2002 s60 2.4T Fixing rough shifts in transmission - complete

[Homebrand]

Completed the solenoid refurbishment on the SLS SLT and SLU solenoids.

The solenoids were gummed up in the bushings and the armature definitely didn't fall out under its own weight.

Now I just have to wait till tomorrow to for the RTV to cure for the valve body cover (couldn't get an actual gasket) before doing a fill and replacement procedure for the fluid.

I'm am going to have a sleepless night about this gasket goop and whether or not it is going to seal as I had major trouble keeping the ATF off the bottom of the housing face. It dripped forever and every time I left it longer than a minute, there was a bit more there.



The HARDEST part by far was the reinstallation of the valve body cover without fouling the RTV. Plus the fact I couldn't get a torque wrench in there to know that I had the proper torque on the bolts.
Even if it leaks - hopefully slowly- i'll still be able to see if it worked, and if it did, i'll just pay a transmission shop to reinstall the pan so it doesn't leak!


Anyway, big thanks to Mike (precopster) for his write ups which gave me the confidence to go ahead with it.

I will post tomorrow night with background and full results.
Fingers crossed

[precopster]

You can hit the pan with a hairdryer on the hottest setting for 5 minutes just to help cure the RTV before filling. It dries fast when heated. The Nissan dealers will have a gasket from certain Maxima years. If it leaks I can look up the years in the ATSG guide and report back. Good luck !!

[Homebrand]

If you want to refurbish your solenoids in the AWW55-50SN transmission, read this thread by precopster

https://www.matthewsvolvosite.com/forums ... =9&t=61062

Okay, so I bit the bullet after reading the above thread by Mike (precopster)

Background:
Rough shifting in transmission, flares on upshift AND downshift when transmission was warm
Had been this way for 4 years (was my brothers car) so guessing at about 100,000kms it started.
Car 2002 s60 2.4T 158,000 kms (current)
Transmission shifts into reverse and drive were delayed and harsh even when cold.

1. Driveability when cold was basically fine, smooth shifts, no slipping or banging - This was important in my decision to attempt this, as it indicated the internals of the transmission were still ok.

2. Once temp in transmission hit about 75-80 Celcius (used VIDA Dice to check whilst driving), the shifts become rough. Upshifts between 2-3 would flare dramatically and then slam into gear. Sometimes gears 3-4 as well.
3. When coasting to a stop, even the downshifts were clunky, to the point where it I thought I was going to damage the transmission.
4. Most concerning was if I was coasting down in speed and then tried to accelerate again. The car would rev high and then slam into gear.
5. I drove it this way for a while whilst feathering the pedal gingerly once the transmission was warm to try not to "over-rev" the engine when the transmission didn't engage.


My first attempt at a cheap fix was Lucas Transmission additive: What have I got to lose?
The additive certainly helped reduce the slamming into gear - instead it would rev-out then sort of slip into gear without the BANG - like a slipping clutch on a manual - It certainly DID NOT fix the problem.

Went to Volvo dealer - No Way would they look at the valve body - New/refurbished transmission only options. Outrageously expensive. (Funny that the procedure for solenoid replacement is in the VIDA software)

Went to transmission shops - Quoted between $1,800 - $2,300 to fix valve body with no guarantees it would work. Ok, so that's not really an option with no guarantee.

Anyway - Followed Mikes instructions with some differences and those from VIDA.

Removed the valve body cover - and remove only the SLS, SLT and SLU solenoids.
Again - refer to the link for Mikes thread above for instructions.
I was not refurbishing the entire valve body (even though I had the transgo kit with the parts) as I became impatient and didn't want to wait for the gasket kit.
Ground the backs off the solenoids as per this video
I found it useful to tap the back/bottom "cover" to make it tilt once the rim around the cap was gone. This freed it to allow easier removal.
The armatures were definitely not sliding out like they should. GREAT!! So far, the sticking solenoids theory was standing up well.
Followed the very detailed Transgo instructions for clearing the bushings and put them back together.
Reinstalled, and closed everything up.
NOTE: I didn't buy new solenoids as I was paranoid the adjustment may not be right and I certainly did not want "adjustment" issues once I had the job done.

Did a full transmission fluid replacement - Used 11 litres in total to get it coming out cherry red. Nulon Multi Vehicle Synthetic - Compatible with the JWS requirements etc.
Reset the transmission fluid counter with my Dice set-up.
DID NOT Reset adaptations as I didn't adjust the solenoid - I simply refurbished it.

Did it work?
I took it out and clocked up about 200kms of driving today in all traffic conditions.

The transmission is the smoothest it has EVER been.
I would go as far as saying it is flawless. It has without a doubt cured my transmission problems.

Give it a go if you have the same problems.
I am NOT a mechanic but I AM willing to read, read and read some more, then have a go.
The most complicated thing I had done with a car before this (mechanically) was change out some basic parts and change oil/filters etc.
I'll update the results as time goes on so people in the future may read the longer term results.

But thanks to Mike for encouraging people in general to have a go at this and his detailed videos and posts. Hope this post adds some more weight to Mikes existing thread on this topic.

[Homebrand]

1,000kms in and still all great.
Garage shifts are delay free and smooth.

Maybe a slight bump if accelerating/braking/accelerating in quick succession under 30km/h.
But it think i'm being too sensitive and am pretty sure this is normal if the car is trying to keep up with rapid throttle position changes back and forth.

I'll update at 5,000kms or if something dramatic happens in the meantime.

[precopster]

Hey Homebrand welcome to the mile high revived 2001 AW55-50 transmission club. It's a great feeling getting on top of a problem with loose change that Volvo charges thousands for

Wife's 2002 is still going strong also. Shifts have finally adapted to optimum and is a great drive. Just edging 305K kilometres

Let's see if I can do the same with my 2001 XC70.......

[Homebrand]

Thanks Mike.
I ended up doing the re-adaptation tonight as well.
It feels completely sorted.
It is indeed a bloody great feeling to have the tranny sorted, particularly against all the pessimistic advice I was given by dealers and auto shops!
Always easier to follow in someone else's footsteps that has done it before!!!
Like you, I hope other people give this a go before spending major bucks or scrapping their cars.
Next is the A/C clutch plate shimming (may do the "breadclip" approach) and BPS replacement.

[precopster]

What is a BPS replacement? Is that a brake pedal switch? If so with some patience these can be repaired.

[Homebrand]

It was the boost pressure sensor. The one on the intake pipe giving me the two codes from another thread I made. It resolved the "hesitation" issues from standstill and sporadic "engine stumbling" I was having.