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2000 S80 in-car Transmission rebuild problem

Help, Advice, Owners' Discussion and DIY Tutorials on the Volvo S80 model. Sometimes called an "executive car", the S80 was and continues to be Volvo's top-of-the-line passenger car.
thr3shold
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2000 S80 in-car Transmission rebuild problem

Post by thr3shold » Sat Oct 19, 2019 3:33 pm

I'm utilizing Oly_850's great write up to attempt my in-car transmission rebuild but have run into a roadblock; both the steering shaft u-joint retaining bolt and the rack and pinion bolt into the engine both seem like they want to shear right off. I've soaked them best I could in penetrating fluid, but are there any suggestions? Assuming I can't remove either bolt without shearing it off is there even any way forward? Thanks for all your help in advance.



thr3shold
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Re: 2000 S80 in-car Transmission rebuild problem

Post by thr3shold » Sun Oct 20, 2019 12:33 pm

Solved. The bolts just needed time for the oil to work? Plus whacking it some more and they both came free.



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SuperHerman
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Re: 2000 S80 in-car Transmission rebuild problem

Post by SuperHerman » Tue Oct 22, 2019 9:30 pm

My only words of wisdom is to pressure test your seals before reinstalling the clutch assembly. I did the job, it is not bad.



thr3shold
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Re: 2000 S80 in-car Transmission rebuild problem

Post by thr3shold » Wed Nov 20, 2019 4:20 am

I finished the job and everything seemed great(smooth crisp shifts over 5 miles), but then the transmission started acting funny during a longer trip(burned clutch smell and a feeling of bogging down/resistance). I realized I didn't reset the transmission computer to have it adapt to all the new parts, but I haven't touched my VADIS laptop setup in 4 years and I'm having trouble getting it working again. Is there an alternate method to clear the computer memory?



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SuperHerman
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Re: 2000 S80 in-car Transmission rebuild problem

Post by SuperHerman » Sat Nov 23, 2019 8:54 pm

I don't think that is your problem. Resetting computers will not help.

I fear you made the same mistake I made. There is one bolt, the longer one, that has a higher torque value than the others. If you did not torque this correctly you will have a leak which will burn up a few of your clutch packs.

Did you pressure test your seals?

Ask how I know. That said, if this is your problem, you can just change out those clutch disks and be out for around $50.00. If it is your seal, you will have to replace it and the burned disks.



thr3shold
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Re: 2000 S80 in-car Transmission rebuild problem

Post by thr3shold » Mon Nov 25, 2019 3:05 pm

I torqued all the bolts according to spec in the ATSG book and went over all bolts twice to make sure they didn't change values due to flexing. I was unable to pressure test the seals as I don't have an air compressor. I got VADIS working on a VM installation and reset the module and the car so far shifts fine over a few very steep hills in my area and about 30 miles of driving. I'm not ruling out your claim, but if it comes down to a bolt not being torqued correctly I don't think that is likely the cause in this case as I was almost paranoid about making sure I did that part correctly.



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SuperHerman
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Re: 2000 S80 in-car Transmission rebuild problem

Post by SuperHerman » Mon Nov 25, 2019 7:49 pm

Well I hope I am wrong, I really do. Hopefully the reset resolves your issues.

My experience on first rebuild is I screwed up on bolt 380 (figure 189) of the ATSG book (I think that was the one). I torqued in stages - which was a mistake. This bolt goes to 25 N.m, and I left it at 12 N.m. In my first failed attempt, as bolt 380 is longer and ties into the drive sprocket support, and it was not torqued correctly it loosed and didn't seal. My symptoms were similar to yours but it got worse. Mine only lasted 2-3 miles.

On my second rebuild attempt I didn't check the seals as they worked the first time. Mistake as I had it professionally rebuilt the next time and they told me that is what failed, but it worked great for 6 months or more.

How does your fluid look and smell? Make sure to give it a good smell as on my second rebuild the fluid was clean, as the filter did its job, but the filter clogged up.



thr3shold
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Re: 2000 S80 in-car Transmission rebuild problem

Post by thr3shold » Tue Nov 26, 2019 5:55 am

What should the fluid not smell like? Smells like trans fluid to me.



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Re: 2000 S80 in-car Transmission rebuild problem

Post by June » Tue Nov 26, 2019 6:18 am

thr3shold wrote:
Tue Nov 26, 2019 5:55 am
What should the fluid not smell like? Smells like trans fluid to me.
Dextron has a plastic bottle smell to me. I checked mine the other day and it still has that smell. Open a fresh bottle and compare the scent to what is in the transmission. June


My Volvo cars owned
1989 740 GLT ordered
1994 850 4door standard shift ordered
1996 960 ordered
1998 S90 ordered totalled after 3 weeks
1998 V70 GT dealer stock car
2002 S80 T6 ordered totalled
2004 S80 T6 dealer stock car and current car owned

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SuperHerman
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Re: 2000 S80 in-car Transmission rebuild problem

Post by SuperHerman » Wed Nov 27, 2019 12:31 pm

You mentioned it had a "burnt clutch smell" - that smell should not be in the new fluid.



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