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.
2003 Volvo S80 T-6FACTORY OEM SERVICE PROCEDURE
Transmission - Removal And Installation
- Transmission
- Gearbox, removing
- Notes
- Filling in Diagnostic and Check lists
- Disconnecting the battery lead
- Removing engine compartment components
- Removing the dipstick
- Removing the gear selector cable from the lever and mounting on the gearbox
- Removing the mounting screws from the gearbox/starter motor
- Removing the right screw from the gearbox
- Installing the lifting beam and lifting hook on the engine lifting eyelet
- Removing splash guards
- Removing the screws for the cable conduit and ground lead bracket on the sub-frame
- Removing the nut for the lower ball joint/control arm
- Remove the control arms, track rod and spring strut on both sides
- Removing the screws for the sub-frame support plates (both sides)
- Removing the stub axle from the control arm
- Removing the drive shaft from the stub axle (right-hand side)
- Removing the cap for the drive shaft support bearing
- Removing the drive shaft
- Press up the sub-frame on the right-hand side
- Removing the nuts and screws for the steering gear sub-frame
- Removing the screws for the torque rod from the gearbox
- Removing the exhaust pipe from the turbocharger (TC)
- Removing the front cross member
- Removing the bracket for the cable for the heated oxygen sensor (HO2S) from the sub-frame
- Removing the exhaust pipe mounting in the rear cross member
- Removing the screw for the rear engine pad
- Removing the rear engine mounting
- Preparations for removing the stub axle on the left-hand side
- Removing the left drive shaft from the gearbox
- Lowering the sub-frame
- Removing the lower oil pipe from the gearbox
- Lowering the engine and gearbox
- Removing the 6 screws for the torque converter, and the 7 screws for the gearbox/engine
- Preparations when removing gearbox
- Installing the fixture on the mobile jack and gearbox
- Removing all 7 screws for the gearbox/engine
- Removing the gearbox
- Cleaning and checking
- Removing the transmission
- Notes
- Disconnect the battery lead
- Remove the engine compartment components
- Install the lifting hook
- Remove the hose for the clutch cylinder
- Disconnect the connectors. Disconnect the transmission cables
- Remove the gear selector housing
- Remove the screw and the tie strap for the cable harness and the ground lead
- Remove the screw and the clamp for the servo oil pipe
- Remove the screws for the transmission / engine
- Install the lifting beam and the lifting hook on the engine lifting lugs
- Remove the suspension components
- Remove the screws for the cable conduit and the ground lead bracket on the sub-frame
- Remove the nut for the lower ball joint / control arm
- Remove the control arms and the tie rod from both sides
- Remove the screws from the sub-frame support plates (both sides)
- Remove the wheel spindle from the control arm
- Press up the sub-frame on the right-hand side
- Remove the drive shaft from the wheel spindle (right-hand side)
- Remove the support bearing cap from the drive shaft
- Remove the drive shaft
- Remove the front cross member
- Remove the bracket for the heated oxygen sensor (HO2S) wiring
- Remove the steering gear nuts and the screw from the sub-frame
- Preparatory work for removing the wheel spindle on the left-hand side
- Remove the left drive shaft from the transmission
- Lower the sub-frame
- Remove the screw for the rear engine pad
- Remove the rear engine mounting
- Remove the screw for the front engine pad. Remove the torque rod screws in the transmission
- Lower the engine with the transmission
- Preparations for removal of the transmission
- Install the fixture on the mobile jack
- Locate the fixture against the transmission
- Remove the transmission
- Lubrication, transmission
- Oil level, checking (-2003)
- Oil level, checking (2004-2006)
- Replacing the bevel gear/chain housing
- Notes
- Removal
- Preparations
- Removing the right drive shaft
- Pay attention to the following when removing propeller shaft
- Removing the propeller shaft
- Disconnecting the steering gear from the engine pad
- Removing the chain housing bracket
- Removing the bevel gear/chain housing
- Checking the sealing ring
- Separating the bevel gear/chain housing
- Checking the chain housing
- Checking the bevel gear
- Installation
- Replacing the carrier plate
- Gearbox, removing
Factory Service Tools
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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.
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