Removal & Installation: Transaxle: Removal

1. Shift the gear selector lever to Neutral position.
2. Remove the following components:
   • Battery.
   • Air cleaner housing and the intake manifold. See appropriate MECHANICAL article in ENGINES.
   • Timer valve from the air cleaner housing (turbocharged).
   • Battery shelf.
   • Bolts securing the bracket for the air cleaner housing.
3. On models equipped with turbocharged engines, remove the following:
   • Hose between the pipe from the charge air cooler and the outlet pipe from the turbocharger. See Fig 1 . Tie the pipe to the radiator.
   • Brake vacuum hose from the nipple on the intake manifold and the clamp on the engine.
   • Hose between the throttle body intake pipe and the charge air cooler.
   • Loosen the clamp for the intake pipe at the throttle body a few turns.
   • Turn the pipe in towards the engine as far as possible. Secure it using a tie strap.
4. On all models, remove the transaxle cables. Remove the gear selector cables from the bracket and levers. See Fig 2 .
5. Remove the transaxle lever. Knock out the split pin. Disconnect the connector for the back-up light switch.
6. Remove the clutch hydraulic line using the following steps:
   1. Using hose pliers, clamp the hose between the brake fluid reservoir and the clutch master cylinder. See Fig 3 .
   2. Remove the clutch line from the adapter by pulling out the locking tongue which locks the quick-release connector to the adapter. Remove the quick-release connector from the adapter.
   3. Wipe up any brake fluid that leaks out.
   4. Reinstall the locking tongue in the adapter.
   5. Protect the ends of the clutch cable from contamination with a plastic bag.
   6. Lift the pipe out of holder on the side of the transaxle and place it to one side.
   7. Remove the ground lead from the transaxle.
   8. Remove the clamps for the engine cable harness.
7. Loosen the nut for the rear engine pad/splash guard a few turns. Remove the five bolts securing the starter motor to the transaxle. Remove the cable duct above the transaxle. See Fig 4 .
8. Remove the bolt for the torque rod and torque control arm on the engine. See Fig 5 . Disconnect the ground strip from the firewall.
9. Install engine lifting beam (999 5716). See Fig 6 . Install lifting hooks (999 5460 and 999 5185). Lift the engine to relieve the load on the engine mounts.
10. Remove the front wheels and the ABS sensor. See appropriate ANTI-LOCK article in BRAKES.
11. Remove the front axle nuts.
12. Remove the front protective cover. See Fig 7 .
13. Disconnect the control arms from the stub axles. See appropriate AXLE SHAFTS article in DRIVELINE/AXLES.
14. Remove the mounting bolt for the cable conduit on the sub-frame.
15. Remove the carbon filter container with its hoses from the sub-frame (certain versions). Cut off the tie strap for the hoses. Hang the container from the car body.
16. Unhook the pipe from the sub-frame. Loosen the clamp for the exhaust pipe behind the three-way catalytic converter.
17. Remove the bolted joint. Remove the bolts for the oil pipe brackets. Remove the two bolts for the torque rod mounting support on the transaxle. See Fig 8 .
18. Drain the transaxle oil.
19. Remove the right axle shaft. See appropriate AXLE SHAFTS article in DRIVELINE/AXLES.
20. Remove the bolt for the front engine pad in the sub-frame. Loosen the bolt for the engine pad/steering gear approximately one turn. See Fig 9 . Remove the 5 steering gear mounting nuts in the sub-frame.
21. Remove the bolts for the sub-frame. Position appropriate transaxle jack under the left-hand side of the sub-frame as support. Remove the bolts securing the sub-frame support brackets on the left and right-hand sides. See Fig 10 . Loosen the two bolts for the sub-frame mounting in the bodywork on the right-hand side by approximately .6" (15 mm). On all-wheel drive models, loosen bolt a maximum of 5 turns. Remove the bolts on the left-hand side.
    CAUTION: Check that the steering gear screws release from the sub-frame. Ensure that the control arm is free of the drive shaft boot on the right-hand side.
22. Lower the sub-frame. Remove the transaxle jack. Let the sub-frame hang on the bolts on the right-hand side.
    CAUTION: Ensure that the steering gear hangs securely on the hook or tie strap so that the lower steering shaft does not slide out of the steering column.
23. Mount the steering gear on the left-hand side in the hole in the frame member flange using appropriate hook or tie strap. See Fig 11 . Remove the bolt for the engine pad/steering gear. Remove the nut on top of the engine pad. Remove the engine pad.
24. Remove the rear engine mounting Remove the cable clamps for the heated oxygen sensor cable from the cover. Remove the cover at the rear engine mounting and the rear mounting from the transaxle. See Fig 12 .
25. Remove the left axle shaft. See appropriate AXLE SHAFTS article in DRIVELINE/AXLES.
    CAUTION: If the engine is lowered too much, the exhaust pipe may press the steering gear down. Ensure that no cables and hoses are pinched or stretched.
26. Lower the engine and the transaxle. Lower with lifting hook until the distance between the lifting beam and the mounting for the upper torque rod is 14.4-14.6" (365-370 mm). Ensure that the engine dipstick is free from the fan.
27. Support transaxle with transmission jack.
28. Removing the remaining 7 bolts between the engine and transaxle.
    CAUTION: Ensure that the transaxle comes straight out from engine without stressing the clutch driven plate center.
29. Remove the transaxle. Pull the transaxle straight out from the engine. Lower the transmission jack.

Fig 1: Identifying Charge Air Cooler Pipes

Courtesy of VOLVO CARS OF NORTH AMERICA.

Fig 2: Identifying Gear Selector Cable Attachment Points

Courtesy of VOLVO CARS OF NORTH AMERICA.

Fig 3: Locating Clutch Slave Cylinder Hydraulic Line

Courtesy of VOLVO CARS OF NORTH AMERICA.

Fig 4: Locating Upper Transaxle-To-Engine Bolts & Cable Duct

Courtesy of VOLVO CARS OF NORTH AMERICA.

Fig 5: Locating Torque Control Arm

Courtesy of VOLVO CARS OF NORTH AMERICA.

Fig 6: Installing Engine Lifting Beam

Courtesy of VOLVO CARS OF NORTH AMERICA.

Fig 7: Identifying Front Protective Cover

Courtesy of VOLVO CARS OF NORTH AMERICA.

Fig 8: Locating Torque Rod Mounting bolts

Courtesy of VOLVO CARS OF NORTH AMERICA.

Fig 9: Locating Steering Gear Nuts

Courtesy of VOLVO CARS OF NORTH AMERICA.

Fig 10: Identifying Sub-Frame Bolts

Courtesy of VOLVO CARS OF NORTH AMERICA.

Fig 11: Securing Steering Gear

Courtesy of VOLVO CARS OF NORTH AMERICA.

Fig 12: Locating Rear Engine Mounts

Courtesy of VOLVO CARS OF NORTH AMERICA.