P2 2005 V70M56 subframe drop SNAFU composite list

Help, Advice, Owners' Discussion and DIY Tutorials on Volvo's stylish, distinctive P2 platform cars sold as model years 2001-2007 (North American market year designations).

2001 - 2007 V70
2001 - 2004 V70 XC (Cross Country)
2004 - 2007 XC70 (Cross Country)
2001 - 2009 S60
2003 - 2007 S60 R
2004 - 2007 V70 R

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abscate  
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P2 2005 V70M56 subframe drop SNAFU composite list

Post by abscate »

A psuedo-randomly ordered list of things that I did wrong which either wasted time, resources, or just sucked.

Preparation

Lost snap ring on clutch adapter assembly - flew off into River Styx. You just need to ease those clips up a bit to release the pipe.
Could not release heater hoses at firewall - ended up releasing at block via hose/Jubilee clamps
Snapped of Air cleaner elbow at intake manifold attachment
Really fussed with gear shift cable releases until I had them off. To release from bracket, slide rear piece back, then pry cables up with blunt wood. After cables are released, bracket can be removed with 2x M6
Engine mount on firewall is difficult to ratchet off due to clearance
Exhaust mount plate has an M8 screw into rear subframe I forgot
Be ready to catch clutch/brake fluid and seal off hose once pulled from adapter
The flywheel ring cranks sensor has to be removed (one M6) as well as the plastic adapter - this is bolted into the engine with two T40 and the plastic part drops into he transmission - preventing removal.

The drop
Don't use S hooks to hold engine - positively bolt chain or shackle to lifting eyes
Keep wood under engine to mitigate falls
watch clearance of PS hose and dipstick on front of engine as lowered - VIDA does not recommend removal but I think I will next time

Starter bolts AND starter have to be removed as starter has a unthreaded stud which fits into transmission and will prevent separation.

Missing one release bearing hold down bolt
Forgot to remove ground strap M6 bolt attached to front of subframe
Front engine mount (called Right engine mount in VIDA) had bad rubber - need new one.
Lower torque mount bad rubber - need new one.
Right hand side caliper bleed screw is frozen - working on it with PB Blaster - ordered new ones.
Could not remember location orientation of clutch adapter pipe plate - undocumented, picture helped jog memory
Trouble getting M10 firewall engine mount, top bolt in.
Exhaust plate fouled the sway bar on subframe installation - managed to remove it without having to drop subframe again.
One exhaust plate bolt stripped or won't thread

User error - I didn't release the right side (near firewall) engine mount at the subframe - VIDA says you pry away sway bar to access this. This works, I just got cute and thought I could work around that. It turns out to get the engine back in the right place you want all three mount points loose at the subframe - not at the engine attach point. Short version, if I had followed directions, it would have been easier. The time saved not hassling with the mount bolt was lost 5x in struggling with the attach bolts. Live and learn

User success - The manual transmission only weighs 76 pounds, so it is easy to manipulate from ground. I put two overlength M10 bolts into the top two holes, then walked the transmission up on a floor jack, level, lift, level lift...until I could thread 5 turns on the two bolts. Now I had an alignment jig - and sure enough, the transmission slid right onto the clutch first time. I also took a bit of weight under the engine so I wasn't swaying the engine on the chains when I went to mate the transmission, I raised it 1/2 inch with chains, blocked under it with wood, then lowered until it was firm.
Empty Nester
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1999-V70-T5M56 2005-V70-M56 1999-S70 VW T4 BMW
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cuhfs
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Post by cuhfs »

As they say... Other than "that" Mrs. Lincoln, how was the play? :roll:
95 850 Sedan Auto Trans
98 V70 Manual Trans
01 C70 Manual Trans
04 XC70 Auto
04 C70 Auto
06 XC90 Auto (ORE)
06 S80
12 S60
96 850 Wagon Manual Trans (parts car)

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Post by abscate »

The play left me $3000 richer and in a position to consider flipping some Volvos with bad transmissions - even better, talking some others into doing this. I bet I could probably halve the time on this on the second pass. First time you spend a lot of time staring at stuff.
Empty Nester
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1999-V70-T5M56 2005-V70-M56 1999-S70 VW T4 BMW
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Post by JRL »

How do you get 3K?
7, 8 tops (flat rate) hour job on a FWD Volvo so even at $135 an hour, you're not remotely close to 3K!
2000 V70R Black, 144,000 miles Wife's R.
2007 V70 2.5T White/Oak 111,000 MILES. Polestar tune, IPD bars, rear spoiler, dark grey Thors, DWS 06, HU850, sub.

Contact info for purchases: jrl1194@aol.com

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Post by abscate »

I was adding up all the work I did, plus the value of experience

Indeed , the clutch is about $1000 in labour and $1000 in parts with DMF

Ive racked about 30,000 miles on this beast Jim, this is the first non-scheduled repair bill. It's been so cheap I don't mind the noise, harsh ride, and crappy fuel economy of the P2...

:-)
Empty Nester
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Post by abscate »

VIDA Skipped the step of disconnecting MAP vacuum hose from the sensor. If you don't do this it will pull off when the engine is dropped, and throw a P0106 code
Empty Nester
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