Installing gearbox

To set the manual you must:

a) preliminary tasks:

- Establish a transmission on a support 999 5979 in the mounting position and fix brackets (see. Fig. 5.33);

- Apply a small amount of grease 1161246-2 slots on the input shaft;

- Apply grease to splines 1161035-9 (right half) on the gearbox;

- Slide the transmission to the engine so that the shaft went into slots on the clutch disc and install the right axle on the slots;

b) Attach the transmission to the engine:

- Place and tighten the four mounting screws (Fig. 5.35), a torque of 50 Nm;

- Remove the support 999 5972;

c) connect the gearbox support to the body:

- Fit the gearbox support with three bolts (Fig. 5.24);

- Adjust the position of the motor with a lifting device and install the bolt in the support on the body;

- Put the three screws and tighten to 45 N ?� m;

- Lower the engine so that the hoisting beam ceased to hold it;

- Tighten the bolt from the body, tighten the moment 98 Nm;

- Release the motor from the hoist;

d) set bolts on top of the gearbox and tighten to 50 N ?� m (Fig. 5.20);

d) Set the starter in his place, and put the three mounting bolts (Fig. 5.19) and tighten to 50 N ?� m;

- Lift the car;

- Remove protection from the spider and remove the plug from the hole transmission;

- Turn the steering wheel all the way to the right;

- Carefully set to the left axle differential (see. Fig. 5.33);

- Turn the steering wheel fully to the left and set the bottom bolt in shock / fastening element knuckle;

- Install protective covers;

- Put the three screws and tighten to 25 N ?� m;

g) attach the knuckle to the shock absorber:

- Put the top bolt;

- Tighten both bolts to 90 N ?� m;

- Set the brake lines to the bracket and fix the bracket;

- Secure the ABS system in brackets;

- Clean the connector and connect the wire reversing light switch;

- Connect the connection with "weight" gearbox (see. Fig. 5.25), thoroughly clean the contact surfaces;

- Secure the torque 40 Nm;

h) set the right axle and a flexible shaft to the gearbox of a speedometer;

- Fill the hole with a locking pin hermetic 1161058-1;

If the hole from the gearbox is at the bottom (the base of the space between the teeth) between two slots, the corresponding hole in the half-line must be in the top (top), and vice versa;

- Install two new locking pin in the floor;

- Install a new O-ring on the speedometer flexible shaft and secure it;

- With the power of press in the flexible shaft into the body and put the retaining ring (see. Fig. 5.31);

- Set the wheels;

and) to set the bar a gear change;

- Lubricate the articulated joints parts grease Volvo 1161241-3;

- Check the rubber elements;

- Reposition the gearshift rod and insert the bolt (Fig. 5.28) tighten the bolt to 16 N ?� m;

a) establish a central longitudinal beam:

- Mount the bearings on the motor bracket (Fig. 5.27);

- Put in the support bolts and profit them;

- Put the four screws on the longitudinal beam to the body: Front - long bolts; Rear - short bolts;

- Tighten the bolts to four beams bolts 69 Nm; two bolts of support of the engine 52 Nm;

- First, tighten the rear bolt and then the front;

- Install heat shield and the first set screw A (Fig. 5.26); then the remaining two bolts, tightening torque 10 Nm;

l), pour oil into the gearbox:

- Substitute the filler (reference) hole;

- Fill the gearbox with oil to the lower edge 3345534-6 filler plug;

- Put on the filler (control) opening new O-ring;

- Put the plug and tighten the filling (control) of the opening, 22 N ?� m;

m) Set mud flaps, engine:

- Tighten the three screws on the left mudguard and tighten to 17 Nm (Fig. 5.24);

- Install the front mudguard, fix its bolts and screws to 10 N ?� m (Fig. 5.23);

- Install the flywheel sensor and secure it with two screws, tighten the screws to 20 Nm;

n) set the clutch slave cylinder on the gearbox (Fig. 5.14):

- Press the piston as far as possible into the cylinder;

- Remove the clip from the clutch slave cylinder;

- Insert the plug stem in the clutch;

- Place the two mounting bolts of the cylinder;

- Tighten the bolts to 30 Nm;

- Place the handset with the union "Banjo", tighten the fitting to 25 N ?� m;

a) set the rotational movement of the air filter (Fig. 5.18) and tighten to 10 N ?� m;

- Check the air intake;

- Set the air inlet hose (Fig. 5.13).

- Connect the hose and secure with two clamps;

Set the preheating hose.

n) Set:

- The negative battery cable; cover of the engine torque 11 Nm;

p) run the engine and check the operation of the clutch.