Volvo Coupes/Sedans/Wagons 1970-1989 Repair Guide

Automatic Transmission

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REMOVAL & INSTALLATION



See Figures 1 and 2


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.

1800 Series
  1. Disconnect the battery ground and lift off the windshield washer container.
  2.  
  3. Disconnect the throttle cable from the lever and bracket.
  4.  
  5. Remove the radiator attaching bolts.
  6.  
  7. Raise the vehicle and support front and rear on jackstands.
  8.  
  9. Drain the oil into a clean container.
  10.  
  11. Disconnect the driveshaft from the transmission flange.
  12.  
  13. Disconnect the oil cooler pipes and remove the sump reinforcing bracket.
  14.  
  15. Remove the converter attaching bolts.
  16.  
  17. Place a jack or transmission dolly with holding fixture under the transmission.
  18.  
  19. Remove the shift control rods, shift lever bracket and rear crossmember.
  20.  
  21. Disconnect the front muffler clamp and the speedometer cable from the case.
  22.  
  23. Lower the jack until the filler pipe touches the firewall.
  24.  
  25. Disconnect all electrical connections at the case.
  26.  
  27. Remove the two upper bolts from the converter housing, the filler pipe and the two remaining converter housing bolts.
  28.  
  29. Lower the jack and pull the transmission to the rear to clear the guide pins.
  30.  

The transmission must not be tilted forward or the converter will slide off the input shaft.

  1. Install the transmission by balancing it on the jack or dolly and loading it straight onto the engine.
  2.  
  3. Install the two upper bolts for the converter housing, the filler pipe and two of the housing bolts. Torque the converter-to-drive plate bolts to 27 ft. lbs.
  4.  
  5. Connect the wiring to the transmission switches.
  6.  
  7. Elevate the jack and place the transmission in its final position. Install the speedometer cable and secure the front muffler clamp.
  8.  
  9. Install the rear crossmember, the shift lever bracket and the shift control rods. Tighten the crossmember bolts to 18 ft. lbs. (24 Nm). Once the crossmember is secure, the jack may be removed.
  10.  
  11. Install the remaining converter housing bolts, the sump reinforcement and connect the oil cooler pipes.
  12.  
  13. Attach the driveshaft and refill the oil in the transmission.
  14.  
  15. Lower the vehicle from its stands and install the radiator attaching bolts.
  16.  
  17. Attach the throttle cable to the lever and bracket and adjust if necessary.
  18.  
  19. Replace the windshield washer container and attach the negative battery cable.
  20.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the BW55/AW55 transmission mounting components-AW70 and AW71 are similar



Click image to see an enlarged view

Fig. Fig. 2: Access to the coupling flange bolts-AW55, BW 55, AW70 and AW71 transmissions

140 Series
  1. Disconnect the negative battery cable. Remove the dipstick and filler pipe clamp.
  2.  
  3. Remove the bracket and throttle cable from the dashboard and throttle control.
  4.  
  5. Disconnect the exhaust pipe at the manifold flange.
  6.  
  7. Raise the car and support on jackstands at the front and rear axles.
  8.  
  9. Drain the fluid into a clean container.
  10.  
  11. Disconnect the driveshaft from the transmission flange.
  12.  
  13. Disconnect the selector lever controls (shift linkage) and the pan reinforcing bracket.
  14.  
  15. Remove the converter attaching bolts.
  16.  
  17. Support the transmission with a jack or a transmission dolly and holding fixture.
  18.  
  19. Remove the rear crossmember.
  20.  
  21. Disconnect the exhaust pipe and rear engine mount brackets.
  22.  
  23. Remove the speedometer cable and filler pipe.
  24.  
  25. Install a wooden block between the engine and firewall; lower the jack until the engine contacts the block.
  26.  
  27. Make sure no tension is put on the battery cable.
  28.  
  29. Disconnect all electrical wiring at the transmission case.
  30.  
  31. Disconnect the starter cable and remove the starter.
  32.  
  33. Remove the converter housing bolts.
  34.  
  35. Pull the transmission backwards to clear the guide pins.
  36.  
  37. When reinstalling, load the transmission straight onto the engine and install the converter housing bolts. Tighten the converter-to-drive plate bolts to 27 ft. lbs. (37 Nm).
  38.  
  39. Install the starter and connect its cable; hook up all other wiring to the transmission case.
  40.  
  41. Using the jack, elevate the transmission and engine into their proper position. Install the speedometer cable and the filler pipe.
  42.  
  43. Reconnect the exhaust pipe and the rear engine mount brackets.
  44.  
  45. Install the rear crossmember and tighten its bolts to 18 ft. lbs. (24 Nm). When the crossmember is secure, the jack may be removed.
  46.  
  47. Install the converter attaching bolts. Connect the selector lever controls and the pan reinforcing bracket.
  48.  
  49. Connect the driveshaft to the transmission flange.
  50.  
  51. Lower the car from its stands and refill the transmission fluid.
  52.  
  53. Reconnect the exhaust pipe at the manifold flange.
  54.  
  55. Reinstall the bracket and throttle cable and adjust if necessary.
  56.  
  57. Install the dipstick and filler pipe.
  58.  
  59. Reconnect the negative battery cable.
  60.  

164 Models and 1975 240 Series
  1. Disconnect the negative battery cable. Remove the dipstick and filler pipe clamp.
  2.  
  3. Remove the bracket and throttle cable from the dashboard and throttle control.
  4.  
  5. Disconnect the exhaust pipe at the manifold flange.
  6.  
  7. Raise the car and support on jackstands at the front and rear axles.
  8.  
  9. Drain the fluid into a clean container.
  10.  
  11. Disconnect the driveshaft from the transmission flange.
  12.  
  13. Disconnect the selector lever controls (shift linkage) and the pan reinforcing bracket.
  14.  
  15. Remove the converter attaching bolts.
  16.  
  17. Support the transmission with a jack or a transmission dolly and holding fixture.
  18.  
  19. Remove the rear crossmember.
  20.  
  21. Disconnect the exhaust pipe brackets and remove the speedometer cable from the case.
  22.  
  23. Remove the filler pipe.
  24.  
  25. Install a wooden block between the engine and firewall; lower the jack until the engine contacts the block.
  26.  
  27. Make sure no tension is put on the battery cable.
  28.  
  29. Disconnect all electrical wiring at the transmission case.
  30.  
  31. Disconnect the starter cable and remove the starter.
  32.  
  33. Remove the converter housing bolts.
  34.  
  35. Pull the transmission backwards to clear the guide pins.
  36.  
  37. When reinstalling, load the transmission straight onto the engine and install the converter housing bolts. Tighten the converter-to-drive plate bolts to 35 ft. lbs. (47 Nm).
  38.  
  39. Install the starter and connect its cable; hook up all other wiring to the transmission case.
  40.  
  41. Using the jack, elevate the transmission and engine into their proper position. Install the speedometer cable and the filler pipe.
  42.  
  43. Reconnect the exhaust pipe and the rear engine mount brackets.
  44.  
  45. Install the rear crossmember and tighten its bolts to 18 ft. lbs. (24 Nm). When the crossmember is secure, the jack may be removed.
  46.  

  1. Install the converter attaching bolts. Connect the selector lever controls and the pan reinforcing bracket.
  2.  
  3. Connect the driveshaft to the transmission flange.
  4.  
  5. Lower the car from its stands and refill the transmission fluid.
  6.  
  7. Reconnect the exhaust pipe at the manifold flange.
  8.  
  9. Reinstall the bracket and throttle cable and adjust if necessary.
  10.  
  11. Install the dipstick and filler pipe.
  12.  
  13. Reconnect the negative battery cable.
  14.  

1976 and Later 240 and DL Series
  1. Disconnect the negative battery cable. Remove the dipstick and filler pipe clamp.
  2.  
  3. Remove the bracket and throttle cable from the dashboard and throttle control.
  4.  
  5. Disconnect the exhaust pipe at the manifold flange.
  6.  
  7. Raise the car and support on jackstands at the front and rear axles.
  8.  
  9. Drain the fluid into a clean container.
  10.  
  11. Disconnect the driveshaft from the transmission flange.
  12.  
  13. Disconnect the selector lever controls (shift linkage) and the pan reinforcing bracket.
  14.  
  15. Remove the converter attaching bolts.
  16.  
  17. Support the transmission with a jack or a transmission dolly and holding fixture.
  18.  
  19. Remove the rear crossmember.
  20.  
  21. Disconnect the exhaust pipe brackets and remove the speedometer cable from the case.
  22.  
  23. Remove the filler pipe.
  24.  
  25. Install a wooden block between the engine and firewall; lower the jack until the engine contacts the block.
  26.  
  27. Make sure no tension is put on the battery cable.
  28.  
  29. Disconnect all electrical wiring at the transmission case.
  30.  
  31. Disconnect the starter cable and remove the starter.
  32.  
  33. Remove the converter housing bolts.
  34.  
  35. Pull the transmission backwards to clear the guide pins.
  36.  
  37. When reinstalling, load the transmission straight onto the engine and install the converter housing bolts. Tighten the converter-to-drive plate bolts to 35 ft. lbs. (47 Nm).
  38.  
  39. Install the starter and connect its cable; hook up all other wiring to the transmission case.
  40.  
  41. Using the jack, elevate the transmission and engine into their proper position. Install the speedometer cable and the filler pipe.
  42.  
  43. Reconnect the exhaust pipe and the rear engine mount brackets.
  44.  
  45. Install the rear crossmember and tighten its bolts to 18 ft. lbs. (24 Nm). When the crossmember is secure, the jack may be removed.
  46.  
  47. Install the converter attaching bolts. Connect the selector lever controls and the pan reinforcing bracket.
  48.  
  49. Connect the driveshaft to the transmission flange.
  50.  
  51. Lower the car from its stands and refill the transmission fluid.
  52.  
  53. Reconnect the exhaust pipe at the manifold flange.
  54.  
  55. Reinstall the bracket and throttle cable and adjust if necessary.
  56.  
  57. Install the dipstick and filler pipe.
  58.  
  59. Reconnect the negative battery cable.
  60.  

All 260, GL Series
  1. Disconnect the negative battery cable and remove the air cleaner.
  2.  
  3. Disconnect the throttle cable.
  4.  
  5. Remove the two upper converter housing bolts.
  6.  
  7. Remove the filler pipe.
  8.  
  9. Raise the vehicle, support it front and rear with jackstands and drain the transmission oil into a clean container.
  10.  
  11. Remove the splash shield (8 bolts).
  12.  
  13. Disconnect the front muffler from the rubber hanger.
  14.  
  15. Disconnect the driveshaft from the transmission flange.
  16.  
  17. Remove the exhaust pipe brackets at the rear of the transmission.
  18.  
  19. Remove the rear crossmember.
  20.  
  21. Remove the rear engine support and exhaust pipe bracket.
  22.  
  23. Remove the speedometer cable.
  24.  
  25. Disconnect the cooler lines at the transmission.
  26.  
  27. Remove the electrical connections from the transmission.
  28.  
  29. Remove neutral start switch, if mounted on the case.
  30.  
  31. Remove shift control rod.
  32.  
  33. Remove the engine-to-transmission cover plate.
  34.  
  35. Remove the starter motor and cover.
  36.  
  37. Remove the converter-to-drive plate bolts.
  38.  
  39. Position a jack or a transmission dolly with holding fixture under transmission.
  40.  
  41. Remove the two lower converter housing bolts.
  42.  
  43. Pull the transmission back and down to clear the guide pins.
  44.  
  45. When reinstalling , support the transmission on the jack and position at the rear of the engine. Attach the transmission and install and tighten the starter and bolts.
  46.  
  47. Connect the oil filler pipe at the lower end but do NOT tighten the nut yet.
  48.  
  49. Install the upper retaining bolts for the case and tighten them to 35 ft. lbs. (47 Nm). Install the bracket and nuts for the oil filler pipe.
  50.  
  51. Now tighten the lower nut for the oil pipe. Correct torque is 60-70 ft. lbs. (81-95 Nm).
  52.  
  53. Attach the converter to drive plate bolts and torque them to 35 ft. lbs. (47 Nm).
  54.  
  55. Install the cover plate for the alternate starter position. Install the lower cover plate and tighten the bolts only to 5-6 ft. lbs.
  56.  
  57. Move the gear selector into position 2 (second form the front) and attach the front end of the control rod.
  58.  
  59. Attach the rear end of the control rod. Rough adjustments may be done by turning the entire assembly; fine adjustments are done only by turning the serrated sleeve. Maximum visible thread is 1 1 / 8 in. or 29mm.
  60.  
  61. Check the control rod adjustment. The free-play from DRIVE to its forward stop should be the same as from 2 to its rearward stop. Adjust linkage as necessary to establish this free-play.
  62.  
  63. Install the neutral safety switch if it is mounted in the case.
  64.  
  65. Install the oil cooler pipes.
  66.  
  67. Attach the driveshaft to the drive flange on the transmission.
  68.  
  69. Install the exhaust pipe bracket, the rear engine mount and the speedometer cable.
  70.  
  71. Install the transmission crossmember and tighten its bolts to 35 ft. lbs. (47 Nm).
  72.  
  73. Install and tighten the exhaust pipe clamps and the rubber muffler hanger.
  74.  
  75. Install the splash guard under the engine.
  76.  
  77. Attach the throttle cable to the bracket and adjust as necessary. Check the full throttle adjustment; the pulley should touch the stop with the accelerator pedal floored. Adjust the transmission cable as outlined previously in this section.
  78.  
  79. Install the air cleaner, fill the transmission with the correct amount of fluid and lower the car to the ground.
  80.  

700 Series

See Figures 3, 4 and 5

  1. Place the gear selector in the PARK position; if equipped with ZF 22, place selector in NEUTRAL.
  2.  
  3. Disconnect the kickdown cable at the throttle pulley on the engine. Disconnect the battery ground cable.
  4.  
  5. Disconnect the oil filler tube at the oil pan, and drain the transmission oil.
  6.  



Click image to see an enlarged view

Fig. Fig. 3: Remove these external parts from the ZF 22 transmission


CAUTION
The oil will be scalding hot if the car 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 AW 71 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. Remove the transmission crossmember assembly.
  8.  



Click image to see an enlarged view

Fig. Fig. 4: Access to the coupling flange bolts-AW/BW55 and AW70, AW71 transmissions



Click image to see an enlarged view

Fig. Fig. 5: Access to the coupling flange bolts-ZF 22 transmission. Above: D24 and D24T. Below: B23 and B230

  1. Disconnect the exhaust pipe at the joint and remove the exhaust pipe bracket from the exhaust pipe. Remove the rear engine mount with the exhaust pipe bracket.
  2.  
  3. On D24T models, remove the starter motor. On B28F V6 models, remove the bolts retaining the starter motor.
  4.  

  1. Remove the cover for the alternate starter motor location on B28F models. Remove the cover plate at the torque converter housing bottom on B28F models.
  2.  
  3. Disconnect the oil cooler lines at the transmission.
  4.  
  5. Remove the two upper bolts at the torque converter cover. Remove the oil filler tube.
  6.  

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

  1. Remove the two lower bellhousing screws.
  2.  
  3. Remove the screws retaining the torque converter to the drive plate. Pry the torque converter back from the drive plate with a small pry bar.
  4.  
  5. Slowly lower the transmission as you pull it back to clear the input shaft. Do not tilt the transmission forward, or the torque converter may slide off.
  6.  

To install:
  1. When reinstalling, install the two lower bolts in the casing as soon as the transmission is in place. For B28 motors, 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. Now tighten the nut for the oil tube to 65 ft. lbs. (88 Nm).
  6.  
  7. Install the bolts for the coupling flange; tighten the bolts hand-tight first, then tighten in a crisscross pattern to 32 ft. lbs. (43 Nm).
  8.  
  9. Reinstall the rear engine mount with the exhaust pipe bracket and reconnect the exhaust system.
  10.  
  11. Reinstall the transmission crossmember; when it is securely bolted in place, the supporting jack may be removed.
  12.  
  13. Reinstall the driveshaft.
  14.  
  15. Making sure that both the transmission linkage and the shift selector in the car are in the PARK position (NEUTRAL for ZF 22 transmission), attach the actuator rod and the reaction rod. Adjust the shift linkage as necessary.
  16.  
  17. On AW71 models, install and connect the wiring to the solenoid valve.
  18.  

  1. Connect the kickdown cable at the throttle pulley. Adjust the cable if necessary.
  2.  
  3. Fill the transmission with oil. Attach the negative battery cable.
  4.  

 
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