2004 XC90 T5 Transmission Paradox

TexasCoder · Post by **TexasCoder** » 23 Feb 2011, 02:22

Hey Guys,

Anyone out there rebuilt, or know of someone who has rebuilt an AW 5 speed tranny on an XC90? I have rebuilt my share of GM 4 speeds (mainly the 4L60E), and found this spec sheet for the Volvo's tranny: http://www.automaticchoice.com/Catalogue/aw_55-50.pdf

From all my research, it seems that the 2003-2005 model XC90 (T5 FWD with AW tranny) come with the AW55-50SN and the AWD has the AW55-51SN model. Looking at that link, and the exploded view of the transmission, I cannot see why a "shop" would charge so much for rebuilding these models. Sure, I suppose, the rebuild kit is what kills you, the cheapest I could gleam from the internet was around $1100. But that is a small drop in the bucket when you call around to a few shops and find out they charge anywhere between 3,500 - 5,000 for rebuilding one.

Am I missing something on these things? Is there some deal with the devil, or mystical solar system alignment that has to be performed in order to work on one of these?

Granted, at 150k on the odometer, my tranny is smooth and perfect. But, I know the day is coming when she starts to slip, or get a little rough around the edges. On that day, I am about 3/4 tempted to just drop it myself and rebuild it.

I posted this because this is, by far, the best site out there for XC90 owners, and a lot of smart people, way smarter than me, have answered questions on this forum...and I know someone out there must have some experience with these transmissions.

Thanks for any input/light you can shed on this question!

Post by **jimmy57** » 23 Feb 2011, 08:15

Due to some issues with valve bodies, the rebuilders put in new or reman valve bodies or they do a valve body upgrade themselves with new solenoids (many more of them on this gearbox) and some improved spool valves.
The gearbox is a very easy one to dismantle and re-assemble due to the way it splits open.
Usually they put in new band apply pistons too.
This gearbox is used in a lot of vehicles and it had issues in all of them. There is a good bit of upgrade parts made by the auto trans supply companies. Transtar website probably lists several things if you searched it using "AW55-50SN).
The model difference on AWD is for the angle gear drive sleeve .
If you wear it out and it had good shift performance then you probably need a $350 kit and a $400 reman torque converter, 12 quarts of fluid, and a tube of the appropriate RTV sealer. You will have to fashion a clutch press but that is easy with some ingenuity. Transtar on Irving Blvd will have the parts and probably an overhaul guide.

TexasCoder · Post by **TexasCoder** » 23 Feb 2011, 08:53

jimmy57: Thank you sir. This gives me a little more "breathing" room on this tranny. I knew it had to be pretty straight forward (as far as transmissions go), but also figured the shops out there were feeding off owners who did not know better. Don't get me wrong, I have friends who own shops, and they are honest and earn every honest dollar they make, but the majority of shops are just evil.

My shop press and vise have saved me on more than one occasion. I helped a neighbor rebuild his 46RE dodge ram transmission, got down to the point where I had to compress the 800 pound spring assembly that had to be compressed in order to engage/remove the snap ring...that was fun

We actually used a series of clutch alignment tools as a guide to align the gears in that thing (as we re-assembled it)...it was touch and go, but saved us from having to buy the alignment tool

Although, next time I do one of those jobs, I am certainly making him buy the tool, or talking to someone who has an old shaft we could use!

I see that we are practically neighbors (I live in Denton), I will give Transtar a ring and see what they offer, and if I can buy a manual from them. If anything, the manual would make for some "prep" ready for when the day comes

Thanks again!