G/box: TF-80SCAWD: - 2003 XC90 D5 Auto Gearbox problem - PLEASE HELP ...

jsbaldwin · Mar 3rd, 2015, 09:10

Hi,

This is my first post on this site and I hope someone can help...

I had a major oil leak on my car between the engine and Gearbox , after research I found out about the core plug issue.... D'oh !

I like a challenge (I'm a DIY mechanic , not a professional by a LONG shot )

So I went for it , dropped the subframe and gearbox and hey presto , the "rubber" core plug was hanging out ... brill , replaced with a new metal core plug and put everything back together.

Now here's the problem... I've no gears now !

I only lowered the box , didn't disconnect it , but it lost a lot of oil. So I put a few litres in through the dipstick (removed the breather pipe)but the new fluid is not going any where , the dipstick is reading way over and still bright red.

So I've started the car removed the top hose from the cooler and connected a pipe to get the fluid pumping round .... but its not pumping out ????

It seems like the box is not pumping oil round the gearbox to the relevant areas , valve body , cooler etc....

The box was fine before I took it out .. is the pump mechanical off the engine ? or electrical ? have I left something disconnected ?

I had no bits left over http://www.volvoforums.org.uk/images.../icon14.gifand the car is back all running fine , I've had it running for around 5-10min to get the fluid moving but it seems that its not running through the system... Dip stick reading way over and red, I checked at the bottom of box by letting some out and it is brown ish , so its not mixing ...

Any ideas / thoughts ? please feel free to point out if I have done something stupid https://www.volvoforums.org.uk/images/icons/icon7.gificon7.gif

I'm not sure if the model of gearbox in the prefix of this message is correct for my car...

Thanks for any help advice.

James

Ducklakeview · Mar 3rd, 2015, 10:45

It's possible that the torque converter has become disengaged from the pump when you've lowered the box, as it has a tendency to "slide out" from the gearbox input shaft. If this is the case, and you've just bolted it all back together, there's also a good chance that you'v3e damaged the TQ, front pump or both.. If there is definitely zero fluid pressure/movement, then I'm afraid at the very least, the box will need to come out again to inspect..

The TQ should sit approx 14mm back as per this pic from VIDA

Mike

Tannaton · Mar 3rd, 2015, 12:50

The problem is almost certainly what Mike has described. if you remove the torque converter from the gearbox (even partially) which i assume you did to have lost oil, you refit it by loading it and rotating it clockwise whilst pushing it into the gearbox. You should hear and feel it drop into the gearbox TWICE as the different splines locate, at which point the gap measure as shown above will be 13-14mm.

Hopefully if you relocate it will be okay but damage to the pump is likely - given the effort needed to remove the box again and risk of further damage (swarf in oil?) I would suggest you get it checked before refitting. This chap didn't get away with it but for other reasons: http://www.volvoforums.org.uk/showthread.php?t=224582

You have the AISIN WARNER AW55-51SN gearbox which is used in most, if not all, 163BHP D5's and most early 5 cylinder petrol Volvo's with AWD. The AW55-50 is the non AWD version.

That's really rotten luck as I know how difficult and long a job it is to drop the gearbox without the aid of a workshop ramp....

jsbaldwin · Mar 3rd, 2015, 16:45

Thanks for the responses.

I thinking back over when I put it back together, there was a jolt when the last 10mm of the gap between the gearbox and engine closed , so I'm sure I've knackered the oil pump , which is a real pain !!!

Never mind , we live and learn !!! , I will drop the box back out and take it to a specialist near me 3D transmissions in Reading to check it out and replace the pump and possibly the TQ.

Many thanks for the replies.

2004 xc90 · Mar 4th, 2015, 23:49

Ha. I did exactly the same thing.
Did you remove the starter motor and then unscrew the 6 bolts from the flywheel? I didn't and the car is still in bits.

When I put it back together, I had dislocated the torque converter and damaged the spines in the gearbox. Had to take it all apart again to file them back into shape.

SkipjackUK · Mar 6th, 2015, 07:43

Where is the transmission fluid dipstick? I didn't know there was one.

SkipjackUK · Mar 6th, 2015, 10:38

oh there it is

never noticed that before

Mar 3rd, 2015, 09:10	#1
jsbaldwin New Member Last Online: Mar 3rd, 2015 16:45 Join Date: Feb 2015 Location: Maidenhead	2003 XC90 D5 Auto Gearbox problem - PLEASE HELP ... Hi, This is my first post on this site and I hope someone can help... I had a major oil leak on my car between the engine and Gearbox , after research I found out about the core plug issue.... D'oh ! I like a challenge (I'm a DIY mechanic , not a professional by a LONG shot ) So I went for it , dropped the subframe and gearbox and hey presto , the "rubber" core plug was hanging out ... brill , replaced with a new metal core plug and put everything back together. Now here's the problem... I've no gears now ! I only lowered the box , didn't disconnect it , but it lost a lot of oil. So I put a few litres in through the dipstick (removed the breather pipe)but the new fluid is not going any where , the dipstick is reading way over and still bright red. So I've started the car removed the top hose from the cooler and connected a pipe to get the fluid pumping round .... but its not pumping out ???? It seems like the box is not pumping oil round the gearbox to the relevant areas , valve body , cooler etc.... The box was fine before I took it out .. is the pump mechanical off the engine ? or electrical ? have I left something disconnected ? I had no bits left over http://www.volvoforums.org.uk/images.../icon14.gifand the car is back all running fine , I've had it running for around 5-10min to get the fluid moving but it seems that its not running through the system... Dip stick reading way over and red, I checked at the bottom of box by letting some out and it is brown ish , so its not mixing ... Any ideas / thoughts ? please feel free to point out if I have done something stupid https://www.volvoforums.org.uk/images/icons/icon7.gificon7.gif I'm not sure if the model of gearbox in the prefix of this message is correct for my car... Thanks for any help advice. James

Mar 3rd, 2015, 10:45	#2
Ducklakeview 239,450 miles & counting! Last Online: Jul 2nd, 2017 22:13 Join Date: Jun 2013 Location: Merseyside	It's possible that the torque converter has become disengaged from the pump when you've lowered the box, as it has a tendency to "slide out" from the gearbox input shaft. If this is the case, and you've just bolted it all back together, there's also a good chance that you'v3e damaged the TQ, front pump or both.. If there is definitely zero fluid pressure/movement, then I'm afraid at the very least, the box will need to come out again to inspect.. The TQ should sit approx 14mm back as per this pic from VIDA Mike Last edited by Ducklakeview; Mar 3rd, 2015 at 10:51.

Mar 3rd, 2015, 12:50	#3
Tannaton Bungling Amateur Last Online: Today 00:13 Join Date: Aug 2014 Location: Beverley, East Yorks	The problem is almost certainly what Mike has described. if you remove the torque converter from the gearbox (even partially) which i assume you did to have lost oil, you refit it by loading it and rotating it clockwise whilst pushing it into the gearbox. You should hear and feel it drop into the gearbox TWICE as the different splines locate, at which point the gap measure as shown above will be 13-14mm. Hopefully if you relocate it will be okay but damage to the pump is likely - given the effort needed to remove the box again and risk of further damage (swarf in oil?) I would suggest you get it checked before refitting. This chap didn't get away with it but for other reasons: http://www.volvoforums.org.uk/showthread.php?t=224582 You have the AISIN WARNER AW55-51SN gearbox which is used in most, if not all, 163BHP D5's and most early 5 cylinder petrol Volvo's with AWD. The AW55-50 is the non AWD version. That's really rotten luck as I know how difficult and long a job it is to drop the gearbox without the aid of a workshop ramp.... Last edited by Tannaton; Mar 3rd, 2015 at 13:02.

Mar 3rd, 2015, 16:45	#4
jsbaldwin New Member Last Online: Mar 3rd, 2015 16:45 Join Date: Feb 2015 Location: Maidenhead	Thanks for the responses. I thinking back over when I put it back together, there was a jolt when the last 10mm of the gap between the gearbox and engine closed , so I'm sure I've knackered the oil pump , which is a real pain !!! Never mind , we live and learn !!! , I will drop the box back out and take it to a specialist near me 3D transmissions in Reading to check it out and replace the pump and possibly the TQ. Many thanks for the replies.

Mar 4th, 2015, 23:49	#5
2004 xc90 Junior Member Last Online: Sep 6th, 2015 17:36 Join Date: Jan 2013 Location: Belfast	Ha. I did exactly the same thing. Did you remove the starter motor and then unscrew the 6 bolts from the flywheel? I didn't and the car is still in bits. When I put it back together, I had dislocated the torque converter and damaged the spines in the gearbox. Had to take it all apart again to file them back into shape.

Mar 6th, 2015, 07:43	#6
SkipjackUK VOC Member Last Online: Mar 10th, 2023 20:29 Join Date: Jul 2013 Location: Leeds & Crewe	Where is the transmission fluid dipstick? I didn't know there was one.

Mar 6th, 2015, 10:38	#7
SkipjackUK VOC Member Last Online: Mar 10th, 2023 20:29 Join Date: Jul 2013 Location: Leeds & Crewe	oh there it is never noticed that before

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