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Discussion Starter · #1 · (Edited)
M66 Repair: No 1st, or 2nd? problem solved.

Hey gang! I am a proud new owner of a beautiful 2007 v70r 6speed manual. I am Loving the car but had to make the first repair and thought I'd share what broke and how I fixed it incase anyone else runs into this problem.

I'm not exactly sure how this happened, but I lost 1st, and 2nd gear. Parked the car in the garage and the next morning the shifter felt like an actual joystick; it wouldn't engage the left gears and was very loose in all other gears. My initial thought was that the shift cable had popped out but no such luck. Upon inspection and some comparison to my buddies v70r we found something had gone amiss with the shift control assembly on the m66 transmission.

The Volvo Technical Update 1 was a very helpful in diagnosing where the break occurred. Here is a link in case you need it https://www.volvoclub.org.uk/tech/2004r/R5-M66.pdf

<a href="http://s174.photobucket.com/user/Benz50602/media/v70r/Screen%20Shot%202016-01-11%20at%2019.40.44_zpsbhmuq5ii.png.html" target="_blank"><img src="http://i174.photobucket.com/albums/w83/Benz50602/v70r/Screen%20Shot%202016-01-11%20at%2019.40.44_zpsbhmuq5ii.png" border="0" alt=" photo Screen Shot 2016-01-11 at 19.40.44_zpsbhmuq5ii.png"/></a>

Getting access to this part is quite easy, just remove the airbox. The passenger side shift cable clips onto the control assembly and will pop off easily. Try to get the trans in the neutral before you remove the cables if you plan to take out the assembly. Next, the pin has to be punched out to get the black weighted portion of the drivers side cable off. The pin was not hard to punch out and definitely worth putting in a safe place.

<a href="http://s174.photobucket.com/user/Benz50602/media/v70r/GOPR3707_zpss0jcnwx2.jpg.html" target="_blank"><img src="http://i174.photobucket.com/albums/w83/Benz50602/v70r/GOPR3707_zpss0jcnwx2.jpg" border="0" alt=" photo GOPR3707_zpss0jcnwx2.jpg"/></a>

Once the cables are off you can remove "detent 5th 6th gear" and the four bolts that hold the controller to the transmission. There is a wire for the reverse light and lock out solenoid on the back of the controller that unclips.

Side note: the Detent bolt would also be a great fill plug if needed.

<a href="http://s174.photobucket.com/user/Benz50602/media/v70r/GOPR3712_zps3lngotfp.jpg.html" target="_blank"><img src="http://i174.photobucket.com/albums/w83/Benz50602/v70r/GOPR3712_zps3lngotfp.jpg" border="0" alt=" photo GOPR3712_zps3lngotfp.jpg"/></a>

There is a gasket that needs to be broken and can easily be done with some light tapping on with a screw driver. During reassembly, clean off as much of the old material as possible and use your gasket making material of choice.

<a href="http://s174.photobucket.com/user/Benz50602/media/v70r/GOPR3715_zpsukwniosi.jpg.html" target="_blank"><img src="http://i174.photobucket.com/albums/w83/Benz50602/v70r/GOPR3715_zpsukwniosi.jpg" border="0" alt=" photo GOPR3715_zpsukwniosi.jpg"/></a>

The next part can be a little bit tricky. The shift controller lifts straight out of the transmission. You will likely need to do some jiggling and finagling to get it out. There is plenty of room for it to clear the ABS pump so no worries there. You may have to manipulate the shift levers a bit. Once removed the culprit was found. The pin that guides the shift levers through the shift gate had snapped off. When you play around with the mechanism you can see how this the absence of this pin does not allow the controller to move the shift forks properly. In the picture below you can see the new shift controller with the pin vs the old broken one. If you were good with metal and machine work I think it would be very possible to just replace this pin and be back on the road. The moral of the story here is don't be too rough with the shifter or this pin will break. A new controller assembly is not cheap, but easier to stomach than a entirely new transmission.

<a href="http://s174.photobucket.com/user/Benz50602/media/v70r/c6aa1b08-6ad3-48b4-9bee-cb2fa03c1a30_zpsiz49aoz6.jpg.html" target="_blank"><img src="http://i174.photobucket.com/albums/w83/Benz50602/v70r/c6aa1b08-6ad3-48b4-9bee-cb2fa03c1a30_zpsiz49aoz6.jpg" border="0" alt=" photo c6aa1b08-6ad3-48b4-9bee-cb2fa03c1a30_zpsiz49aoz6.jpg"/></a>

While the control assembly is out this is a great time to change out your transmission fluid if need be. I went with amsoil manual transmission and transaxle fluid 75w90 (4.2 Pints) and feel like it smoothed out the gear changes a bit. Once the fluid was drained I used a magnet to go hunting around for the pin, luckily I found it. I imagine this pin would do some serious and violent damage if it found itself into the gears so I am quite happy that was not the case and I was able to remove it.

Check out the guts of the m66 and some 90k old transmission fluid.

<a href="http://s174.photobucket.com/user/Benz50602/media/v70r/GOPR3720_zpsd8zgpa22.jpg.html" target="_blank"><img src="http://i174.photobucket.com/albums/w83/Benz50602/v70r/GOPR3720_zpsd8zgpa22.jpg" border="0" alt=" photo GOPR3720_zpsd8zgpa22.jpg"/></a>

Once the new gasket material is in place, getting the control assembly back in is just like taking it out. Make sure it is in the neutral position and gently jiggle the assembly into place. You can ensure it is in correctly by moving the shift levers and hearing/feeling the shift forks engage. In my experience both removal and installation was much easier than I expected.

Once everything was put back together the shifter felt perfect and the turbocharged smiles continued.
 

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That's a hell of a first repair. Welcome to the club, you look like you'll do just fine :thumbup:
 

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Great job, thanks. To repair you bought an entirely new shift controller, right? What was the part number and cost?
 

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Discussion Starter · #5 ·
Great job, thanks. To repair you bought an entirely new shift controller, right? What was the part number and cost?
From an online volvo parts store the new shift controller (part # 30751776) was $407.

Had I to do it over again I would have taken the part to a machine shop to see if they could simply replace the broken pin. It does not appear like a hard thing to do with the right set of tools.
 

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Cool. Maybe you could sell your broken one for repair on the Classifieds and recoup some cost.
 

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Awesome job. I love when things are mechanical and not just wires and relays.
 

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Always great when someone adds something new to the knowledge base. Last year, I had a big leak where the shift control mates to the transmission. The hardest part of the job was probably just going to town with the punch tool and making sure that the pin didn't fly into some inaccessible crevice when it finally popped out.
http://forums.swedespeed.com/showth...Leak-Looks-Expensive!&highlight=shift+control

Did you buy the shift control assembly brand new or used? I will be replacing mine at some point due to noisy shifts and slight roughness. In case anyone is curious, it's Volvo P/N 31256246, and it is not inexpensive.
 

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Were you aggressive with the shifting in your car before this happend? That is the only thing I can think of to cause that to happen. I mean I banged gears all the time when I had the M66 car, and I never broke anything. Maybe your part was made just a little bit out of spec by the factory, and that's why it failed.
 

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Great write up. And you have a great car. I know because I took care of it for 8 years from when it was new to when you bought it from me. Sorry you had to go through this so soon after buying the car. I was not rough with it and you and your dad didn't have it long enough to abuse it. Maybe the R just missed me. By the way, the photos you sent me were terrific. I'm glad the car ended up in a good home....um....garage!!
 

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Discussion Starter · #14 ·
Were you aggressive with the shifting in your car before this happend? That is the only thing I can think of to cause that to happen. I mean I banged gears all the time when I had the M66 car, and I never broke anything. Maybe your part was made just a little bit out of spec by the factory, and that's why it failed.
My guess is that this part was defective from the factory based on the shear pattern in the metal. This v70r has been well cared for it's entire life. I have never seen the need to slam shifts on any car, especially this one. IMO the pull from the turbo is far more enjoyable than a snappy shift.
 

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Discussion Starter · #15 ·
Great write up. And you have a great car. I know because I took care of it for 8 years from when it was new to when you bought it from me. Sorry you had to go through this so soon after buying the car. I was not rough with it and you and your dad didn't have it long enough to abuse it. Maybe the R just missed me. By the way, the photos you sent me were terrific. I'm glad the car ended up in a good home....um....garage!!
Thank you! We are beyond lucky to have such a tremendously well cared for R. This has been the only hiccup we've had and it was a relatively simple repair. We replaced all 4 struts in the fall which was a bit more of a challenge but glad we did it. Dad tore his rotator cuff first day of the ski season so the car has been in the heated garage on the battery tender most of the winter. I've got no doubt that the R misses you. Next time you are in Colorado you are more than welcome to visit and take her out for a good long drive!
 
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