Is it time for a new automatic gearbox ?

[vtl]

Yes, AWD drivetrain damage.

You can always swap in your differential. This is what I did. My donor transmission was from FWD S60, I believe.

[greffel]

When you say swap differential ...that's inside the transmission ?

What about the angle gear?

[vtl]

Yes, inside the transmission. You take the final drive (two gears) out of your transmission out and put into your donor gearbox.

Angle gear can be reused.

[greffel]

No manual needed since I have you guys?

If I do this Should I do anything more to the R transmission?
It's from a 2004 with only 15000km on it. Has been in storage since 2006 I guess.

[vtl]

You can google "AW55 ATSG pdf", but I found it is more convenient to have it in a dead tree copy form.

Casing in a 15k kms transmission should be virgin, I'd guess.

[firstv70volvo]

No manual needed since I have you guys?

If I do this Should I do anything more to the R transmission?
It's from a 2004 with only 15000km on it. Has been in storage since 2006 I guess.

The 2004 R transmission would likely require the differential swap like Vtl did to get the same final drive ratio you have now. If it's a good transmission and you can't find anything else you might want to consider this transmission. I believe the R automatic is the AW55-50 or 51SN 5 speed up to MY2005 then I think they switch to the 6 speed auto in 2006.

Looks like the final drive ratio for the R transmission is 2.65.
https://www.volvoclub.org.uk/tech/r-05-specs.shtml

[greffel]

Yes, inside the transmission. You take the final drive (two gears) out of your transmission out and put into your donor gearbox.

Angle gear can be reused.

Have looked at a couple of videos...
The only part that I have to change is the differential/finaldrive shown in this video?


1. remove bell housing
2. swap the differential
3. clean and reseal bell housing

...all done ?

[vtl]

1. remove bell housing
2. swap the differential
3. clean and reseal bell housing

...all done ?

More like:

1. remove bell housing
2. remove oil pump
3. partially disassemble parking hw
4. remove the final drive
5. install your differential (only)
6. install the bell housing back, w/o sealant, tighten the bolts
7. measure differential bearing preload
8. remove bell housing
9. either correct the preload with another shim and go to 5 or proceed to 10.
10. install the final drive
11. assemble parking hw
12. install the pump (can be tricky, see the videos)
13. install bell housing using sealant on clean surfaces

Improper differential bearing preload is very bad.

You may choose to install a new axle seals between 4 and 10 while you are here.

[firstv70volvo]

1. remove bell housing
2. swap the differential
3. clean and reseal bell housing

...all done ?

More like:

1. remove bell housing
2. remove oil pump
3. partially disassemble parking hw
4. remove the final drive
5. install your differential (only)
6. install the bell housing back, w/o sealant, tighten the bolts
7. measure differential bearing preload
8. remove bell housing
9. either correct the preload with another shim and go to 5 or proceed to 10.
10. install the final drive
11. assemble parking hw
12. install the pump (can be tricky, see the videos)
13. install bell housing using sealant on clean surfaces

Improper differential bearing preload is very bad.

You may choose to install a new axle seals between 4 and 10 while you are here.

If you plan to do this it would be a good idea to have some shim material on hand. I didn't have to make any adjustment but if you do need to make a change there's a shim washer behind the tapered bearing race that would adjust the preload with a thicker of thinner shim(s). I don't know the dimension, Vtl?. According to the manual the rotational preload should be between 6-11 inch pounds or 0.70-1.20Nm.

I'm not sure if you can find different shim sizes at a transmission shop but there are other sources for shim washers if you have the the correct ID OD dimensions.
https://www.mcmaster.com/shim-washers/s ... m/id~80mm/

You can see the shim here behind the large bearing race. It's called a front differential bearing race selective shim and according to the manual there are shims available between 1.00mm and 1.90mm in 0.05mm increments.

[vtl]

If the preload is a bit weak, like it was in my case, a trusted shim material source can be used: an aluminum can



The shim went in under the steel washer, so the bearing race is not touching it.

Preload measuring, btw:





Before the reshimming it was 0.5 Nm.