Preparing the S80 for transmission overhaul

ACk · Post by **ACk** » 25 Mar 2012, 21:47

Hi everyone, hope you are all well.. so here it is , i have the car lifted and ready to start dismantling the lovely 4T65GT.. should be alot of fun huh... lol ...

so yesterday, i replaced the plugs with new ones, checked all the coils, one of them needed a new rubber boot, replaced that with a nee one, insulated all the old wire looms with new one's and wrapped with electrical tape, installed everything back , and the car wouldnt turn over, after 2 trys it turned over and it was barely idling!!!!?????? what happened here? im not that old c'mon now..lol... pulled off the intake plubing, checked the coil wires and i had forgotten the ground wire, so i bolted it to the valve cover, and the rattling got less, but it was still idling rough, (before all this the car ran perfect), did i reverse one of the coil wires?? as far as how the wires are evenly distributed , thats how i put them all back.. now im puzzled and its too cold to think... anywho if anyone has ran into this.. please chime in, oh BTW, there was a louder than usual suction sound"shhhhhhhhhhhh" ,but again, everything i removed was intalled the same way.. or did i ??? and at the tail pipe had alot of fuel odor, running rich, the enigne was choking???? i dono....

Post by **dcarlson12** » 26 Mar 2012, 14:35

You are sure you tightened the 'hold down' bolts for ALL the coils?
When I have changed the plugs on my 99 S80 T6 I remember removing the turbo pipes across the top to remove the cover to access the coils. I guess these are what you are calling intake plumbing? Did you disturb any wiring for the MAF sensor? Sucking sound? Did you tighten all clamps on suction lines?

ACk · Post by **ACk** » 27 Mar 2012, 00:16

hi, i sure did.. its not the first time i have removed the coils,plugs, plumbing, etc... i need to trace my previous steps, it was a simple plug change... ill check all the wires again!! thanks

ACk · Post by **ACk** » 29 Mar 2012, 21:51

3 hours into removing the 4T65E... this is going to be an interesting project, while im at it, im going to rebuild the turbo's and polish some piping and such... saturday i will install the engine suport bar and raise the engine and crawl underneath...some pix comiing soon

Post by **boosted5cyl** » 30 Mar 2012, 12:37

Here's some info on the Mitsubishi TD03-8G for you....

: TD03info.png (6.32 KiB) Viewed 3376 times

Free play Tolerances
Radial: 0.009" (0.223mm) - 0.019" (0.483mm)
Axial :0.0015" (0.038mm - 0.003 (0.076mm)

Wastegate Actuator pressure: 6.5PSI

This kit "might" work, check with them first: http://baeturbosystems.com/turboservice ... ent-2.aspx
Gpopshop stock rebuild kits too, although there are not listed on the website so use the contactus form: http://gpopshop.com/contact-us/

ACk · Post by **ACk** » 31 Mar 2012, 21:46

Thanks THUMBS UP!

ACk · Post by **ACk** » 31 Mar 2012, 21:53

k... 3 hours into the overhaul, all the upper areas are removed (VADIS) , i siphoned the trans fluid, WOWWWWW, it was blackkkk, contaminated, i was looking at the dipstick and it was a redish-light brown, but once i started to pump the oil , in a clear jug, thats when i discovered how contaminated the fluid was.

So in the next few days im going to instal the engine support bar and place the car on jack stands and start the real work

. stay tuned for pix.

Need to order/buy a tranny oil cooler with AN fittings and get the hoses pressure fitted at HOSE LINE in Glendale ca., (GREAT people, great service, great prices ), i can buy the B&M or Hayden coolers from my work

but they are slip on hose style fittings. We'll see what makes more sense and practical yet durable in the sense of leaks.

ACk · Post by **ACk** » 03 Apr 2012, 22:15

NEED ADVISE ABOUT JACK STAND POSITION.. i know i can place the jack stands by the front subframe mounting area, however im removing the transmission and i have to lower the subframe, so i have place the stands behind the front wheel under the frame. there are jacking notches in the middle of the frame, however i need the front lifted, well i have already.. stupid question, will i bend anything? its not under the floorboard FYI

, its right below where the front door hinge would be .. thats where the frame is , with some plastic covers. its been good so far.. thoughts? thank you much!

PS.. is there a directional flow from the transmission? meaning : does the flow go from bottom to top? is there one line that may have pressure and one return? this is on the external trans cooler..

ACk · Post by **ACk** » 09 Apr 2012, 00:07

so...5 hours into the removal so far... axles are out..subframe is dropped and im tired... next is unbolting the torque converter and instal the jack to pull the infamous transmission out.. i will post pictures soon..

new sway bar links are on their way and tie rod ends as they were about to give out.
while the transmission is going to the shop im going to pull of the oil pan and clean it up, gaskets/seals are on their way for that, and i will replace the timing belt as well and clean up all the crud thats been built up over the years on the block/frame and etc.

next im going to focus on the suspension and downpipe and custom 3'' inch exhaust built my myself

... i love this project , alotttttt of work ... stay tuned my fellow Volvo lovers

ACk · Post by **ACk** » 17 Apr 2012, 22:41

i have attached a few pix, everything is ready for the tranny to drop down, this part is tricky, i cant find the floor jack attachment as mentioned in the VADIS pdf file, in order for me to safely lower the tranny, so im a little flustered .... but it will come out