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REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Volvo S40 / V40 (from 1996 to 2000, the year of issue)

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Volvo S40 / V40
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Volvo
S40 / V40
General Information
Operation and maintenance of car
Design and specifications Engine
Engine repair
Transmission
Overview
Specifications
Construction, inspection and replacement of the clutch
Filling and bleeding hydraulic clutch system
Adjust the clutch pedal
Replacing the clutch slave cylinder
Design elements and replacement gearbox
Design and operation of transmission
Removing gearbox
Installing gearbox
Replacing the oil seal on the input shaft gearbox removed
Replacing right axle gearbox oil seal
The gear change mechanism
Brakes
Front suspension and steering
Rear suspension
Engine Management System Fenix 5.1
Electric. Wiring and components
Body
Diagrams
 


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Removing gearbox



To remove the CP type:
a) preliminary tasks:
- Open the bonnet;
- Disconnect the negative battery cable;
- Remove the cover of the engine;

Fixing the inlet hose of the air filter
Fig. 5.13. Securing the hose inlet air filter: 1 and 3 - the site of attachment of the hose crankcase ventilation; 2 and 6 - clamps; 4 - air sensor connector; 5 - an air hose pump; 7 - a hose of the air filter


b) remove the inlet air hose from the air filter (see. Div. "Replacing the clutch slave cylinder" and Fig. 5.13);
c) remove the air filter assembly;

Tighten the screws on the air filter (shown by arrows)
Fig. 5.18. Tighten the screws on the air filter (shown by arrows)


- Remove the two screws (Fig. 5.18);
- Raise the filter and remove the rotary motion;
g) Remove the clutch slave cylinder (see. Div. "Replacing the clutch slave cylinder");
d) remove the flywheel sensor, which is located at the top of the clutch by unscrewing two screws on the sensor and remove the sensor in the direction;
e) disconnect the starter:

The starter mounting bolts (arrows)
Fig. 5.19. The starter mounting bolts (arrows)


- Remove the three screws (Fig. 5.19) in front of;
- Remove the starter motor with adjustable rotational movement of the sleeve;

Bolts manual (indicated by arrows)
Fig. 5:20. Bolts manual (indicated by arrows)


g) unscrew the fixing screws at the top of the gearbox (Fig. 5.20);

Installation of the lifting beam
Fig. 5.21. Installation of the lifting beam


h) set the lifting beam (Fig. 5.21), zachalte engine for lifting eyelets and lift it slightly;

Gearbox mountings from the body (arrow)
Fig. 5.22. Gearbox mountings from the body (arrow)


i) disconnect the transmission mount from the body (Fig. 5.22):
- Remove the three nuts supports transmission;
- Remove the bolt bearing on the body;
- Remove both feet;

Removing the front mudguard of the engine
Fig. 5.23. Removing the front mudguard of the engine


a) Remove the front mudguard of the engine (Fig. 5.23)
l) Remove the left mudguard of the engine:

Left mudguard bolts (arrows)
Fig. 5.24. Left mudguard bolts (arrows)


- Remove the three screws from the top (Fig. 5.24);
- Remove the left mudguard;

Bolt mass wires to the CP (arrow)
Fig. 5.25. Bolt mass wires to the CP (arrow)


m) disconnect the connection with "weight" of the gearbox by removing the bolt (Fig. 5.25);

Heat shield bolts (arrows)
Fig. 5.26. Heat shield bolts (arrows)


n) Remove the heat shield on the right axis, removing the three screws (Fig. 5.26);

The mountings of the engine mounts and the central longitudinal beam (shown by arrows)
Fig. 5.27. The mountings of the engine mounts and the central longitudinal beam (shown by arrows)


a) remove the central longitudinal beam (Fig. 5.27):
- Unscrew the two nuts of the engine mounts;
- Remove the four screws on the central longitudinal beam;
- Remove the two screws from the rubber grommets;
- Remove the central longitudinal beam;
n) Disconnect the rod from the shift gearbox:

Fixing rods shift to the CP
Fig. 5.28. Fixing rods shift to the manual: 1 - Rod; 2 - a bolt; 3 - a nut


- Unscrew the nut 3 (Fig. 5.28) and push the bolt 2 up;
- Tie rod of a gear change;

Disconnecting the reverse gear switch
Fig. 5.29. Disconnecting the reverse gear switch


p) Disconnect the reverse gear switch (Fig. 5.29);
c) Drain oil from the gearbox:
- Remove the bolt and remove the pallet;
- Place the container;
- Remove the drain plug;
- Make sure that the oil into the engine;
- Put the drain plug with a new sealing ring and tighten to 38 N ?� m;
t) Disconnect the flexible shaft of the speedometer from the gearbox:

The connection between the speedometer cable on the CP
Fig. 5.30. The connection between the speedometer cable to the control panel: 1 - a cable of a speedometer; 2 - the locking pin


- Clean the connection (Fig. 5.30);
- Remove the locking pin 2 of the gearbox;
- Gently pull the flexible shaft 1 of a speedometer from a transmission;
- Close the connection hole;
v) remove the front wheel:
- Loosen the bolts of the front wheels;
- Hang out the front wheels;
- Put the support legs;
- Remove the front wheel;
f) Remove the right axle:

Disconnecting the right axle
Fig. 5.31. Disconnecting the right axle:
1 - mandrel


- Remove the two locking pin with a mandrel diameter of 5 mm (Fig. 5.31);
- Turn out the top bolt and loosen bottom bolt knuckle;
- Press the knuckle and carry out axle shaft as far as possible from the shaft of the gearbox;
x) Disconnect the left axle:

Tighten the screws on the protective cover half-axis (indicated by arrows)
Fig. 5.32. Tighten the screws on the protective cover half-axis (indicated by arrows)


- Remove the three screws that secure the protective bellows (Fig. 5.32);
- Remove the ABS wire bracket;
- Remove the locking clip and remove the pipe from the brake arm;
- Remove the two adjustment screws and remove the shock absorber from the knuckle;
- Turn the steering wheel all the way to the right;
- Carefully remove the shaft from the gearbox;
- Close the spider hole and transmission;
- Turn the steering wheel to the center position;
c) remove the gearbox:

Installation support under the gearbox
Fig. 5.33. Installation support under the gearbox


- Establish a support 999 5972 and secure it under the gearbox (Fig. 5.33);
- Remove the engine mounting bolts connection with manual transmission;
- Lower the engine and transmission so that they do not touch the body by the distributor;
- Remove the gearbox;
h) Remove the items from the old gearbox:
- Support;
- Adjusting sleeve 1 and 6;
- Switch 8 reversing light;
- 4 clutch release bearing, fork 3 and a rubber sealing element 2;
- Remove the pin 5;
- Clean and check the removed parts:
- Check the clutch and pull the plug, as described in Section. "Clutch";
e) set the details in the new transmission;

Removing parts with CP
Fig. 5.34. Removing parts with manual: 1, 6 - adjusting sleeve; 2 - sealing member;
3 - the plug; 4 - the bearing; 5 - pin; 7 - a bolt; 8 - backup light switch


- Remove the plug and remove the protective cover, move them to the old gearbox;

A WARNING
If the transmission is not replaced, and set the withdrawal must be replaced right seal and O-ring. See "Replacing the gland right axle."

- Replace the setting sleeve;
- Apply sealant (catalog number 1161099-5) on the reverse gear switch, switch, tightening torque 22 Nm;
- Lubricate the ball bearings with grease the clutch fork Volvo number 1161246-2;
- Replace the clutch, fork and a rubber sealing element;
- Put the pin 5, the torque
50 Nm
- Mount bracket tube hydraulic clutch, torque 48 Nm;
- Put the support with a torque of 40 Nm.




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Installing gearbox

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