1994 960, AW 30-40 Transmission drain plug has no crush washer, not sure if that bolt is really on there.

maxbarkly · Post by **maxbarkly** » 03 Jan 2019, 08:11

Howdy folks,

First time actually posting here, but this site has been invaluable as I work on my wagon.

Own a 1994 Volvo 960 (Edgar), it has around 96,000 miles on it and I would consider it to be in VG+ condition (if we're using vinyl grades). The original owner only drove it to work and back and took it to the dealership on the regular, he traded it to get a new wagon. I have 5 years of service records from Volvo of Princeton that has helped me determine what the car needs.

Ive noticed some erratic shifting in the car (revs real high from 1st/2nd, or stutters about a little on the highway when hitting the throttle) and I decided to do a drain and fill on the aw30-40 transmission. Some real burnt toast came out of the pan, and i topped it back off with Genuine Volvo ATF DexIII/Merc. I assume that 1st and 2nd were the only two gears this transmission ever knew before me given the mileage, and it would rev real high sometimes between 1st and 2nd. After changing the fluid, I drove around the parking lot doing K turns at increasing speeds to massage in that new fluid, and now the car definitely drives much smoother, especially in the lower gears. I am certain I will be doing another few drain and fills over the course of the year to clear out the system completely (I am in NYC, and have no garage, I have to be able to pack up my work before sundown, thats why I havent pulled the line to the radiator to do a full flush), but Im very happy with the results so far.

Alright so here's my actual questions: When I took out the plug from the pan, it had no crush washer, and I was honestly confused by the size of it relative to the oil pan drain plug. Should there have been a crush washer here? I refilled the system with what I took out, and tightened to the point of "good and tight." I gave it a good half turn and it never felt like it was giving more resistance (even tried using my torque wrench to 28 ft-lbs (then 20 ft-lbs) but it never registered), and my instincts told me that I should be careful not to strip this bolt. I checked it this morning real fast and its not leaking, though i still want to get under the car and look. Should I be worried about how tight this bolt is?

Thanks for indulging my car neurosis.

lummert · Post by **lummert** » 03 Jan 2019, 10:58

The OE part number for the drain plug gasket is 3549223. 12 mm x 18 mm copper.

maxbarkly · Post by **maxbarkly** » 03 Jan 2019, 11:10

Thank you, going to order that now. Looks like Im going to be doing another fresh fill sooner than I anticipated.

Just to confirm (if you can), 3549224 is the OE part number for the drain plug, correct? FCP Euro's site is unkind to 960s and what parts are supposed to fit.

lummert · Post by **lummert** » 04 Jan 2019, 07:17

3549224 is for the drain plug, this part fits 240, 260, 740, 760, 780, 940, 960, S90, V90. years 79-98.

dm635 · Post by **dm635** » 04 Jan 2019, 13:43

Yes does take a crush washer. It is not a common size. As I don't have a spare in my baggy of spare crush washers. Don't worry about disconnecting the transmission line for a flush. A series of drain and fills does the job just fine. For some reason on a few 960's I've found that attempting to loosen the trans line at the radiator will start to twist the line as the nuts is loosened. Requiring a full trans line replacement. Essentially parking the car as you locate another. Don't know why, but it has happened a few times only on the 960.