Another TF80SC issue post
 

Hi all,

I had an issue with clunky gear changes on my 2007 XC90.
i put this down to sticky solenoids and as the fluid hadn't been changed with 95K on the clock i thought i'd chance my arm with that, hoping it would help.


The level plug Torx bolt was rounded off so i had to remove the whole level plug, dumping all the fluid. this was done on a cold engine. I installed a new level plug and refilled with the same amount of new fluid 5.5L.

I got the box upto 50-55C using VIDA and checked the levels. Drained until i only had a drip from the bottom. I also cycled through the gears a few times, leaving 20seconds between changes.

Now when i drive the car from cold i get extreme over revving and the gears dont seem to engage.

I get the following codes on VIDA

TCM-002A gear 3 incorrect gear ratio
TCM-012D Gear shift function wrong ratio

I reset the counter for the oil, should i reset the adaptations too?

Any help greatly appreciated, thanks

Update:

Car is now totally undrivable, when I put it into drive it takes 20-30seconds before it engages then I have no power just loads of revs like the clutch isn't engaged.

I have a whole load of codes too. See attached

It sounds like what I’ve read on the net before. Change the gearbox oil when it’s playing up and you risk making it worse as you’re possibly taking out the “thicker” bits from the areas that are holding it together. I would imagine it’s rebuild time but if you haven’t already I would be trying reset the adaptations just to check.

Rebuilds come in two flavours from what I gather.

Full rebuild job jobbed with warranty
Cheaper alternative is to try and replace the valve body or the TC to see if this resolves the issue. But then this is all on you with no guarantee.

At 95k miles I would say it’s still financially viable to rebuild.

Also make sure your battery is tip top condition. That will only make things worse or cloud a diagnosis.

Agreed with the above. It sounds like a serious problem, possibly a rebuild.

Not a cheap fix, but there’s only 95k on the clock and its probably still worth doing because XC90’s hold their value. 95k is nothing on a Volvo, but obviously, you’d have to keep the car if you were investing big money into it.

First things first would be to try resetting the adaptions. Then try a gearbox software update (only a Volvo specialist or dealer can do that). If that doesn’t work, then try adding a lubricant such as Lucas into the transmission which has known to be effective. Doesn’t cost much, worth a try.

Failing that, then it’s a new valve body which costs about £1,500 or a rebuild of the transmission… rebuild costs around £2,600. Just so you know prices.

You need to speak to a gearbox specialist ideally and they’ll advise you what they suggest doing. Personally, I think its worth trying resetting adaptions/software updates first. Start cheap. You never know.

You have a few comms errors so that's where I'd start, those ECM and CEM codes are odd. Has it been remapped?

I would :

Clear all the codes, clear the gearbox adaptation memory, go again?

- Did you have the engine running when you checked the level? If not, the lvel will be too low and this could be the cause of your new problems.

- Did you use the correct fluid - should be JWS 3309 spec - nothing else?

Thanks for the replies guys.

I used genuine volvo oil and added Lucas transmission fix.

Then I reset the adaptations and went for the second ride mentioned above. That's when I got all the fault codes attached.

I have reset them and it's still the same.

I am going to speak to volmech in Thornaby tomorrow as they are local to me.

I'm not sure if it has had a remap, it was an Irish import with no history when I got it.

I intend to run this into the ground as its our family run around and we use it to drive down to france every year so I am willing to spend the money to put it right

Also, engine was running when I checked the levels, thanks

Update:

So I realised when cycling through the gears and leaving for a few seconds between changes I had missed out the manual changes.

I done this and tried again. The car wouldn't even engage a gear. I reset all the DTCs again and hey presto I had gears.

I took it for a 50 mile test drive and the gear changes are now silky smooth with no issues. No idea what rectified it, maybe being sat on my drive untouched for a couple of days gave the solenoids time to free up?

Good job because I went to 4 different local gear box specialist who all quoted me £3k and a 2 month wait for the work to be carried out

Hopefully that's the end of the issues now. I might give it a few hundred miles then do another drain and fill