4T65 Transmission
Transmission, installing
Special tools:
951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor
999 5395 REMOVAL TOOL 999 5395 Removal Tool
Note! As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information is always correct.
When replacing with a new transmission
Note! Check the identification plate on the transmission to ensure that the correct transmission is selected for installation.
Checking before installing
Flushing clean the oil cooler
When replacing the transmission, the oil cooler must always be flushed clean because there may be particles in the oil cooler. See Oil cooler, flush cleaning Procedures.
Check that the transmission and engine mating surfaces are absolutely clean.
Also check that the guide sleeves towards the engine are in position and are free of faults.
Lubricate the holes in the transmission (for the guide pins). Use a little grease.
Adjusting the position of the transmission and engine
Adjust height and angle with the mobile jack and the transmission fixture.
Locate the transmission on the engine.
Ensure that the transmission goes straight in relation to the engine and that the torque converter is in the correct location.
Note! If necessary: Turn the engine so that the stator shaft is correctly aligned in the torque converter.
Installing and tightening the screws for the transmission
Install all 6 screws for the transmission and engine.
At the same time, check that the whole of the transmission is in contact with the engine.
Then tighten the transmission / engine screws crosswise. Tighten to 50 Nm.
Remove the fixture from the transmission.
Install the 2 screws on the bracket at the cover for the differential housing.
Tighten the screws. Tighten to 50 Nm.
Installing the splash guard above the transmission
Slide the splash guard up and secure it with a screw at the right drive shaft.
The illustration shows the splash guard when the three-way catalytic converter (TWC) is not in position.
Installing the heated oxygen sensor (HO2S) connectors on the bracket on the transmission
Connect the connectors.
Secure the connectors on the bracket.
Install the clamp with the wiring on the transmission. Tighten the nut. Tighten to 25 Nm.
Lower the vehicle.
Lifting the engine and transmission to the horizontal position
Lift up the engine and transmission to the horizontal position.
Installing the oil pipe at the transmission
Tighten the screw nipples. Tighten to 30 Nm. Counterhold on the connections.
Tighten the nuts at the bracket. Tighten to 25 Nm.
Installing the rear engine mounting
Install:
- the rear engine mounting on the transmission
- the 4 screws for the engine mounting. Tighten to 50 Nm
Installing the engine pad
Insert the engine pad between the bodywork and the three-way catalytic converter (TWC).
Secure the heat shield on the engine pad so that it is against the three-way catalytic converter (TWC).
Installing the engine pad on the engine mounting
Take out the nut, a short extension bar and a socket.
- Insert the nut into the socket so that it remains in place
- Insert the extension bar up to the collision protection system using your left hand
- Move up the engine pad to the engine mounting. Place the nut on the engine pad. Tighten the nut from above.
Installing the sub-frame on the bodywork
See Transmission, installing Gearbox, Installing.
Installing the screw for the rear engine pad through the steering gear
Install the screw. Tighten to 50 Nm.
Installing the collision protection system over the steering gear
Only applies to right-hand drive cars
Installing the left drive shaft on the transmission, wheel spindle and control arm
See Transmission, installing Gearbox, Installing.
Installing the drive shaft and the viscous coupling
Right-hand side:
Carefully align the viscous coupling in the transmission. Ensure that the sealing ring is not damaged.
Install:
- the drive shaft to the viscous coupling. Press the drive shaft so that the locking in the viscous coupling secures the drive shaft
- the bearing cap. Tighten to 25 Nm.
Installing the right-hand drive shaft on the transmission, wheel spindle and control arm
Ensure that the rubber seal is in position on the constant velocity joint.
Align the drive shaft in the wheel arch. Install the screw loosely in the drive shaft.
Install:
- the mobile jack under the sub-frame. Remove both the sub-frame screws. Lower the sub-frame approximately 10 cm
- the wheel spindle on the control arm
- the lock nut loosely.
Lift the sub-frame to the bodywork. Install the screws for the frame
Press the evaporator cable and the oil pipe into place in the sub-frame clips.
Installing and tightening the sub-frame screws
See Transmission, installing Gearbox, Installing.
Installing the screws for the bracket for the heated oxygen sensor (HO2S) cable
Install:
- the screws for the bracket
- the connectors in the sub-frame. Connect the connectors.
Installing the front cross member
Install:
- the screws for the exhaust pipe mounting. Tighten to 10 Nm
- the brake pipe in its holders
- the screws for the cross member. Tighten to 25 Nm.
Secure the heat deflector using rivets (early version).
Installing new lock nuts on the steering gear
Tighten the nuts and screws. Tighten to 50 Nm. Tighten the screw and the clamp for the oil pipe.
Installing the screw for the front engine pad and the torque rod mounting in the transmission
Install:
- the screw for the front engine pad. Tighten to 50 Nm
- the torque rod mounting on the transmission.
Note! Tighten to 50 Nm.
Installing the screws for the cable ducts and ground lead bracket
Tighten to 10 Nm.
Note! Vehicles with parking heaters: Install the heater in the bracket. Tighten the nuts. Tighten to 25 Nm.
Reinstall the fuel line in the clips on the sub-frame.
Installing and tightening front end components (both sides)
See Transmission, installing Gearbox, Installing.
Tightening the ball joint pinion
See Transmission, installing Gearbox, Installing.
Remove the lifting beam and the lifting hook from the engine and the vehicle
Lower the vehicle.
Remove the lifting fixture from the motor.
Install the ground strip. Tighten to 10 Nm.
Installing the torque converter screws
Note! Use new screws.
Install cranking tool 999 5395 REMOVAL TOOL 999 5395 Removal Tool to crank the engine.
Install all 6 screws loosely. Tighten the screws until the heads are in contact with the carrier plate. Then tighten to 35 Nm. Use Torx socket TX50.
Tighten to the torque converter in one of two ways. From above next to the cranking tool. From under the car where the screws can also be accessed.
Raise the vehicle.
Insert a screw in the cut-out under the transmission and turn the engine.
Tighten the 6 screws. Tighten to 35 Nm. Use a Torx TX50 socket (see the illustration).
Installing the clamp for the oil pipe
Install the screw and clamp.
Tighten to 10 Nm.
Installing the charge air hose
Reinstall the rubber hose for the delivery pipe. Tighten the hose clamp.
Installing the screws in the transmission and engine
Install:
- the 3 screws for the transmission and engine. Tighten to 50 Nm
- the ignition setting sender and the screw. Tighten to 10 Nm
- the screw for the clamp for the positive cable. Tighten to 10 Nm.
Installing the starter motor
Remove the cranking tool
Install:
- the starter motor. Tighten the screws. Tighten to 40 Nm
- the positive cables and the connector
- the nut for the positive cables. Tighten to 25 Nm
- the screw for the bracket. Tighten to 25 Nm. Use a ratchet wrench.
Installing the dip stick pipe in the transmission
Use a new rubber seal
Apply petroleum jelly on the rubber seal.
Note! Carefully check that the rubber seal is correctly positioned in the transmission. Failure to do so may result in leakage.
Installing engine compartment components
Install:
- the screw for the splash guard. Tighten to 25 Nm
- the engine pad. Tighten to 50 Nm
- the turbo pipe to the turbocharger (TC). Tighten the clamp
- the lower screw for the oil pipe. Tighten to 25 Nm
- the upper screw for the oil pipe
- the connector
- the tie strap around the electrical wiring.
Installing the hose for the heater pipe
Install the hose on the heater pipe in the firewall.
Press the radiator hose quick-release connector into place on the heater pipe.
Check: Pull the hose.
Installing the gear selector cable on the transmission and lever
Install:
- the ball joint for the gear selector cable on the lever
- the gear selector cable in the bracket
- the connector for the transmission. Press the connector into place properly
Caution! It is important that the connector is pushed into place properly. If it is not correctly connected the gear shift function may stop.
- the connector for the ABS unit.
Installing the upper torque rod
Install:
- the engine stabilizer brace. Tighten the mounting screws. Tighten to 50 Nm
- the screw and a new nut for the engine mounting. Tighten to 80 Nm
- the plastic guard over the spring strut (if applicable). Tighten the screws.
Installing engine compartment components
Install the integrated relay / fusebox. See Brake pipe master cylinder / ABS unit, replacing Brake Pipe Master Cylinder / ABS Unit, Replacing.
Installing the air cleaner (ACL) housing
Install the air cleaner (ACL) housing. See Brake pipe master cylinder / ABS unit, replacing Brake Pipe Master Cylinder / ABS Unit, Replacing.
Finishing work
Filling the transmission with fluid
Note! Oil grade: Only ATF fluid Dexron III (with G-license). Transmission oil, Volvo P/N 116 1521-8 (1 liter container), 116 1621-6 (4 liter container).
Note! Filling with oil: Start by filling with 5.5 liters of oil.
Filling with transmission oil. There are 2 different methods. Method 1
Note! Filling with oil: Start by filling with 5.5 liters of oil.
Fill the transmission with oil. Use a funnel with a plastic hose. Fill through the dipstick pipe.
Clear up any oil spillage under the dip stick pipe.
Filling with transmission oil. Method 2
Note! Filling with oil: Start by filling with 5.5 liters of oil.
Use a converted five liter plastic can (see the illustration).
This method avoids oil spillage. It also provides a more regular flow when filling.
To check the oil level, see Oil level, checking Checking Oil Level.
Note! After replacing the transmission, the transmission's adaption as well as the counter for "Transmission oil, change" shall be reset. Use VIDA Vehicle communication to reset the adaption and the counter.
Check the coolant level in the expansion tank
Top up with water and coolant as necessary (when the engine is at operating temperature).
Raise the vehicle.
Check that there is no oil leakage at the transmission or at the dip stick.
Installing the splash guards and the fender liner
Install:
- The ABS-cable on the mounting
- the splash guard under the engine
- the front splash guard
- the nut for the left fender liner
- the wheels. See Installing wheels Service and Repair.
Lower the vehicle
Assembling the upper and lower steering shaft
- Pull the upper steering shaft down. Assemble the upper steering shaft with the lower steering shaft
- Install the screw and the nut. Tighten to 30 Nm.
Note! Use a new screw and nut.
Checking the steering gear bearing in the boot at the firewall
Check that the steering gear bearing in the boot has not detached from the boot.
If it has become detached apply a little grease to the edge of the boot (around the hole). Press the bearing back down into the boot. See arrow in illustration.
Note! Check that the rubber boot is positioned correctly in the bodywork (see the arrows). Adjust if necessary. Lift up the outer section of the rubber boot. There is a risk that noise from the transmission or engine and road noise may enter the passenger compartment.
Installing the battery lead
See Battery, disconnecting Battery Disconnecting. It is essential that the instructions are followed.
Programming the transmission control module (TCM)
After replacing the transmission the latest software must be programmed into the control module. See the technical journal for information about the most recent software.
Test driving the vehicle
To test drive the vehicle, see Test Drive Form, description Test Drive Schedule, Description.
Note! When changing transmission oil, the transmission's counter for "Transmission oil, change" shall be reset. Use VIDA Vehicle communication to reset the counter.
Note! When changing to a new transmission, the transmission's adaption for "Transmission oil, change" shall be reset. Use VIDA Vehicle communication to reset the adaption.