Is it time for a new automatic gearbox ?

[vtl]

4-5 frictions wear quicker then the rest.

There are couple of common wear spots on the casing. Depending on how bad is yours, it would make more sense to acquire a low-mileage donor gearbox. Or have your casing fixed. @firstv70volvo kindly did such the fix for me (brought the casing to Omega Machine for steel sleeve).

The rest is more or less simple, just get a factory new valve body, don't mess with yours.

[firstv70volvo]

...
I feel quite confident I can rebuild the gearbox with good instructions....
But what should I get?

Vtl and I have rebuilt this transmission and can help with photos and instructions.

It's a big job so you'll need to do some planning up front as far as what tools you'll need, parts you'll need, space and time you'll need.

You'll need about 5 full days to complete this job. It took me a day to remove the engine and start disassembling the transmission, 2 days to rebuild the transmission and another day and a half to install the transmission and sort everything out.

You'll need a transmission rebuild kit ~$500, ATSG manual $55, remanufactured torque converter $150 to $300, new valve body ~$500 and whatever tools you may need. You mentioned you've replaced the valve body about a year ago and if it was a new valve body and it's still working well then you can reuse it but a worn valve body or sticking linear solenoids can cause a lot problems so error on the side of new replacement.

For tools you'll need an engine support bar, a transmission jack or an engine hoist to lower and raise the transmission and some tools you may not have to rebuild the transmission like a spring compressor, clamps, horseshoe ring pliers, etc. but overall there's not many special tools needed to rebuild this transmission.

I have a lot notes and photos if you decide to do this and there's some good disassembly and build videos on Youtube for this transmission.
Here's a good build video, most videos are just showing how to tear them apart, this one shows how to rebuild it too.


As Vtl mentioned the case could be worn in a couple of areas and there could also be some hard parts that need to be replaced so it might be best to find a good used transmission to start with and there are advantages and disadvantages(cost mainly) of rebuilding a good used transmission ahead of time.

[vtl]

On encouraging side, both our transmissions work great! So it's definitely doable.

[greffel]

The vibration that I feel on the 4 gear, would that be worn clutches or a worn case ?
Why do I need a new torque converter ?

[vtl]

Torque converter is a wear item, its frictions usually go out first.

[greffel]

Have looked now for 2 weeks after a replacement gearbox. A gearbox from a 2.5T is no where to be found.
There is a R box available....but will it fit and work?

On a manual gearbox the number down right on the gearbox sticker is the ratio ex. 3.77

Can't find the equivalent on my box

[vtl]

What trim is your S60? Base (N/A, FWD), AWD, T5?

[greffel]

2.5T AWD

[vtl]

Not your model year, but MY2006 and MY2008 were 2.27:1

https://www.media.volvocars.com/us/en-u ... ifications
https://www.volvoclub.org.uk/tech/s60-06-specs.shtml

[greffel]

And the R was 3.33
https://www.volvoclub.org.uk/tech/r-06-specs.shtml

What will happen if a R gearbox goes on to my car ?
Haldex and/or diff will take damage because the different final drive?