  12.  
  13. Remove the transmission.
  14.  

To install:

  1. Install or connect the following:

    Transmission and tighten the lower seven mounting bolts to 37 ft. lbs. (50 Nm)
     
    Reverse lamp switch
     
    Engine mount bracket and tighten to 59 ft. lbs. (80 Nm)
     
    Starter motor
     
    Top three mounting bolts between the engine and transmission and tighten to 37 ft. lbs. (50 Nm)
     

  2.  
  3. Raise the transmission slight and install the left hand engine mount bolt and tighten to 96 ft. lbs. (130 Nm).
  4.  
  5. Install or connect the following:

    Gear selector cable bracket and tighten to 18 ft. lbs. (24 Nm)
     
    Clutch cable
     
    Coolant hose bracket
     
    Transmission cables and adjust if necessary
     
    Air intake assembly
     
    Transmission ground lead
     
    Torque rod mounting and tighten to 37 ft. lbs. (50 Nm)
     
    Sub-frame
     
    Anti-roll bar
     
    Steering gear
     
    Halfshafts
     
    Engine splash guard
     
    Front wheels
     
    Battery box and battery
     

  6.  
  7. Fill the transmission to the correct level.
  8.  
  9. Start the engine and check for leaks.
  10.  

  1. Drain the transaxle fluid.
    NOTE
    Leave the key in the ignition switch.

  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Battery box
     
    Front wheels
     
    Engine splash guard
     
    Halfshafts
     
    Anti-roll bar
     
    Steering gear and hang securely out of the way
     
    Sub-frame
     
    Transmission ground lead
     
    Torque rod mounting
     
    Air intake assembly
     
    Transmission cables
     
    Coolant hose bracket
     
    Clutch cable
     
    Gear selector cable bracket
     

  4.  
  5. Install lifting beam 999-7103 and lifting hook 999-7102 to the engine.
  6.  
  7. Remove the left hand engine mount and lower the engine slightly.
  8.  
  9. Remove or disconnect the following:

    Engine mount bracket
     
    Starter motor
     
    Top three mounting bolts between the engine and the transmission
     
    Reverse lamp switch
     

  10.  
  11. Install transaxle fixture 999 5463 on transaxle jack, using the torque rod mounting bolts to hold it in place. At the same time, fit tool 999 5463-2 support plate and raise the jack so that it is making light contact.
  12.  
  13. Remove the remaining mounting bolts between the engine and transmission.
  14.  
  15. Remove the transmission.
  16.  

To install:

  1. Install or connect the following:

    Transmission and tighten the lower seven mounting bolts to 37 ft. lbs. (50 Nm)
     
    Reverse lamp switch
     
    Engine mount bracket and tighten to 59 ft. lbs. (80 Nm)
     
    Starter motor
     
    Top three mounting bolts between the engine and transmission and tighten to 37 ft. lbs. (50 Nm)
     

  2.  
  3. Raise the transmission slight and install the left hand engine mount bolt and tighten to 96 ft. lbs. (130 Nm).
  4.  
  5. Install or connect the following:

    Gear selector cable bracket and tighten to 18 ft. lbs. (24 Nm)
     
    Clutch cable
     
    Coolant hose bracket
     
    Transmission cables and adjust if necessary
     
    Air intake assembly
     
    Transmission ground lead
     
    Torque rod mounting and tighten to 37 ft. lbs. (50 Nm)
     
    Sub-frame
     
    Anti-roll bar
     
    Steering gear
     
    Halfshafts
     
    Engine splash guard
     
    Front wheels
     
    Battery box and battery
     

  6.  
  7. Fill the transmission to the correct level.
  8.  
  9. Start the engine and check for leaks.
  10.  

Front Wheel Drive & All Wheel Drive



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Install a support fixture to the engine lifting eyes.
  4.  
  5. Drain the transaxle fluid.
  6.  
  7. Remove or disconnect the following:

    Battery and tray
     
    Air intake ducts
     
    Gear select cables and link plate
     
    Reverse light switch connector
     
    Turbocharger inlet pipe, if equipped
     
    Upper engine oil cooler hose
     
    Clutch slave cylinder
     
    Transaxle ground cable
     
    Rear engine mount
     
    Starter motor
     
    Firewall ground cable
     
    Torque arm
     
    Front wheels
     
    Wheel speed sensors
     
    Brake line brackets
     
    Wheel speed sensor wiring brackets
     
    Inner fender liners
     
    Lower ball joints
     
    Stabilizer bar links
     
    Evaporative Emissions (EVAP) canister hoses
     
    Exhaust front pipe
     
    Axle halfshafts
     
    Heated Oxygen (HO 2 S) sensor harness clamps
     
    Vehicle Speed (VSS) sensor connector
     
    Transaxle mount
     
    Transaxle flange bolts
     

  8.  
  9. Loosen the 2 right side subframe-to-body bolts approximately 1 / 2 inch. Support the subframe with a jack and remove the subframe-to-body bolts on the left side.
  10.  
  11. Lower the jack and let the frame hang down from the right side bolts.
  12.  
  13. Tie the left side of the steering gear to the left side frame rail for support. Remove the steering gear engine mount.
  14.  
  15. Lower the engine and transaxle with the lifting hook.
  16.  
  17. Pull the transaxle away from the engine. Lower the transaxle from the vehicle.
  18.  

To install:

  1. Install or connect the following:

    Transaxle and tighten the flange bolts to 37 ft. lbs. (50 Nm)
     
    Transaxle mount and tighten the bolts to 37 ft. lbs. (50 Nm)
     
    VSS sensor connector
     
    HO 2 S sensor harness clamps
     

  2.  
  3. Install the subframe using new bolts. Starting on the left side, lift the frame with a jack. Mount the support brackets on both sides. Tighten the frame bolts to 78 ft. lbs. (105 Nm) plus 120 degrees. Tighten the bracket bolts to 37 ft. lbs. (50 Nm). Repeat the procedure for the right side. Remove the subframe jack.
  4.  
  5. Install or connect the following:

    Steering gear engine mount and tighten the bolts to 37 ft. lbs. (50 Nm)
     
    Axle halfshafts
     
    Exhaust front pipe
     
    EVAP canister hoses
     
    Stabilizer bar links
     
    Lower ball joints
     
    Inner fender liners
     
    Wheel speed sensor wiring brackets
     
    Brake line brackets
     
    Wheel speed sensors
     
    Front wheels
     
    Torque arm and tighten the bolts to 26 ft. lbs. (35 Nm) plus 40 degrees
     
    Firewall ground cable
     
    Starter motor
     
    Rear engine mount and tighten the bolts to 37 ft. lbs. (50 Nm)
     
    Transaxle ground cable
     
    Clutch slave cylinder
     
    Upper engine oil cooler hose
     
    Turbocharger inlet pipe, if equipped
     
    Reverse light switch connector
     
    Gear select cables and link plate
     
    Air intake ducts
     
    Battery and tray
     

  6.  
  7. Fill the transaxle to the correct level.
  8.  
  9. Start the engine and check for leaks.
  10.  

5-Cylinder Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the transaxle fluid.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Air intake assembly
     
    Upper charge air pipe
     
    Upper torque rod
     
    Engine stabilizer brace
     
    Intake pipe from the charge air cooler (CAC)
     
    Coolant hose from the heater unit
     
    Transmission cables
     
    Reverse lamp switch connector
     
    Cable conduit
     
    Starter motor
     
    Ignition setting sender
     

  6.  
  7. Raise and support the engine.
  8.  
  9. Remove or disconnect the following:

    Engine splash guards
     
    Anti-roll bar link at the spring strut
     
    Wheel spindle from the control arm
     
    Drive shaft from the wheel spindle
     
    Sealing ring for the CV-joint housing
     
    Drive shaft
     
    Steering gear sub-frame bolts
     
    Rear engine pad
     
    Torque rod mounting bolts from the transaxle
     
    Cross members
     
    Heated oxygen (HO 2 S) sensor cable bracket
     
    Left halfshaft from the transaxle
     
    Transfer case, if equipped
     
    Rear engine mount
     
    Inner fender liner
     

  10.  
  11. Install transaxle fixture 999 5463 on transaxle jack, using the torque rod mounting bolts to hold it in place. At the same time, fit tool 999 5463-2 support plate and raise the jack so that it is making light contact.
  12.  
  13. Remove the transaxle flange bolts.
  14.  
  15. Remove the transaxle.
  16.  

To install:

  1. Install or connect the following:

    Transaxle and tighten the bolts to 37 ft. lbs. (50 Nm)
     
    Rear engine mount and tighten the bolts to 37 ft. lbs. (50 Nm)
     
    Transfer case, if equipped
     
    Sealing ring for the CV-joint housing
     
    Drive shaft on the transaxle
     
    Wheel spindle on the control arm
     
    Steering gear sub-frame bolts using new lock nuts. Tighten the bolts to 37 ft. lbs. (50 Nm).
     
    Rear engine pad and tighten the bolt to 37 ft. lbs. (50 Nm)
     
    Heated oxygen (HO 2 S) sensor cable bracket
     
    Cross members and tighten the bolts to 18 ft. lbs. (25 Nm)
     
    Torque rod mounting bolts using new bolts and tighten to 37 ft. lbs. (50 Nm)
     
    Fender inner liner
     
    Starter motor and tighten the bolts to 29 ft. lbs. (40 Nm)
     
    Ignition setting sender and tighten to 88 inch lbs. (10 Nm)
     
    Cable conduit
     
    Reverse lamp switch connector
     
    Transaxle cables
     
    Coolant hose on the heater unit
     
    Intake pipe from the charge air cooler (CAC)
     
    Engine stabilizer brace
     
    Torque rod
     
    Upper charge air pipe
     
    Air intake assembly
     
    Negative battery cable
     

  2.  
  3. Fill the transaxle to the correct level.
  4.  

 
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