M90 Gearbox - Hard shifting from 2nd to 3rd

Jun 8th, 2005, 12:05

Hello - The M90 gearbox in my '98 945 (65K mi) is getting harder and harder to shift from 2nd to 3rd. When it is cold there is no problem, but once it is fully warmed up it tends to stick half-way across the gate. There is no crunching or anything when it does go in which makes me think it could be the selector mechanism.
Haynes says nothing about the M90 but I recall the dealer replacing a bush somewhere in the shift mech when the car was a couple of years old.
Can anyone suggest what may be the problem and where I can find instructions to replace the offending part? Has anyone ever stripped the M90 to replace syncro rings etc?

ranger · Jun 8th, 2005, 16:49

just out of intrest is the m90 gearbox in your 945 the same as the m90 box in my 960 2.5 and are they interchangable.mine to is stiffer when hot iwas thinking of getting a recon box.let us know how you get on.

Jun 9th, 2005, 10:23

pretty sure it is the same animal mechanically - ratios may be different (have seen jottings in this forum that suggest two variants of the M90 with only the ratios differing). volvo dealer did something once with the gear linkage whilst it was in for service (did not ask them to look at it - they just did it) which makes me think that there is a recurring issue with shift quality. the shift quality is perfect when cold so i really think that this is a linkage problem. may ask the local volvo specialist for advice when it goes in for MOT in a month.
does anyone know where I can get the volvo workshop manual from for this 'box?

Grizlyadams · Jun 9th, 2005, 19:44

>just out of intrest is the m90 gearbox in your 945 the same
>as the m90 box in my 960 2.5 and are they interchangable.mine
>to is stiffer when hot iwas thinking of getting a recon
>box.let us know how you get on.

White block M90s are different from red block M90's, you will need a whiteblock M90 to go on the back of your whiteblock engine, good luck finding one at the scrappies... :-)
Griz

Peter Milnes · Jun 10th, 2005, 01:19

If you are going to the National on Sunday I will let you have a look at the M90 supplement.

All the best, Peter.

Jun 10th, 2005, 10:49

sadly i can't make the national this sunday. where can i obtain a copy of the m90 supplement (and it it super-expensive)?

Jul 4th, 2005, 11:26

Here is an update on my shifting problem. I tried flushing the clutch hydraulic circuit, replacing the fluid. While doing this, it struck me that the biting point of the clutch is very low down, and the pedal is a bit soft for the first inch of travel. No air in the system, but i did think that the hydraulic hose at the slave cylinder end had a bit of give in the side walls - it seemed to bulge a tiny little bit when the pedal was pressed. The hose is marked 'not for brakes' so is probably the cheapest hose Volvo could find for the job. Looked on VADIS and it seems the turbo models have a hose that comes complete with that loop of metal tubing bonded on the end (thus making it a specialist part). I wonder if I can bodge a brake hose to fit - or failing that, take it to the local hose doctor to be replaced.
Despite being a major city, Bristol and does not have a Volvo dealer - only an 'authorized repairer'. Watch this space.

Jun 8th, 2005, 12:05	#1
gremalkin Guest Location:	M90 Gearbox - Hard shifting from 2nd to 3rd Hello - The M90 gearbox in my '98 945 (65K mi) is getting harder and harder to shift from 2nd to 3rd. When it is cold there is no problem, but once it is fully warmed up it tends to stick half-way across the gate. There is no crunching or anything when it does go in which makes me think it could be the selector mechanism. Haynes says nothing about the M90 but I recall the dealer replacing a bush somewhere in the shift mech when the car was a couple of years old. Can anyone suggest what may be the problem and where I can find instructions to replace the offending part? Has anyone ever stripped the M90 to replace syncro rings etc?

Jun 8th, 2005, 16:49	#2
ranger Junior Member Last Online: Sep 15th, 2008 20:13 Join Date: Dec 2002 Location: dunstable	RE: M90 Gearbox - Hard shifting from 2nd to 3rd just out of intrest is the m90 gearbox in your 945 the same as the m90 box in my 960 2.5 and are they interchangable.mine to is stiffer when hot iwas thinking of getting a recon box.let us know how you get on.

Jun 9th, 2005, 10:23	#3
gremalkin Guest Location:	RE: M90 Gearbox - Hard shifting from 2nd to 3rd pretty sure it is the same animal mechanically - ratios may be different (have seen jottings in this forum that suggest two variants of the M90 with only the ratios differing). volvo dealer did something once with the gear linkage whilst it was in for service (did not ask them to look at it - they just did it) which makes me think that there is a recurring issue with shift quality. the shift quality is perfect when cold so i really think that this is a linkage problem. may ask the local volvo specialist for advice when it goes in for MOT in a month. does anyone know where I can get the volvo workshop manual from for this 'box?

Jun 9th, 2005, 19:44	#4
Grizlyadams RWD FTW!!! Last Online: Mar 19th, 2019 09:06 Join Date: Dec 2002 Location: Why should i have to tell you! View Photos By: Grizlyadams	RE: M90 Gearbox - Hard shifting from 2nd to 3rd >just out of intrest is the m90 gearbox in your 945 the same >as the m90 box in my 960 2.5 and are they interchangable.mine >to is stiffer when hot iwas thinking of getting a recon >box.let us know how you get on. White block M90s are different from red block M90's, you will need a whiteblock M90 to go on the back of your whiteblock engine, good luck finding one at the scrappies... :-) Griz

Jun 10th, 2005, 01:19	#5
Peter Milnes Premier Member Last Online: Apr 10th, 2014 00:01 Join Date: Feb 2002 Location: Tonyrefail	RE: M90 Gearbox - Hard shifting from 2nd to 3rd If you are going to the National on Sunday I will let you have a look at the M90 supplement. All the best, Peter.

Jun 10th, 2005, 10:49	#6
gremalkin Guest Location:	RE: M90 Gearbox - Hard shifting from 2nd to 3rd sadly i can't make the national this sunday. where can i obtain a copy of the m90 supplement (and it it super-expensive)?

Jul 4th, 2005, 11:26	#7
gremalkin Guest Location:	RE: M90 Gearbox - Hard shifting from 2nd to 3rd Here is an update on my shifting problem. I tried flushing the clutch hydraulic circuit, replacing the fluid. While doing this, it struck me that the biting point of the clutch is very low down, and the pedal is a bit soft for the first inch of travel. No air in the system, but i did think that the hydraulic hose at the slave cylinder end had a bit of give in the side walls - it seemed to bulge a tiny little bit when the pedal was pressed. The hose is marked 'not for brakes' so is probably the cheapest hose Volvo could find for the job. Looked on VADIS and it seems the turbo models have a hose that comes complete with that loop of metal tubing bonded on the end (thus making it a specialist part). I wonder if I can bodge a brake hose to fit - or failing that, take it to the local hose doctor to be replaced. Despite being a major city, Bristol and does not have a Volvo dealer - only an 'authorized repairer'. Watch this space.

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