Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSVOLVO1991940 TURBO, 4D SEDAN, AW71REPAIR AND DIAGNOSIS (SINGLE PAGE)TRANSMISSIONAUTOMATIC TRANSOVERHAUL - AW70L, AW71 & AW72LCOMPONENT DISASSEMBLY & REASSEMBLYVALVE BODY ASSEMBLYDISASSEMBLY (LOWER VALVE BODY)
1991 Volvo 940 Turbo, 4D Sedan, AW71
Disassembly (Lower Valve Body)
1991 Volvo 940 Turbo, 4D Sedan, AW71SECTION Disassembly (Lower Valve Body)
- Remove lower valve body plate and gaskets. Remove check balls, damping check valve spring, oil cooler by-pass valve and spring. Turn assembly over, and remove set bolt, lower body cover, plate and gaskets. See Figure .
- Remove 4 check balls. Keep balls together to prevent misplacement. Remove retainer from pressure relief valve assembly. Remove spring and valve. See Figure .
- Remove plate and gasket from lower valve body assembly. See Figure .
- Hold valve retainer with valve body side facing down, and press in on primary regulator valve sleeve. Remove valve retainer, sleeve, plunger, spring and primary regulator valve.
- Remove valve retainer for D-2 downshift timing valve. Remove plug and D-2 downshift timing valve. Remove locating pin for 3-4 shift valve. Remove plug, 3-4 shift valve and spring. Remove valve retainer for 1-2 shift valve. Remove plug and lower valve.
- Remove low coast shift valve cover. Remove plug, low coast shift valve, manual plug, locating pin, 3rd coast shift valve plug, locating pin, 3rd coast shift valve and 3-4 shift control valve.
RENDER: 1.0x
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.