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Discussion Starter · #1 · (Edited)
Hi guys.

Some time ago I cannot shift well. The shifting is rough, specially for 1st and 3rd speed.

I found several threads in the forum and I thought it was shifter bushes at first.

But I did a test yesterday by removing the right shifter cable at the gearbox and moving the lever with my hand and It seems to get stuck in the same way as when I drive.

I show you a video, It get stucks in minute 0:05, when It gets stuck, the speed doesn´t get in, and you have to try again.


I need some help for this, I´m a bit confusing with this problem.

Could be the problem here in this part?



Thank you very much!!
 

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I hate to break this to you but here goes:

I have plenty of experience with the Volvo s60r's and especially the 04's. What you are experiencing and describing has to do with an internal problem pertaining to the transmission.

There was a TNN by Volvo on which the rough shifts were due to an improperly (or none at all) greased transmission output shaft. Also, the grease Volvo used at the factory on the 04 models was intended to be "eco-contious" as nearly all other adhesives used in the car and fails over time becoming sticky and guncked up.
Thus, when you're shifting the build-up of residue and grease on the splines are preventing smooth gear selection and clutch engagement because of it (almost like clutch drag).

If you've owned the car for a while a it just recently developped the problem I am sure you can tell your clutch does not engage as smoothly but feels a bit "jerky". Usually, 1 out of 100 times or the shift will be smooth like butter but the subsequent 99 or so will suck.

Here's a quick test:
With the car running, put the car in first gear, then while keeping the clutch fully dissengaged (pedal to the floor) put it back to neutral and try all the other gears, I bet you they all go smoothly.
Another test is to simply engage the gears with the car off, do they engage smooth as they should?

Then the lunrication of the output splines is your problem. This requires the transmission to be removed from the vehicle so if you plan on doing it might as well do the cluctch/pressure plate and slave cylinder at the same time..
Heck even the angle gear sleeve and seals.

Changing transmission and egine mounts, shifter bushings, swapping to the 05+ cables (less slack), changing transmission fuild and any other remedies might help a tiny bit but it will keep feeling stiff and hard to engage gears. Problem will also worsen with colder temperature something making it impossible to engage first in winter after the car has sat.

It was a problem on a buddies 04 and we tore apart the tranny to to the lub job. Mine has the same issue and I am removing the tranny on Thursday to do it along with all the other necessary components.


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I have an 04 R and the trans is out of the car at this point. I have no issues but would like to prevent any. How do you go about greasing the splines?

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As a fellow member of the dissembled car club who has already cleaned much of that original lube and disk dust off my shaft, does anyone know what the recommend lube is?

If nothing else I was at least planning on brushing a little moly lube on the splines where the disk sits before putting it back together, but it would be neat to know what is recommended for this task.
 

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Spray down and clean the splines well. I like to use a small brush and get in well. Volvo has a specialised cleaner they sell for this exact purpose but I've never used it. I usually just use a good gunk remover and then ginish with brake cleaner to remove any residue or oils.

When you buy a new clutch it comes with a small packet of grease (Sachs and Luk fo at least) just take that and sqeeze a bit on the shaft working it on all the splines. Then take whats left and place it inside the shaft bearing of the clutch disk. Put the clutch on the shaft and slip it up and down a few times so the grease between the two parts works ita way in and so you work out any excess grease.
Wipe any grease that seeps out because too much grease can fly of the shaft and onto the clutch causing slippage.

If you don't have the supplied grease maybe a local parts store sells shaft grease or you can use a quality grease that can withstand heat and cold well (white lithium grease, bearing grease). But someone will have to confirm anout that.

Were your splines lubricated, dry or dirty when the tranny was removed?

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Okay a few clarifications.

1. It's the input shaft, not output. My bad.
2. White lithiun grease works well (I use this stuff all the time)

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Lubed, but I was only about 15K miles into my first replacement clutch. Getting a bit old and contaminated with disk dust, but still freely floating. Splines still in great shape too.

Judging by the look of the original it was some kind of moly-lube. Tis the reason I will be putting a light coat on the cleaned splines of both the shaft and disk before it goes back together unless I hear differently.
 

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Yea at 15k the lube would still be holding up well and lubing as it should. Like I said, lube the shaft, lube the disk and slide them on each other making sure to whipe of any excess so as to not contaminate the clutch.

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Discussion Starter · #9 ·
I thank you Viron for your sincerity and your time.

The point is that some transmission jobs have been done in my car, from previous owner.

I have many Volvo invoices and between them there are:

May 2008 - 45.000 kms



- Parts replaced:
Part 2, part number 9143885​
Part 25, part number 9143911​

Part 3 on this other diagram , part number 30735126.



They also changed transmission oil, Part number 1161648

February 2009 - 47.000 kms

- Parts replaced:

New Angle gear, part number 36000340​
Part 2, part number 9143885, Again​
Transmission oil, part number 1161745​

I don´t know why about the diference between transmission oil part numbers (and price)??

April 2014 - 94.000 kms

- Parts replaced:
Clutch and control cylinder (slave cylinder??), part number 31259889.​

So... Related to these replacements, is normal and is it possible they didn´t apply Volvo TNN about grease transmission output shaft while doing all of those things?

I will do the tests you suggested and I´m going to try to realize if the problem depends on the temperature (here were I live the temperature is very stable).

Thank you very much.
 

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To the first repairs you referenced, those apply to the angle gear (transfer case) and I would not see them affecting shifting.

If you've had the clutch replaced last year I find it difficult to believe it is acting up...then again, like you said, I've seen people install clutches without grease and cleaning the area well. This allows a build up of disc dust and contaminants which may have cause the premature symptom you are experiencing.

If the clutch was replaced by a Volvo dealership or shop it should have a warranty on parts and labour so I suggest you go down and speak with them. Explain the issue and show them the TNN. Try and speak with the mecanic who did the job and see if he remembers what he did and whether or not he cleaned and greased the splines or simply slapped the disc on and called it a day.

Here is the TNN info along with Volvo's reccomended spline cleaner and grease (although, as stated others such as white lithiun and molybium will work fine).


TNN43-47-2005-11-01 Title: Difficult to engage 1st and/or
reverse gear.
MODEL: Vehicles with 5 or 6 Speed Manual Transmissions, M. YEAR: 1999-2005
Some customers may complain that it is difficult to engage 1st and/or reverse gear, especially after the car has been sitting overnight.

This Tech Net Note supersedes the previous 43-47, dated 8/5/04. Please update your files. This applies to all 1999 S/V/C 70 cars, as well as S40/V50/S60/V70 cars built before: 544 -053404, 545 -048974, 384 -425275, 285 -459438

WARRANTY CLAIM INFORMATION
LABOR OP LABOR DESCRIPTION LABOR TIME
43104 Gearbox, remove and install
S60R: 5.9
V70R: 5.8


And for those who do remove their gearbox,
use Volvo spray 1161657 to clean the input shaft and then apply
Volvo sprayable PFPE grease nr 30759651

Report back with the shifting test as it will help narrow down the possibilities.

Regards,

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Discussion Starter · #11 ·
First of all, sorry for answering so late. My girlfriend usually drives my car, these days I´ve driven it myself and I could test it better.

I hate to break this to you but here goes:

I have plenty of experience with the Volvo s60r's and especially the 04's. What you are experiencing and describing has to do with an internal problem pertaining to the transmission.

There was a TNN by Volvo on which the rough shifts were due to an improperly (or none at all) greased transmission output shaft. Also, the grease Volvo used at the factory on the 04 models was intended to be "eco-contious" as nearly all other adhesives used in the car and fails over time becoming sticky and guncked up.
Thus, when you're shifting the build-up of residue and grease on the splines are preventing smooth gear selection and clutch engagement because of it (almost like clutch drag).

If you've owned the car for a while a it just recently developped the problem I am sure you can tell your clutch does not engage as smoothly but feels a bit "jerky". Usually, 1 out of 100 times or the shift will be smooth like butter but the subsequent 99 or so will suck.
I read several times about that Volvo TNN in the forum.

In my case, the shift sometimes goes good and sometimes goes "jerky". I would even say that It goes well most times.

I have to say that when I bought the car I realised that shifting was not perfect, but I thought It would be about cables..

I´ve been the owner for a year now, and the shifting is worse than when I bought the car.

In my case, It gets stuck sometimes when I want to engage 1st gear from neutral, and especially when I want to downshift from 4th to 3rd gear.

Here's a quick test:
With the car running, put the car in first gear, then while keeping the clutch fully dissengaged (pedal to the floor) put it back to neutral and try all the other gears, I bet you they all go smoothly.
Another test is to simply engage the gears with the car off, do they engage smooth as they should?
With clutch pedal to the floor, I engage 1st and put it back to neutral and I try all the gears, it seems what you said is right, BUT, sometimes 1st and 3rd goes hard and It gets stuck a bit. So... I don´t know what to think.

With the car off, should I do the test with the clutch dissengaged or not?

As I can see in my car, I think the shifting mechanism in the gear knob has a lot of play and it makes shifting worse. But maybe It has also the TNN problem.

For the moment, I´ve bought some shifting mechanism parts in Volvo (as described in another post) to reduce that play in the gear knob and I´ve also ordered the Snabb shifting bushings so I can notice how much it improves.

I will change this first because is the "cheaper" part. I will follow your advise in any case and will do the tests again after that.

I also want to comment something "curious". After changing oil and filters, cleaning injectors and changing a pair of vacuum lines the car goes much more smoothly, and I have noticed the shifting smoother also.

The upper engine mount is very damaged and I supposse the lower will also be. So If after changing oil and those staff it goes better I think changing mounts will improve.

I think you may be right about the grease in the shaft but I think It would be my last option because of $$$

I will update the post.

Thank you!
 

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Discussion Starter · #12 ·
To the first repairs you referenced, those apply to the angle gear (transfer case) and I would not see them affecting shifting.

If you've had the clutch replaced last year I find it difficult to believe it is acting up...then again, like you said, I've seen people install clutches without grease and cleaning the area well. This allows a build up of disc dust and contaminants which may have cause the premature symptom you are experiencing.

If the clutch was replaced by a Volvo dealership or shop it should have a warranty on parts and labour so I suggest you go down and speak with them. Explain the issue and show them the TNN. Try and speak with the mecanic who did the job and see if he remembers what he did and whether or not he cleaned and greased the splines or simply slapped the disc on and called it a day.
BTW, I forgot this post.

Yes, the clutch was replaced in a Volvo dealership. The problem is that I bought the car 300 miles away from my home, so... I cannot speak with them, i wish I could.
 

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Make sure your TCV hoses are not interfering with the shift mechanism. Lots of shops forget to put the hose bundle back in its tab after they pull the airbox and symptoms like you describe are the result.
 
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