Volvo Coupes/Sedans/Wagons 1970-1989 Repair Guide

Adjustments

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FRONT BAND ADJUSTMENT



BW 35 Transmission
  1. Remove the pan as outlined in the Pan Removal and Installation section.
  2.  
  3. Insert a 6mm gauge block between the adjusting bolt and the servo cylinder. Tighten the bolt with an inch-pound torque wrench to 10 in. lbs.
  4.  
  5. Adjust the position of the adjusting bolt spring. It should be 1-2 threads from the lever.
  6.  
  7. Remove the gauge block and torque wrench. Make sure that the long end of the adjusting bolt spring is inserted in the cam for the front brake band.
  8.  
  9. Install the pan as outlined in the Pan Removal and Installation section.
  10.  

REAR BAND ADJUSTMENT



BW 35 Transmission
  1. An access hole is provided in the right side of the transmission tunnel. On some 140 series and 164 models, it is necessary to disconnect the right heater duct. Lift up the carpet and position it to one side. Remove the rubber plug from the access hole.
  2.  
  3. Loosen the locknut from the adjusting screw located on the right side of the transmission case.
  4.  
  5. Using a 5 / 16 in. square socket and a foot-pound torque wrench, tighten the adjusting screw to 10 ft. lbs.; then back off the adjusting screw one complete turn.
  6.  
  7. Without disturbing the adjustment, tighten the locknut.
  8.  
  9. Install the rubber plug, fit the carpet, and install the heater duct if removed.
  10.  

The BW55, AW55, AW70, AW71 and ZF22 transmissions are equipped with a multi-disc (band) system which does not require any adjustment. No provision is made for band adjustment, even at overhaul.

SHIFT LINKAGE ADJUSTMENT



1970-71 140 Series and 164 Model (With BW 35 Transmission)

See Figure 1

  1. Disconnect the pull rod from the selector shaft lever. Place the selector lever in NEUTRAL.
  2.  
  3. Place the lever on the transmission in the central position. Adjust the length of the pull rod so that, on 140 series models, the ball socket can easily be snapped onto the lever ball, and so that, on 164 models, the pin can easily be pushed through the yoke and lever. When the pull rod is adjusted correctly, the distance to the link in the NEUTRAL position should be equal to the distance to the link in the DRIVE position.
  4.  
  5. Make sure that the gear indicator points correctly on the scale (quadrant). Adjustments are made to the cable sleeve at the indicator.
  6.  



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Fig. Fig. 1: Adjust the gear selector linkage for proper engagement-1970 140 series and 164 models

  1. Make sure that the output shaft is locked with the control lever in the PARK position.
  2.  
  3. Connect the pull rod to the selector shaft lever.
  4.  

1971-73 1800 Series

See Figures 2 and 3

  1. Check to make sure that the transmission lever and the lever at the linkage bracket are parallel. If necessary, adjust the length of the lower control rod.
  2.  
  3. Disconnect the upper control rod from the intermediate lever. Place the gear selector in NEUTRAL. Also set the transmission lever to its third (neutral) position. Adjust the length of the upper control rod so that the ball socket aligns with the ball stud. Connect the control rod to the lever.
  4.  



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Fig. Fig. 2: Adjust the length of the lower control rod to cause the distances to the inhibitor plate in "A" and "B" to be equal

  1. If the upper control rod adjustment is correct, the distances to the inhibitor plate in NEUTRAL and DRIVE (A and B) should be equal.
  2.  



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Fig. Fig. 3: Adjust the gear selector between the clearances shown according to specification-1972 and later models except 1800 series

  1. Make sure that the output shaft is locked with the selector lever in the PARK position.
  2.  

1972-73 140 Series and 164 Models

See Figure 4

  1. Disconnect the shift rod from the transmission lever. Place both the transmission lever and the gear selector lever in the "2" position.
  2.  
  3. Adjust the length of the shift control rod so that a small clearance (distance B) of 1mm is obtained between the gear selector lever inhibitor and the inhibitor plate when the shift control rod is connected to the transmission lever.
  4.  



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Fig. Fig. 4: Adjust the bottom end of the gear selector to set clearance between DRIVE towards NEUTRAL to be the same as "2" towards "1"-

  1. Position the gear selector lever in DRIVE and make sure that a similar small clearance (distance A) of 1mm exists between the lever inhibitor and the inhibitor plate. Disconnect the shift control rod from the transmission lever and adjust if necessary.
  2.  

  1. Lock the control rod bolt with its safety clasp and tighten the locknut. Make sure that the control rod lug follows with the transmission lever.
  2.  
  3. After moving the transmission lever to the PARK and "1" positions, make sure that the clearances "A" and "B remain the same. In addition, make sure that the output shaft is locked with the selector lever in the PARK position.
  4.  

1972-75 140 Series, 164 Models, and 240 Series With BW 35 Transmission

  1. Disconnect the shift rod from the transmission lever. Place both the transmission lever and the gear selector lever in the "2" position.
  2.  
  3. Adjust the length of the shift control rod so that a small clearance (distance B) of 1mm is obtained between the gear selector lever inhibitor and the inhibitor plate, when the shift control rod is connected to the transmission lever.
  4.  
  5. Position the gear selector lever in DRIVE and make sure that a similar small clearance (distance A) of 1mm exists between the lever inhibitor and the inhibitor plate. Disconnect the shift control rod from the transmission lever and adjust, if necessary.
  6.  
  7. Lock the control rod bolt with its safety clasp and tighten the locknut. Make sure that the control rod lug follows with the transmission lever.
  8.  
  9. After moving the transmission lever to the PARK and "1" positions, make sure that the clearances "A" and "B" remain the same.
  10.  

1976 and Later Models Except 700 Series
  1. With the engine off, check that the distance between the DRIVE position and its forward stop is equal to the distance between the "2" position and its rearward stop when the gear selector is moved. If you are not sure, remove the gear quadrant cover, and measure.
  2.  
  3. If adjustment is necessary, a rough setting is made by loosening the locknut and rotating the clevis on the control rod to the transmission. A fine adjustment can be made by rotating the knurled sleeve between the control rod locknut and the pivot from the gear selector lever. Increasing the rod length will decrease clearance between the DRIVE position and its forward stop, and vice versa. Maximum permissible length of exposed thread between the locknut and the control rod is 28mm.
  4.  

700 Series With AW70/71 or ZF22 Transmission

See Figures 5, 6 and 7

Before adjusting shift linkage, make sure the starter motor operates only in PARK or NEUTRAL positions; that the back-up light illuminate only in R and that the shift lever is vertical in PARK with the car level.

  1. Place the shift lever in PARK.
  2.  
  3. Loosen the locknuts on the adjustment and reaction rods (on the linkage under the car).
  4.  



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Fig. Fig. 5: Loosen the locknuts on the adjustment and reaction rods-AW70/AW71 automatic transmissions

  1. Make sure the shift lever is in PARK. Turn the driveshaft until it locks in position.
  2.  
  3. Position the gear linkage lever (A) vertically and tighten the locknut. (The gear selector lever may hit the dashboard if the linkage lever is positioned too far backwards.)
  4.  
  5. Press the reaction rod arm backwards until a slight resistance is felt. Tighten the locknut to 3.5 ft. lbs. This is just enough to hold it it in place and still allow adjustment; it will be fully tightened later in the procedure.
  6.  



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Fig. Fig. 6: Adjust rod arm "A" as necessary by turning the locknuts (see arrows) on the adjustment rod (left) or reaction rod (right)

  1. Move the shift selector to DRIVE and:
    1. For AW70/71 transmissions: Check the free-play in DRIVE when the lever is gently moved towards NEUTRAL. The play should be noticeable and less than or equal to the free-play in 2 when the lever is moved gently towards 1 . If the play is correct, tighten the locknut to 15 ft. lbs. (20 Nm). If the lever is rigid in position 2 (no free-play), move the reaction lever forward about 2.5mm. If the lever is rigid in position DRIVE, move the reaction lever backwards about 2.5mm. Again check free-play and, if correct, tighten the locknut to 15 ft. lbs. (20 Nm).
    2.  
    3. For ZF22 transmissions: Check the free-play in DRIVE when the lever is gently moved towards NEUTRAL. The play should be noticeable and less than or equal to the free-play in "3" when moved towards "2." If the play is correct, tighten the locknut to 15 ft. lbs. (20 Nm). If the lever is rigid (no free-play) in position "3", move the reaction lever forward about 2.5mm. If the lever is rigid in the DRIVE position, move the lever backwards about 2.5mm. Recheck the free-play and if correct, tighten the locknut to 15 ft. lbs. (20 Nm).
    4.  

  2.  



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Fig. Fig. 7: Check the clearance between "D" and "N" then check between 1st and 2nd

  1. Recheck that the starter engages only in PARK or NEUTRAL and that the reverse lights illuminate only in REVERSE. On certain cars, the reverse lights may not engage after the shift linkage is adjusted; in this case, adjust the reaction lever slightly forward, thereby reducing the play in DRIVE when moved towards NEUTRAL.
  2.  

THROTTLE AND DOWNSHIFT CABLE ADJUSTMENT



1970-75 Models

Correct adjustment of the throttle cable is imperative for the proper shifting of the transmission. Connect a tachometer to the engine and an oil pressure gauge to the rear of the transmission for this adjustment.

PROCEDURE A
  1. Warm up the engine and check the idle speed against specifications in the Tune-Up Chart. Make sure that the throttle cable and cable housing (outer sheath ) are attached correctly.
  2.  
  3. On dual carburetor engines, the threaded sleeve should be screwed to within 1 / 32 in. (0.8mm) of the crimped stop on the cable.
  4.  


CAUTION
Firmly apply the handbrake and block all four wheels. The next test requires momentary acceleration in gear.

  1. With one foot firmly on the brake pedal and the accelerator fully depressed, make sure that the carburetor is at the full-open stopped position and that the line pressure reading is 160 psi minimum.
  2.  

PROCEDURE B

If the cable stop has been damaged, the adjustment disturbed, or if the transmission is not functioning properly, the throttle cable must be adjusted as follows:

  1. Firmly apply the parking brake and place blocks in front and in back of the wheels.
  2.  
  3. Place the gear selector in DRIVE. Note the line pressure readings at 700 rpm and 1200 rpm. The line pressure increase between the two readings should be a minimum of 15 psi and a maximum of 20 psi for B20 engines, and 25-30 psi for B30 engines.
  4.  
  5. If the pressure increase is below the standard, the effective length of the outer cable (cable housing) must be increased. If the pressure increase is above specification, shorten the effective length of the cable. The length of the outer cable is determined by the adjuster. Adjust it and retest as necessary.
  6.  

PROCEDURE C

If the cable itself has been damaged and is in need of replacement, the transmission oil pan must be removed. Refer to "Fluid Pan Removal and Installation". Adjust the new cable as follows:

Do not attempt to lubricate the new cable; it is pre-lubricated.

  1. With the pan removed, observe the position of the throttle cable cam (in the transmission) in relation to the accelerator pedal position.
  2.  
  3. With the accelerator fully released and the carburetor lever at the idle stop, the heel of the cam must contact the full diameter of the downshift valve, taking up all of the slack in the inner throttle cable.
  4.  
  5. With the accelerator fully depressed and the carburetor lever at the full-open stop, the constant radius area of the cam must be the point of contact with the downshift valve.
  6.  
  7. Make sure that the outer cable (cable housing) is correctly positioned in its adjuster.
  8.  

1976 and Later Models (Except Diesel)

See Figure 8

  1. The throttle plate angle and throttle cable must be adjusted first. Disconnect the cable at the control pulley and the linkage rod at the throttle shaft.
  2.  
  3. Set the throttle plate angle by loosening the adjusting screw locknut and backing off the screw. Turn in the screw until it just makes contact and then one additional turn. Tighten the locknut.
  4.  
  5. Adjust the linkage rod so that it fits onto the throttle shaft pulley ball without moving the cable pulley. Attach the throttle cable to the pulley and adjust the cable sheath so that the cable is stretched but does not move the cable pulley. Fully depress the gas pedal and check that the pulley contacts the full throttle stop.
  6.  
  7. With the transmission cable hooked up, check that there is 0.010-0.040 in. (0.25-0.60mm) clearance between the cable clip and the adjusting sheath. The cable should be stretched at idle.
  8.  



Click image to see an enlarged view

Fig. Fig. 8: Adjust the cable in the locations shown-AW70/AW71 and ZF transmissions

  1. Pull out the cable about 1 / 2 in. (13mm) and release. A distinct click should be heard from the transmission as the throttle cam returns to its initial position. Depress the gas pedal again to wide open throttle. Check that the transmission cable moves about 2 in. (50mm). Adjust as necessary at the adjusting sheath.
  2.  

Diesel Models

See Figures 9, 10, 11 and 12

If the engine is cold, the cold start device must be disengaged before the linkage can be adjusted. To disengage the cold start device, loosen screw (1) in the illustration, push the lever forward and turn the sleeve 90°


WARNING
Do not touch screw (2) in the illustration, or the cold start device will have to be reset on the test bench.

To adjust the linkage:


Click image to see an enlarged view

Fig. Fig. 9: Disconnect the link rod lever and adjust the cable at its plastic adjuster

  1. Disconnect the link rod lever on the injection pump by unsnapping the plastic clamp on the ball joint of the link rod and pulling the lever off the socket on the accelerator arm.
  2.  
  3. Turn the plastic cable adjuster until the cable is stretched out but does not cause the pulley to move from its idle stop.
  4.  



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Fig. Fig. 10: Depress the accelerator pedal and make sure the pulley notch touches the maximum speed stop

  1. Have an assistant press the accelerator pedal to the floor and check to see that the pulley notch touches the maximum speed stop.
  2.  

For manual transmission models, proceed to step 7.

  1. To adjust the kickdown cable on models with automatic transmission, have an assistant press the accelerator pedal to the floor and measure how much inner cable is exposed on the kickdown cable. It should be exposed approximately 2.05 in. (52mm) between the end positions.
  2.  



Click image to see an enlarged view

Fig. Fig. 11: Adjust the kickdown cable by setting the clearance between the cable clip and the cable sheath to 0.01-0.04 in. (0.25-1.00mm)

  1. Return the accelerator pedal to idle position. The kickdown cable should be stretched and the distance between the kickdown cable clip and the cable sheath should be 0.01-0.04 in. (0.25-1.00mm).
  2.  
  3. If either of these measurements are not correct, adjust them at the threaded end of the cable sheath.
  4.  
  5. On all models, connect the link rod to the injection pump accelerator arm.
  6.  
  7. Have an assistant floor the accelerator pedal and adjust the link rod length so that the injection pump accelerator arm touches the maximum speed adjusting screw.
  8.  
  9. Return the accelerator pedal to the idle position and check to see that the accelerator arm touches the idle speed adjusting screw. If not, loosen and move the link rod ball joint in its oblong slot on the accelerator arm until the arm touches the idle speed adjusting screw. Tighten the ball joint.
  10.  



Click image to see an enlarged view

Fig. Fig. 12: A maximum clearance of 0.012 in. (0.3mm) is permitted between the pulley and the maximum speed stop.

  1. Repeat steps 8 and 9 until the linkage is correctly adjusted.
  2.  

A maximum clearance of 0.012 in. (0.3mm) is permitted between the pulley and the maximum speed stop.

  1. Reconnect the cold start device, if disconnected.
  2.  

 
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