Volvo repair manual

TJMAS · Post by **TJMAS** » 19 Jun 2010, 10:35

New to forum but what I've seen it's a amazing wealth of info. Wondering where I can get the volvo procedere for removing and changing the flex plate (fly wheel) on a 2003 xc90. Dealer quoted 12 hours labor and I can't pay that at this time on a troubled car with 165,000 miles. A manual would make it so much easier. Thanks

Post by **JDS60R** » 19 Jun 2010, 12:29

What motor and trans?

TJMAS · Post by **TJMAS** » 19 Jun 2010, 13:03

Sorry I did'nt say. It's the T6 engine but not sure about the trans.

Post by **JDS60R** » 19 Jun 2010, 13:09

No Problem - only gearbox on a T6 is the 4T65AWD

added gearbox

Post by **JDS60R** » 19 Jun 2010, 13:10

and in case you didn't know this already

TJMAS · Post by **TJMAS** » 19 Jun 2010, 13:29

How about gearbox removal

TJMAS · Post by **TJMAS** » 19 Jun 2010, 14:06

JDS60R thanks for the help so far. I'd like to throw out my assessment of why I believe I have fly wheel damage and see what you think. During other repairs I had to do I had to lower the oil pan. I replaced the pan with bolts completed my other repairs. upon starting the engine I heard a screach for a second or two and by the time I could turn the engine off the reduced engine preformance mode set in. I found that one of the three approx. 4" bolt by the bell housing holding the oil pan had not gone into the proper hole but had actually wedged between where it was supposed to go and the fly wheel. Removed it and the engine runs fine except a slight flutter at idle. the snapon code says cam shaft/crank shaft sensor and the car won't come out of limp mode. I believe the bolt damaged the slots on the flywheel so the sensor is not reading properly for the timing. I no it sound redicously stupid to happen but it did. The bolts don't slide through any type of guide an can be wiggled side to side trying to find the threads. The sensor is on top so that should'nt be damaged. I was going to pull the intake and starter and see if I can see damage on the fly. What do you think besides it stinks?

Post by **JDS60R** » 19 Jun 2010, 14:21

First pull clean and test the sensor - what if the bolt just carved up some unused metal and contaminated the sensor.

I will have to go look at the oil pan bolts now and see how any of the bolts could have touched (and where) the flywheel).

The ones going straight up (oil pan) and the ones going across it should have missed it. My thoughts would be that oil pan bolts (even if they missed the hole ) shoudl have missed the outer edge of the flywheel.

I work on the T5 so much I have to think about a T6. I will look at oil pan removal pics but right now - I'm thinking sensor - electromagentic/hall effect with residual magnetism is holding metal particles.

Post by **JDS60R** » 19 Jun 2010, 14:27

Are you talking about the bolts labeled '5" in the pics . If not -which ones?

Post by **JDS60R** » 19 Jun 2010, 14:35

Just checked the procedure - I don't see how you could have hurt the tone ring on the flywheel.

No need to pull the starter (can is you want to) but there is an inspection window on the back side.
In the gearbox removal pdf above (I fixed it ) see the inspection window next to the step called" removing the screws from the torque converter"

Let me know what you found.