Volvo 850 User manual

TRANSMISSION REMOVAL & INSTALLATION - M/T
1995 Volvo 850
Manual Transmission Servicing
850
APPLICATION
TRANSMISSION APPLICATION
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Vehicle Application Transmission Model
850 ....................................... M56L
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REMOVAL & INSTALLATION
Removal
1) Release steering wheel adjustment lever. Push steering
wheel as far forward and upward as possible. Lock steering wheel with
lever. Put shift lever in Neutral.
2) Remove battery, air cleaner, air intake, battery shelf and
air cleaner bracket retaining screws. Remove transmission selector
cables from bracket and levers. Tap out pin and remove selector link
plate. Disconnect back-up light switch connector.
3) Remove cable tie from engine cable harness. Remove ground
wire from gearbox. Remove circlip and clutch slave cylinder from
gearbox. Leave bellows on cylinder. Loosen nut on rear engine
mount/splash guard. Remove 5 bolts securing starter motor and gearbox.
Remove cover over high tension wiring. Lift coolant expansion tank off
bracket and allow it to hang free.
4) Remove bolt securing torque arm to engine. Disconnect
ground lead next to torque arm. Using 2 bolts from torque arm, install
Lifting Lug (999 5459) to valve cover. Install Lifting Lug (999 5464)
to manifold heat guard. Install and adjust Lifting Yoke (999 5428) to
lifting lugs.
5) Install Supports (999 5033) on fenders. Install Lifting
Beam (999 5006) on supports. Install lifting beam directly above lugs
on lifting yoke. Install Lifting Hook (999 5460). Lift hook about .20"
(5 mm) to relieve weight on engine mountings. Measure and record
height of lifting hook above engine.
6) Remove front wheels. Remove ABS sensor from left outboard
shaft. DO NOT disconnect ABS electrical connector. Disconnect left and
right brake lines and ABS cable brackets. Unhook brackets and allow
them to hang free. Remove front plastic nuts from left fender liner
and any Torx screws. Remove left hub center nut. Remove hub center nut
locking clip. Remove hub center nut.
7) Remove front splash guard bolts. Push guard forward so
locating pins on back come loose. Disconnect front of splash guard and
remove. Remove splash guard under engine. Remove ball joint-to-link
arm nuts on both sides. Disconnect link arms from ball joints.
Disconnect and remove link arms from anti-roll bar.
8) Remove bolts connecting cable pipe on subframe and unhook
pipe from frame. Disconnect charcoal canister from subframe and hang
from body. Disconnect exhaust gas tie behind 3-way catalytic
converter. Remove bolts holding pipe brackets to steering gear in
subframe. Remove 2 bolts holding steady-bar bracket to gearbox.
9) Remove bolts from front engine mounting subframe. Loosen
bolts securing steering gear to engine mounting about one turn. Remove
nuts holding steering gear to subframe. Disconnect subframe from
vehicle by positioning Jack (998 5972-0) under left side of subframe.

Tighten jack up gently against subframe. Remove bolts on both sides of
subframe brackets. Loosen 2 right subframe-to-body bolts.
10) Lower subframe while ensuring steering gear bolts DO NOT
hang up. Ensure MacPherson strut disengages from right axle shaft
bellows. Remove jack and allow subframe to hang free on right side.
Hang steering gear on left side using Hook (999 5045) in hole in frame
member flange. Ensure lower steering wheel shaft section does not slip
out of steering column.
11) Remove engine mount-to-subframe bolts and nut on top of
engine mount. Remove engine mount. Disconnect HO2S cable terminals
from cover. Disconnect speedometer connector and cable. Remove rear
engine mount cover and rear mounting from gearbox.
12) Remove left axle shaft by twisting and pulling out
MacPherson strut. Tap axle shaft end with plastic mallet and pull
shaft from hub. Using Lever (999 5462), remove axle shaft from
gearbox. Use care not to damage axle shaft seal or bellows. Install
Plug (999 5488) to seal hole. Clean metal glue off hub axle shaft
splines.
13) Use lifting hook and lower engine and gearbox until about
5" (130 mm) of hook thread is clear. DO NOT lower engine too much, as
exhaust pipe may press on steering gear. Ensure no wiring or hoses are
pinched or stretched, and that dipstick clears fan.
14) Install Universal Tool (999 5972) and Gearbox Fixture
(999 5463) to jack. Attach gearbox fixture to gearbox using bolts from
steady-bar bracket. At same time, position Support Plate (5463-2) on
fixture. Raise engine. Remove remaining bolts securing gearbox to
engine. Pull gearbox straight out from engine without any breaks in
clutch plate center.
Installation
1) Ensure mating flanges on gearbox and engine are clean and
engine locating sleeves are in place. Install gearbox to engine using
jack and gearbox fixture. Ensure gearbox lines up straight with engine
without any breaks in clutch plate center. Install 7 engine-to-gearbox
bolts and tighten in rotation to 37 ft. lbs. (50 N.m). Remove gearbox
fixture and jack from gearbox.
2) Raise Lifting Hook (999 5460) to level previously recorded
in step 5) under REMOVAL. Ensure no cables, wiring, or hoses are
pinched or trapped. Install 3 rear engine mount-to-gearbox bolts.
Tighten 2 rear bolts to 37 ft. lbs. (50 N.m). Remove front bolt.
Engage cover with engine mount and tighten bolt to 37 ft. lbs. (50 N.
m).
3) Install engine mounting locating pin in cover and install,
but DO NOT tighten, NEW nut. Install, but DO NOT tighten, engine
mounting steering gear bolt. Disconnect support hook. Install HO2S
cable and clips in cover. Install speedometer connector and cable.
4) Start with left side and raise subframe. Install 4 NEW
bolts with greased threads. Install bolts to subframe and support
plate. Tighten frame bolts to 77 ft. lbs. (105 N.m), then tighten
another 120 degrees. Move jack to right side, remove existing bolts,
and repeat procedure.
5) Remove lifting hook, lifting beam, hooks, supports and
lifting lug. Remove lifting lug on rear of engine. Tighten manifold
heat guard bolts. Install rear engine mounting splash guard nuts and
tighten to 37 ft. lbs. (50 N.m). Install 5 NEW steering gear nuts and
tighten to 37 ft. lbs. (50 N.m).
6) Install NEW steady bar bracket-to-gearbox bolts and
tighten to 13 ft. lbs. (18 N.m), plus an additional 90 degrees
(earlier version), or tighten to 26 ft. lbs. (35 N.m), plus an
additional 60 degrees (later version). Install bolts holding pipe
brackets to steering gear and tighten to 18 ft. lbs. (25 N.m). Tighten
exhaust clamp.
7) Use care not to damage drive shaft seal or bellows and

install right axle shaft to gear box. Install bearing cap and tighten
to 18 ft. lbs. (25 N.m). Ensure ABS sensor gear well area is free of
dirt and install left axle shaft. Push in axle shaft so it engages
with differential. Ensure axle shaft circlip snaps into place. Use
care not to damage axle shaft seal or bellows.
8) Apply Metal Glue (1161370-0) to axle shaft splines. Use a
socket wrench to hold suspension arm down and twist MacPherson strut
clear and insert axle shaft in hub. Oil nut threads and flange and
hand-tighten NEW axle shaft nut.
9) Ensure ball joint seating in suspension arm is clean and
free of grease. Tighten inside and outside nuts to 13 ft. lbs. (18 N.
m), plus an additional 120 degrees. Apply Rustproofing Material
(1161432-8) to area between ball joint, suspension arm and nuts. Use
NEW nuts and install link arm to anti-roll bar. Tighten nuts to 37 ft.
lbs. (50 N.m).
10) Tighten left hub center nut to 89 ft. lbs. (120 N.m),
plus an additional 60 degrees. Use a chisel and tap locking flange
onto axle shaft slot. Install brake lines and ABS cable brackets on
both sides.
NOTE: Ensure ABS sensor seat is perfectly clean.
11) Install ABS sensor on wheel spindle and tighten to 7 ft.
lbs. (10 N.m). Install plastic nuts and Torx screws to inner shield on
left side. Install cable pipe on subframe, charcoal canister, and
subframe under engine.
12) Install cover under engine and push it toward front of
vehicle. Push up at back so cover locating pins fall in place. Install
bolts. Install wheels. Ensure brake disc pad contact surfaces are
clean. Grease hub center locating pin in front of pad using
Rustproofing Agent (1161038-3). Install bolts and tighten in pairs to
81 ft. lbs. (110 N.m).
13) Install 5 gearbox-to-engine and gearbox-to-starter bolts.
Tighten gearbox-to-engine bolts to 37 ft. lbs. (50 N.m). Tighten
gearbox-to-starter bolts to 30 ft. lbs. (40 N.m). Install clutch slave
cylinder and clip. Without moving fork, remove temporary strap from
throw-out bearing fork. Install ground wire and lead tie. Install
back-up light switch connector. Install shift lever link plate and
locking pin. Install selector cables in brackets.
NOTE: Outside bracket and selector cables have Yellow markings.
14) Lubricate selector levers with Grease (1161241-3).
Install selector cables to levers. Install 2 washers and clips.
Install high tension wire cover, expansion tank, air cleaner-to-
bracket bolts, spark plug cover, battery shelf, air cleaner and
battery.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
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Application Ft. Lbs. (N.m)
ABS Sensor Bolt ................................... 7 (10)
Bearing Cap Bolts ................................ 18 (25)
Engine Mount-To-Gearbox Bolts .................... 37 (50)
Engine-To-Gearbox Bolts .......................... 37 (50)
Gearbox-To-Engine Bolts .......................... 37 (50)
Gearbox-To-Starter Bolt .......................... 30 (40)
Hub Center Nut .............................. ( 1) 89 (120)
Knee Guard Bolts ................................. 15 (20)

Link Arm-To-Anti-Roll Bar Nuts ................... 37 (50)
Lug Nuts ........................................ 81 (110)
Pipe Brackets-To-Steering Gear Bolts ............. 18 (25)
Rear Splash Guard Nuts ........................... 37 (50)
Steady Bar Bracket-To-Gearbox Bolts
Early Version .............................. ( 2) 13 (18)
Later Version .............................. ( 3) 26 (35)
Steering Gear Nuts ............................... 37 (50)
Subframe & Support Plate Bolts .............. ( 4) 77 (105)
Suspension Arm-To-Ball Joint Nuts ............ ( 5) 13 (18)
(1) - Tighten nut an additional 60 degrees.
(2) - Tighten bolts another 90 degrees (early version).
(3) - Tighten bolts another 60 degrees (late version).
(4) - Tighten bolts another 120 degrees.
(5) - Tighten nuts an additional 120 degrees.
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