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2000 S80 DIY 4T65EV-GT rebuild (in car) Topic is solved

Everything on the Volvo S80. Sometimes called an "executive car", the S80 was Volvo's top-of-the-line passenger car. P2 platform.
This topic is in the MVS Volvo Repair Database » S80 Transmission Rebuild In-Car DIY
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Oly_850
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Joined: 6 February 2011
Year and Model: 2000 S80 T6
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Volvo Repair Database 2000 S80 DIY 4T65EV-GT rebuild (in car)

Post by Oly_850 »

Hello MVS readers,

I have a 2000 S80 T-6 with the same P0756 troubles everyone usually runs into, namely no shift into 3rd or 4th. Swapping the whole solenoid set had no effect, so it was time for a complete unit swap or a rebuild. As this is my project car, and I'd done a few VW transmissions before, I decided to do it myself. The idea came from watching this series of videos on YouTube, it's possible to fix the problem our cars have without actually removing the transmission, so this rebuild just replaces all the clutches and worn bushings and the 4th gear shaft, leaving the torque converter and differential alone:

This is a series of videos on fixing a 4T65E on a domestic GM vehicle while it's still in the car, which at 156k, was all I really needed.



I also bought this DVD which proved invaluable:

http://www.ebay.com/itm/221235749284

And this ATSG manual just for light reading:

https://www.atsg.us/atsg/gm-manuals-1/4t65e.html

After a few nights of reading, I bought a rebuild kit and 4th gear shaft from Dave Norris at Triple Edge Performance. Dave is an excellent resource and happily answered all of my questions. I also bought a wring harness connector repair kit, and a new 2003+ improved 4th gear shaft with hardened splines. Total cost ~$280.

http://shop.tripleedgeperformance.com/4 ... K8400R.htm

I just followed the steps in the videos, looked at the manual ( .pdf version ) and hauled the thing apart, rebuilt the clutches, installed all new frictions and bushings from the kit.

Success! It drives like a dream, transmission runs completely silently and shifts beautifully. It's very, very fast. :). Some photos and comments:
Attachments
FWD engine lowering tool from Astro Pneumatics, about $70 on Amazon. Used the braided steel cables that came with it, one looped around the intake manifold, the other wound around the engine-to-subframe mount.
FWD engine lowering tool from Astro Pneumatics, about $70 on Amazon. Used the braided steel cables that came with it, one looped around the intake manifold, the other wound around the engine-to-subframe mount.
Assembly lube, be a big shot and buy this stuff instead oh just using Vaseline.
Assembly lube, be a big shot and buy this stuff instead oh just using Vaseline.
Rebuild kit, the 4T65EV units we have differ slightly from their domestic cousins, so get the right one (above).
Rebuild kit, the 4T65EV units we have differ slightly from their domestic cousins, so get the right one (above).
Lowering the engine after dropping down the subframe. Follow the VIDA instructions for this stuff...
Lowering the engine after dropping down the subframe. Follow the VIDA instructions for this stuff...
image.jpg
Cover off, getting it off is not terribly easy, be well fed, rested, and have a sense if humor about you
Cover off, getting it off is not terribly easy, be well fed, rested, and have a sense if humor about you
Valve body and channel plate off, clutch packs and various bits come out. Clean everything, look for wear, missing chunks of steel. All of my bands and hard parts were fine.
Valve body and channel plate off, clutch packs and various bits come out. Clean everything, look for wear, missing chunks of steel. All of my bands and hard parts were fine.
Empty case.
Empty case.
Only cut myself once, watch it, the 4th gear carrier is sharp around the edges. :)
Only cut myself once, watch it, the 4th gear carrier is sharp around the edges. :)
I replaced everything, but these are the real culprits. Burned third gear clutch & ground up splines on the 4th gear shaft
I replaced everything, but these are the real culprits. Burned third gear clutch & ground up splines on the 4th gear shaft
Finish assembly and use DICE / VIDA to reset the fluid change counter and most importantly, put the trans into adaptive mode so it will learn new shift points with all that new hardware inside.
Finish assembly and use DICE / VIDA to reset the fluid change counter and most importantly, put the trans into adaptive mode so it will learn new shift points with all that new hardware inside.
Success! 70mph on I-5 @ 2100 RPM. (Warm it up slowly folks, check the fluid, look for leaks, let the assembly lube melt, make sure it actually shifts THEN go knock yourself out and drive it some. Carefully please.)
Success! 70mph on I-5 @ 2100 RPM. (Warm it up slowly folks, check the fluid, look for leaks, let the assembly lube melt, make sure it actually shifts THEN go knock yourself out and drive it some. Carefully please.)
'12 Ford Focus SE - Black Pearl
Owned:
'00 Volvo S80 T6 - Maroon
'98 Volvo V70 - Red
'90 Volvo 740 GLE - (sold, too far gone)
'96 Volvo 850 GLT - (totaled) :\
Want - A6 Quattro, XC90, C303
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MyS40T4
Posts: 73
Joined: 2 August 2010
Year and Model: S80 T6 2000
Location: Australia
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Post by MyS40T4 »

Fantastic and thanks Oly850 for posting!

Very timely for me as I'm dismantling my own 2000 S80 to rebuild the transmission.

Thanks for the videos as the trans in the video has the same fault as mine - a broken forward band. Plus the shot 3rd gear clutches given the black flakey bits in the filter.

How did you get on replacing the teflon seals (resizing them) and dismantling the clutch packs? Any tricky bits? I've been looking at removing the trans completely to have the torque convertor checked out and flushed...

Good to see DICE/VIDA will run on a macbook with virtual PC (do you use VMware Fusion?). I have VADIS already.
I have the transmission manual and the rebuild DVD.

Finally, with disconnecting the steering rack, is that from the engine bay side or inside the car? Seems silly, but doesn't seem clear to me from the VADIS...


Cheers,

Chris
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matthew1  
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Post by matthew1 »

"I decided to do it myself."

Yep, you're one of us ;-).

Scheduled for entry in the Volvo Repair Database. Good work, MyS40T4 Oly. I made your account MVS Contributor.
Last edited by matthew1 on 08 Jun 2014, 18:02, edited 1 time in total.
Reason: Fixed my goof
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1998 V70, no dash lights on

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Oly_850
Posts: 114
Joined: 6 February 2011
Year and Model: 2000 S80 T6
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Post by Oly_850 »

Oops Matt, that was my write up not Chris'... :)
'12 Ford Focus SE - Black Pearl
Owned:
'00 Volvo S80 T6 - Maroon
'98 Volvo V70 - Red
'90 Volvo 740 GLE - (sold, too far gone)
'96 Volvo 850 GLT - (totaled) :\
Want - A6 Quattro, XC90, C303
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matthew1  
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Contact:
Contact matthew1
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Post by matthew1 »

D'oh! Undo/redo. Sorry Oly!
Help keep MVS on the web -> click sponsors' links here on MVS when you buy from them.

Also -> Amazon link. Click that when you go to buy something on Amazon and MVS gets a cut!

1998 V70, no dash lights on

1997 850 T5 [gone] w/ MSD ignition coil, Hallman manual boost controller, injectors, R bumper, OMP strut brace

2004 V70 R [gone]

How to Thank someone for their post

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Oly_850
Posts: 114
Joined: 6 February 2011
Year and Model: 2000 S80 T6
Location: University Place, WA
Been thanked: 1 time

Post by Oly_850 »

MyS40T4 wrote:Fantastic and thanks Oly850 for posting!

Very timely for me as I'm dismantling my own 2000 S80 to rebuild the transmission.

TF - great! Tough job, but not impossible.

Thanks for the videos as the trans in the video has the same fault as mine - a broken forward band. Plus the shot 3rd gear clutches given the black flakey bits in the filter.

How did you get on replacing the teflon seals (resizing them) and dismantling the clutch packs? Any tricky bits?

TF - the Teflon rings have to be shrunk down after sliding them over the driven shaft. I lubed them up using trans assembly goo, slide them on one at a time into their grooves. Next, I took a Coca-Cola can, sliced off the top, bottom and cut vertically up one side, leaving a slit cylinder. I put that (gently) around the shaft & seals and compressed it with three stainless steel screw on hose clamps. Left it like that for an hour. Whammo, rings compressed.

I've been looking at removing the trans completely to have the torque convertor checked out and flushed...

Good to see DICE/VIDA will run on a macbook with virtual PC (do you use VMware Fusion?). I have VADIS already.

TF - I use Parallels, but VMWare Fusion would work just as well, no hiccups, just acts like XP, except it runs better.


I have the transmission manual and the rebuild DVD.

Finally, with disconnecting the steering rack, is that from the engine bay side or inside the car? Seems silly, but doesn't seem clear to me from the VADIS...

TF - this is easier than you think. Take all the bolts / nuts out of / underneath the steering rack, and take off the left side steering arm from the steering knuckle and suspend it with wire or a zip tie. When you lower the subframe, the steering rack will stay in place, no need to disconnect the steering coupling as the VIDA instructions suggest. Use a pry bar from the back / left of the rack to move it into position, when you're raising the subframe..

Cheers,

Chris
'12 Ford Focus SE - Black Pearl
Owned:
'00 Volvo S80 T6 - Maroon
'98 Volvo V70 - Red
'90 Volvo 740 GLE - (sold, too far gone)
'96 Volvo 850 GLT - (totaled) :\
Want - A6 Quattro, XC90, C303
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Oly_850
Posts: 114
Joined: 6 February 2011
Year and Model: 2000 S80 T6
Location: University Place, WA
Been thanked: 1 time

Post by Oly_850 »

matthew1 wrote:"I decided to do it myself."

Yep, you're one of us ;-).

Scheduled for entry in the Volvo Repair Database. Good work, MyS40T4 Oly. I made your account MVS Contributor.

No worries Matt, Awesome thanks!
'12 Ford Focus SE - Black Pearl
Owned:
'00 Volvo S80 T6 - Maroon
'98 Volvo V70 - Red
'90 Volvo 740 GLE - (sold, too far gone)
'96 Volvo 850 GLT - (totaled) :\
Want - A6 Quattro, XC90, C303
Top
MyS40T4
Posts: 73
Joined: 2 August 2010
Year and Model: S80 T6 2000
Location: Australia
Been thanked: 1 time

Post by MyS40T4 »

Thanks for the replies Oly850,

I'll experiment with the Coke can for compressing the teflon seals and the tips will save me some effort...

Did you fit a shift kit ( http://shop.tripleedgeperformance.com/T ... 84908M.htm ) to lessen the wear on the new clutches?

I was thinking that I'd install a $200 master kit and all the 4T65E 'fixes', based on fear of having to pull it all apart again :-)
Hardened 4th Clutch Shaft
Harness repair kit
Transgo Shift Kit
TCC relief valve
Sonnax TCC Apply Valve
4T65-E AFL Valve Repair Kit (Superior K098)
Line Pressure Booster Kit Part No. 4T65E-LB1
Boost Valve Kit Part No. 84754-30K

Plus new solenoids... All of which adds up to be quite a bit.
Maybe I don't need to apply all the fixes??

I'll be aiming to remove the subframe completely so I can clean it up, remove the sump and do the o-rings and get rid of all the nasty accumulated oil and dirt.

Cheers,

Chris
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Oly_850
Posts: 114
Joined: 6 February 2011
Year and Model: 2000 S80 T6
Location: University Place, WA
Been thanked: 1 time

Post by Oly_850 »

Hi Chris,

I didn't make any changes to the valve body at all, all of the valves and bores were in good shape, so no Sonnax parts. Didn't bother with any Transgo items either, just bought a master kit and a new 4th gear shaft. I did replace all the solenoids however. Runs perfectly with that setup.
'12 Ford Focus SE - Black Pearl
Owned:
'00 Volvo S80 T6 - Maroon
'98 Volvo V70 - Red
'90 Volvo 740 GLE - (sold, too far gone)
'96 Volvo 850 GLT - (totaled) :\
Want - A6 Quattro, XC90, C303
Top
MyS40T4
Posts: 73
Joined: 2 August 2010
Year and Model: S80 T6 2000
Location: Australia
Been thanked: 1 time

Post by MyS40T4 »

Thanks Oly,

I've read so much about the transmission issues that perhaps I'm becoming a little paranoid :-)

I'll just pull it apart and see what it's like before I buy any of the fixes. The car has done 125k miles, but like many, I don't think the trans ever had a fluid/filter change.

Cheers,

Chris
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