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2009 S40 NA Transmission replacement. TIPS

Help, Advice, Owners' Discussion and DIY Tutorials devoted to the second generation C70, S40 and V50 Volvos -- awkwardly model year 2004 ½ onwards -- plus where to go for advice and discussion on Volvo's sporty C30 Coupe powered by Volvo's ubiquitous inline 5-cylinder power plant.
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2009 S40 NA Transmission replacement. TIPS

Post by cliffordhubbard »

Wifes 09 S40 needs new transmission. Found one on craigslist. looking for info on pulling old one out and installing new one. any thoughts?
have access to lift and transmission jack as well as all tools i would need.
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Re: 2009 S40 NA Transmission replacement. TIPS

Post by Brucebo »

Are you still interested in this subject? If you don't what to pull the whole engine/tranny assembly here's what you need to do.

These tools make it easier. This assumes you don't have a car lift and/or a transmission jack.

Engine hoist https://www.harborfreight.com/2-ton-cap ... 69514.html
Load leveler https://www.harborfreight.com/2-ton-cap ... 60659.html
Engine support bar (needed if you change the car height with a jack in the middle of the job) https://www.harborfreight.com/1000-lb-c ... 96524.html

1. The left (US driver's side) of the engine/tranny assembly is supported by 3 bolts from the left engine mount into the top of the tranny.
2. Jack up the car sufficiently so that you can roll the transmission out when lowered onto a dolly.
3. Remove tires and cv axles.
4. Drain transmission fluid.
5. Disconnect transmission oil cooler lines from radiator.
6. Remove battery box and air pump (to gain access to the top of tranny and bell housing). May need to also remove radiator hose.
7. Disconnect mechanical linkage and wiring harness plug.
8. Support left side of engine with stack of lumber or screw jack (or engine support bar).
9. Support right side of tranny with stack of lumber or screw jack.
11. Remove left (driver's side) engine mount (really mounts to tranny).
12. Screw in lifting eyes into two farthest apart mount holes. https://www.amazon.com/gp/product/B0791DYKQK
13. Attach engine hoist to lifting eyes via a load leveler. You will need the load leveler to rotate the tranny to line up the bell housing bolts when re-installing.
14. Remove the tranny mount bracket at the bottom of the tranny.
15. Put a little tension in the engine hoist. Remove supports under tranny.
16. At the back of the tranny, closest to the firewall there is an access port to get to the torque converter screws. There are six of them. They use a torx socket. You need to rotate the crank (via a wrench on the harmonic balancer) to get to all six. Remove the screws.
17. Remove the bell housing bolts.
18. Knock the tranny back with a mallet. It should now be loose, and swinging from the lift.
19. Lower tranny with the engine hoist onto waiting dolly. You can tilt it onto its back to get more clearance. Transmission weighs about 150 lbs.

20. Installation is reverse.
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