Originally Posted by The Hooded Claw (Post 967773)

Ok... Just recently I have noticed there is alot of "I have a Gearbox Noise" Threads so I thought I'd Post this up to help Forum Members out in their Questions..

The Most Common type of Gearbox in Volvo's is the ASW 55-50 SN so we'll assume we're "Working" on that.....

Noises from Gearboxes can come in many many forms but most can be "Solved" (Or at least "Lessened") by changing/Flushing out the old gear oil ect

WHEN DO I FLUSH IT

If the fluid smells of "burnt toast" consider changing it if the colour is more "brown" or "black" than a cherry aid "red" consider changing,

If you do a lot of towing , city driving in heavy traffic, then consider checking the oil smell/colour at about the 50k miles mark, and then every 20k after, and when its looking "brown" more than red, start saving up to change it "sooner" Rather than LATER



HOW DO I FLUSH IT

Auto Boxes come in two "Bits" the Box itself & the Torque Converter each "Bit" is filled with oil but only the Box Itself can can be "Flushed" the torque Converter CANNOT (it has NO DRAIN POINT) the Box contains 3.6 Litres of Oil & the Torque Converter contains 3.8 Litres of Oil

A. Get under the car & locate the Gearbox Drain Plug undo this & allow the old Oil to Drain into a suitable container.

B. Refit the Drain Plug & fill up with Gear Oil NOTE IT MUST BE JWS 3309 SPEC This IS available from Local "Car Shops" but you MUST READ THE SMALL PRINT to ensure you have the correct oil

C. Top up to the Correct Level & Drive the car for Approx 2 Days (As Normal)

D. Repeat steps A & B After driving

E. You MUST repeat steps A & B at least 4 to 5 times to ensure you have completely "Changed the Oil" in BOTH the Box & the Torque Converter.

OVERVIEW

When changing the Oil in the Gearbox the new Oil mixes with the Old Oil in the Torque Converter thats why its necessary to change it Several times As said above its approx a 50 / 50 split between the two & just draining the 3.6 Litres out of the box will NOT be sufficient to effect any change in the Gearboxes operation.

If your Working to a Budget then set aside approx £150 to £200 to do the job properly The Oil is About £6 to £9 per litre & you'll need 16 litres MINIMUM to do the change.

It should be noted however that not all "Gearbox" Clunks & Noises are actually Gearbox related some are far from that E.G. worn or damaged Engine Mountings can cause "Clunks" when driving off from Traffic Lights things like this MUST BE CHECKED & Eliminated before going down the Gearbox Oil Change route.

Another common mis conception is Gearboxes are "Sealed for Life" .. They are not the AWS 55-50 SN box is NOT unique to Volvos they are fitted into many other cars & use Different Identifier Codes

2006– Pontiac Torrent (GM code M09 (FWD), M45 (AWD))
2004– Chevrolet Equinox (GM code M09 (FWD), M45 (AWD))
2004 Saturn Ion (GM code M43)
2003–2005(?) Volvo XC90 2.5T engine only
2002–2008 Lancia Thesis
2002–2005 Opel Vectra C and Opel Signum
2002–2003 Saturn Vue V6
2003-2007 Saab 9-3 (GM code M09)
2004-2006 Nissan Maxima, Nissan Quest, Nissan Altima under Nissan part number RE5F22A, built by Aisin
2001-2007 Renault Laguna V6 and 2.2dci (code SU1)
2001-2005(?) Volvo S60
2004 Volvo S80 (2.5T)
2006– Volvo C30, S40, V50 (T5)
1997-2002 Volvo C70 (Phase 1)
1999- Volvo S/V/C 70

Volvo owners manuals list the transmission as fill for life, meaning that there are no scheduled transmission fluid changes under normal operating conditions. This is controversial and believed by some to be a major contributing factor to increased valve body wear, eventually causing transmission problems that require valve body repair or replacement, and possible transmission overhaul or replacement.

Every Auto Tranny Mech I've ever spoken to recommend regular fluid changes, at least every 50,000 miles. JWS 3309 must be used. If incorrect fluid is used it will result in "improper operation" and eventual Box failure.
Lets look at it this way a AW55-50SN Box is EXACTLY THE SAME as a RENAULT LAGUNA SU1 002 Box (its made in the same factory & Probs on the same Machine) yer read a Volvo Manual & its "SEALED FER LIFE" & then yer read a RENAULT MANUAL & its "Change Oil Every 50,000 Miles !!!"

Rather Confusing isn't it ???

As you can see the "oh I'll Change the Tranny Oil on Sat" thought is NOT AN OPTION & BEFORE you go down THAT route check your .....

Engine Mountings
Drive Shaft Bearing (both Inner & Outer)
CV Joints
Wheel Bearings
Brake pads (fer "Binding")
Tyres (for Uneven Wear & Road Noise)
Brake Backplates (for "Catching" on the Wheel Hubs)

ALL can & DO make "ODD" noises from Time to Time If you've tried everything else & your left with a Gearbox Oil Flush/Change then I hope this has been a useful read.


& My Thanks to Andy D for his help & his "Proof Reading" Skills

Keith