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S40 / V40 '96-'04 General Forum for the Volvo S40 and V40 (Classic) Series from 1995-2004. |
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Reverse light switchViews : 2200 Replies : 13Users Viewing This Thread : |
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Dec 20th, 2014, 19:25 | #1 |
Master Member
Last Online: Jul 19th, 2015 20:48
Join Date: Dec 2007
Location: Bolton
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Reverse light switch
Can anyone tell me where the reversing light switch on a non-GDi S40 1.8 is? I suspect it has packed up but can't find the sodding thing.
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Dec 21st, 2014, 00:10 | #2 |
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Last Online: Aug 1st, 2015 09:34
Join Date: Oct 2013
Location: Southampton
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Really annoying. It's on the gearbox, remove the air box and hose and its the only electric cable going into the gearbox where the gearbox select cables mount on. I've not heard of them failing though are you sure it's not anything else causing it?
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Dec 21st, 2014, 01:21 | #3 |
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Last Online: Nov 15th, 2022 21:34
Join Date: Apr 2010
Location: London / Essex
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Do you have the Volvo M56 gearbox, or the Renault M5P one? The way you can tell, is from the location of the reverse gear on the gearknob. If the reverse is under the 5th gear, then you have the VOlvo M56 gearbox. If you have the reverse on the left of the 1st gear, then you have the M5P gearbox.
Here is how to access the reverse light switch on the 1.9D with the volvo M56 gearbox. It it is pretty much the same as the 1.8 with the M56 gearbox Here is my latest guide: P { margin-bottom: 0.21cm; }P.western { } This guide is for the replacement of the Reverse Light Switch on the Volvo M56 manual gearbox. If you have the Renault M3P or M5P gearbox or the Mitsubishi engined gearbox, then the location of the sensor and the procedure is different. If your reverse lights are not working or sometimes work after wiggling the gear lever, then it is most probably due to a faulty Reverse Light Switch. Tools needed:
The reverse light switch is located under the gearbox mounting bracket, which will have to be undone. The mounting bracket supports the weight of the gearbox on that end so we will need to place a trolley jack under the gearbox and raise it just enough so it just supports its weight. Photo1 (need to take and add one) The job can be done without removing the battery, but I personally chose to remove it out of the way in order to have more space and better access. First of all, you will need to remove the battery clamp (red circle) and disconnect the two terminals (yellow circle). Unplug the connector to the MAF sensor (Red arrow). Loosen the jubilee clip using the 8mm socket (green arrow) and pull out the hose. You can also use a flat blade screw driver to undo the jubilee clip screw). Undo the four clips (yellow arrow) securing the top cover of the air filter box and remove it. Depending on the model of your car, you may have to unclip some more wiring looms or hoses attached to the air filter box. Undo these two 10mm bolts and remove the bottom half of the air filter box. You can now see the gearbox mounting bracket. The reverse light switch is under it. Loosen the 18mm nut (green arrow) but DO not remove it. Undo and remove the 3 13mm bolts (red arrows). You can now swivel the gearbox mount out of the way and you will see the reverse light switch. Disconnect the connector and use the 22mm deep socket to undo the switch. Replace with new reverse light switch and tighten to 25Nm. Plug the connector back on. Swivel down the gearbox mount and Tighten the 3 13mm bolts of the gearbox mounting at 50Nm. Be careful not to over torque these 3 bolts too much, because otherwise you risk damaging the aluminium treads on the gearbox. Then tighten the 18mm bolt to 98Nm. Follow this guide in the reverse order to put everything else back together.
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Current car: 2002 S40 1.9D, 1992 240SE Nullius in Verba
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Dec 21st, 2014, 09:49 | #5 |
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Jun 3rd, 2020, 09:59 | #6 | |
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This guide has been blessing. Unfortunately, I failed removing Gearbox nuts (one in the small ring, 12 oclock position in the photos. I tried lubricating and of course supporting with jack etc. Failed. I have to take it to a proper service for this now (either power tools or some other solution might be needed). At least I know what they need to do now.
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Jun 3rd, 2020, 10:12 | #7 | |
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Last Online: Nov 15th, 2022 21:34
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Location: London / Essex
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Quote:
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Current car: 2002 S40 1.9D, 1992 240SE Nullius in Verba
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Jun 3rd, 2020, 19:46 | #8 |
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Last Online: Nov 6th, 2022 16:57
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Location: Nottingham
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As above, I used a 1/2" breaker bar to slacken them and with a bit of encouragement they came out easy. Steel and aluminium together aren't a great combination as they develop galvanic corrosion which is nature's loctite.
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Present: 2002 C70 2.0T, 2003 Saab 9-5 3.0 V6 TiD Past: 2002 S40 1.9D, 2002 S40 2.0T, 2004 S40 1.8, 2002 & 2004 V40 1.9D, 2006 Saab 9-5 2.3t Various other French and Italian boxes |
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Jun 4th, 2020, 13:54 | #9 | |
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BTW. Wow I didn't expect any replies in such old topic. I am really impressed. |
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Jun 4th, 2020, 17:13 | #10 | |
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Quote:
__________________
Present: 2002 C70 2.0T, 2003 Saab 9-5 3.0 V6 TiD Past: 2002 S40 1.9D, 2002 S40 2.0T, 2004 S40 1.8, 2002 & 2004 V40 1.9D, 2006 Saab 9-5 2.3t Various other French and Italian boxes |
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