2005 5 speed 163 173k gearbox swap

[Bigjimknickers]

My biggest worry is doing the same again with a brand new joint & wasting £45, hence the reason for checking in with you lot!

[Tannaton]

.....as has been said count the splines as there are two types and seemingly no firm cut over date.

[aland]

I’m planning a gearbox swap on mine soon, but it’s a 6-speed manual.
I currently have a whine type noise from the box, which goes when you dip the clutch. You can hear it at low road speeds also. It seems to be gradually getting louder as time goes by.
As the manual boxes are quite rare, I’d rather not find I need some impossible-to-source internal part with the car marooned on the drive, so bought a younger, lower mileage ‘box when one appeared on eBay.
I’ll probably do it next month, along with DMF, clutch and both lower wishbones.

[Tannaton]

Originally Posted by aland

I’m planning a gearbox swap on mine soon, but it’s a 6-speed manual.
I currently have a whine type noise from the box, which goes when you dip the clutch. You can hear it at low road speeds also. It seems to be gradually getting louder as time goes by.
As the manual boxes are quite rare, I’d rather not find I need some impossible-to-source internal part with the car marooned on the drive, so bought a younger, lower mileage ‘box when one appeared on eBay.
I’ll probably do it next month, along with DMF, clutch and both lower wishbones.

You sound well prepared... but are you sure it's not the transfer box??

It will feel like new car afterwards.

FYI so far as I am aware - Volvo don't offer or supply internal components for their own gearboxes - not sure it anyone is able to confirm?

[aland]

Originally Posted by Tannaton

You sound well prepared... but are you sure it's not the transfer box??

I figure it can't be the transfer box, as this noise is there in neutral also, when all the transmission output components will be stationary.

Originally Posted by Tannaton

It will feel like new car afterwards.

FYI so far as I am aware - Volvo don't offer or supply internal components for their own gearboxes - not sure it anyone is able to confirm?

Yes, i've found that before when I had an issue with a V70 'box many years ago, so swapping the whole thing should be the easiest/quickest fix.
I made the mistake of fitting GSF wishbones about 18 months ago (to solve a pulling-to-the-left-when-braking-issue) - but that fault is now back, so will fit genuine wishbones while it's all apart.
I have new driveshaft seals to go in also, as there is a slight weep on one currently.

[gmonag]

I currently have a whine type noise from the box, which goes when you dip the clutch

It could be the clutch!

[aland]

Originally Posted by gmonag

It could be the clutch!

Or maybe the clutch release cylinder...
But until it's apart I won't know - and then the car is marooned - hence I bought the 'box when one appeared to minimise the time off-the-road!

[S60D5-185]

Originally Posted by Bigjimknickers

My biggest worry is doing the same again with a brand new joint & wasting £45, hence the reason for checking in with you lot!

No, don't worry, just fit the new joint and all should be well,

[Bigjimknickers]

May mate counted the spines, new part ordered 2 year warranty off eBay £45- Volvo Guildford £300!

[Bigjimknickers]

24 splines & 78mm OD