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Removal & Installation: Transaxle: Installation

NOTE: The input shaft must be lubricated before a manual transaxle is installed. Do not apply grease to the primary shaft and the throw-out bearing sleeve.
  1. Check that the transaxle cover and engine mating surfaces are clean, the guide sleeves on the engine are in place and undamaged. Apply a light coating of grease in the holes for the guide sleeves (on the transaxle).
    NOTE: Ensure that the transaxle goes straight in towards the engine without any deviations in the clutch plate center.
  2. Install the transaxle. Use a transmission jack to line up the transaxle with the engine. Install the 7 bolts. Tighten in crisscross pattern. Begin with bolts "A" and "B" which pass through the guide sleeves. Lightly tighten the bolts alternately. Check that the transaxle and engine are in contact. Then tighten the bolts alternately to specification. See TORQUE SPECIFICATIONS  . Remove the transmission jack.
  3. Lift the engine and transaxle. Screw lifting hook up so that the engine is hanging horizontally. Ensure that no cables or hoses are pinched.
  4. Install the rear engine mounting on the transaxle. See Figure . Install the mounting on the transaxle (3 bolts). Tighten the two rear bolts. Remove the front bolt. Install the cover. Use the bolt for the mount. Press up the cover against the mount. Tighten the bolt.
  5. Install the engine mount using a new nut. Align the engine pad locating pin in the cover. Install the new nut loosely. Install the screw in the engine pad and steering gear. Do not tighten the screw. Remove the hook or the tie strap. See Figure . Install the heated oxygen sensor cable on the cover using clamps.
    CAUTION: Use new bolts (4 X M14). Lubricate the screw threads. Ensure that the screws for the steering gear locate in the sub-frame.
  6. Install the sub-frame. Start on the left-hand side. Raise the sub-frame using appropriate screw jack. See Fig 1 . Locate the screws for the steering gear in the sub-frame. Install the screws in the sub-frame and the support bracket. Tighten the sub-frame screws to specification. See TORQUE SPECIFICATIONS  . Tighten the sub-frame bracket bolts. Move the screw jack to the right-hand side. Remove the existing screws and repeat the operation.
    Fig 1: Installing Sub-Frame
    G00213952Courtesy of VOLVO CARS OF NORTH AMERICA.
  7. Remove the lifting tools. Tighten the nut for the rear engine pad splash guard.
  8. Install the bolts and nuts for the steering gear and the sub-frame. Install 5 new nuts on the steering gear. Tighten the bolt for the sub-frame front engine mounting. Tighten the bolts for the front and rear engine mountings.
  9. Install the torque rod mounting. Install the torque rod mounting on the transaxle using new bolts. See Figure . Tighten to specification. See TORQUE SPECIFICATIONS  . Tighten the bolts for the oil pipe brackets.
  10. Install the right drive axle on the transaxle. See appropriate AXLE SHAFTS article in DRIVELINE/AXLES.
  11. Install the left drive axle on the transaxle. See appropriate AXLE SHAFTS article in DRIVELINE/AXLES.
  12. Install the cable conduit on the sub-frame. Install the carbon filter container. Clamp the hoses to the sub-frame. Use a tie strap. Hook the hoses into the sub-frame. Tighten the clamp for the exhaust pipe. Twist the pipe when tightening clamp.
  13. Install the front cover and the wheels. Press the front edge into place. Press the cover forward and upwards at the rear so that cover guide is seated in its slot. Install the wheel lug nuts.
  14. Install the five bolts between the transaxle/engine and the transaxle/starter motor. See Figure . Tighten the bolts for the transaxle and engine. Tighten the bolts for the transaxle and starter motor to specification. See TORQUE SPECIFICATIONS  . Install the cable duct on the transaxle.
  15. Install wiring and the quick-release coupling. Clamp the cable harnesses and the ground lead.
  16. Install a new quick-release connector on the clutch hydraulic hose connection. Lubricate the rubber seal using a drop of brake fluid before joining. Check that the striker plate is located in the adapter, then press the clutch hose into place in the adapter so that the striker plate audibly snaps into the groove.
  17. Install the clutch cable in the holder on the side of transaxle. Remove the hose clips from the hose at the clutch master cylinder. Bleed the system. Top up the brake fluid if required.
    CAUTION: The outer mounting and the gear selector cable that will be positioned outermost are marked yellow.
  18. Install the connector, transaxle lever and transaxle cables. Install the connector for the back-up (reversing) light switch. Install the outer gear selector lever and split pin. Install the gear selector cables on the bracket mountings. Lubricate the lugs on the gear selector lever. Install the gear selector cables on the levers. Install the two washers and the two clips. See Figure .
  19. Install the ground strip in the firewall. Install the new bolt and the nut for the torque control arm/torque rod. See Figure . Tighten to specification. See TORQUE SPECIFICATIONS  .
  20. Tighten the clamp (turbocharged engines only). Turn the intake manifold outwards. Align the hose with the charge air pipe. See Figure . Tighten the clamp. Press the pipe up towards the throttle body with one hand. Tighten the clamp. Connect the brake vacuum hose to the intake manifold using the clamp. Install the hose between the pipe from the charge air cooler and the outlet pipe from the turbocharger.
  21. Install the expansion tank. Install the screws securing the bracket for the air cleaner housing. Install battery shelf. Install the timer valve to the air cleaner housing. Install the air cleaner housing with the intake manifold and connections. Install the battery. Install the hoses to the regulator valve.
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