2005 5 speed 163 173k gearbox swap

[Bigjimknickers]

I figured I’d log my activity on this thread on my replacement gearbox, pick up any tips on the way & add a few photos. Maybe it’ll help others, I’m hoping all will be well soon with my 2005 xc.

Back story, my xc90 always had a whinny 4th gear, I tried two 3L sump dumps with jws 3309oil with no joy- the gearbox was lovely & smooth for a short while but a few weeks ago it completely packed up. I bought it in November & done about 4000 miles in it since then & thoroughly enjoyed owning what was previously financially out of my reach, so imagine my disappointment when my £2500 pride & joy was worth £900 scrap (my mate has had the same problem & his was sold for that as export)

So I’ve bought a second hand gearbox from eBay. I asked all the questions- was it tested / is it guaranteed/ does it whine/ what’s the mileage when removed/ please don’t let me buy a pos that will take an age to fit/ remove/return!

So the fella assured me i would not be disappointed & the box came with torque converter, driveshaft & had 83k on the clock when removed, I paid for it & next day it’s sat & my mates garage waiting for me to go & make a start on it.

So I’m off there at 12, his week is finished & this will be our spare time, it won’t interfere with his work (although I’ll still pay him) & I’ll have use of his ramp & tools.
Thanks for reading- any tips welcome.

[Tannaton]

You’ve read my post on this but would add :

If you have access to a 2 post ramp then I would give consideration as to whether it is easier to remove the front subframe in its entirety with the engine & box still on it. Several tasks will then become much easier such as removing the transfer box and torque converter bolts. Taking the engine out sounds extreme but in reality the extra disconnections are not that bad - coolant hoses, fuel pipes, wiring, power steering pipes, exhaust has to be removed anyway. You will need to unbolt and tie up the a/c compressor and check you have enough space to lower the engine with the alternator and power steering pump still attached...

Good luck!

[Bigjimknickers]

Wow, what a day!
Gearbox is ready to come out tomorrow morning, spent the last 2hours trying to get the last gearbox bolt out of the top, what a mother£@cker to get out!
I cracked it and left it for the evening.

Gearbox oil was changed twice less than a month ago & was completely black.

[Bigjimknickers]

http://i584.photobucket.com/albums/s...EEB1EC31B8.jpg

[Bigjimknickers]

[Tannaton]

You've gone quite Jim - did you walk to work today??

:-)

[Bigjimknickers]

I’ll admit, after a weeks work & a 6-7 hour shift on Saturday I was not up for it in Sunday!
Couldn’t get there tonighteither so I’ll be back there tomorrow after work.
I really hope my mate has been cracking on with it...
Trying to do this as well as a full time job isn’t good for me!

[Bigjimknickers]

Oh & I also noticed a lot of oil around the intercooler once I was under the car, looks like a new one is in order next month.
(Monthly xc budget well blown this month!!)

[Tannaton]

Originally Posted by Bigjimknickers

Oh & I also noticed a lot of oil around the intercooler once I was under the car, looks like a new one is in order next month.
(Monthly xc budget well blown this month!!)

I got a pattern one from e-bay for about £80 and it looked better made than the original.

[Bigjimknickers]

So, tonight was quite productive!

Got there & removed the torx bolts holding the TC on, removed the gearbox, fitted the new gearbox did the TC bolts, re fitted the transfer box, rear engine mount & prop shaft.

Just steering rack, driveshafts & sub frame Tomorrow night.