5th gear whining noise.

[emtor]

Originally Posted by lynns hubby

It can take a while for the level to settle if you over fill it a bit. I would be surprised that the gearbox has lasted this long if it has had no oil in since the clutch change in 2015 !!!!!!!

It must have had oil until recently, as you say, the gearbox would never have survived for so long without oil.
The fill hole is also the level hole. According to Haynes one should fill until it drips out of the refill/level hole.
I don't know whether there's an overflow hole or tube or not that oil spills out of if overfilled.
I'm in the process of slamming together sturdy wooden jack supports that will enable me to lift the car one and a half foot off the ground.
Crawling underneath a vehicle and having the area to inspect a couple of inches above my nose is useless.

There are only two places were these boxes can leak, not counting in cracks in the box itself, and that's where the gear selector enters the box and the oil seals where the axels are inserted.
The gear selector seal can be replaced with the box in situ with the proper tools.

[lynns hubby]

I am sure you can replace the seals where the drive shafts fit into the box with out the need to remove the whole gearbox itself. Check the drive shaft ends where they fit into the box for play. You should not be able to move them in any direction radially. If you can then the bearings are worn in the box and allowing the shaft to bounce around moving it away from the seal and letting it leak.
That was a common issue with ford escorts and fiestas back in the day. No good replacing the seal if the shafts are not contacting them 100%

[emtor]

Originally Posted by lynns hubby

I am sure you can replace the seals where the drive shafts fit into the box with out the need to remove the whole gearbox itself. Check the drive shaft ends where they fit into the box for play. You should not be able to move them in any direction radially. If you can then the bearings are worn in the box and allowing the shaft to bounce around moving it away from the seal and letting it leak.
That was a common issue with ford escorts and fiestas back in the day. No good replacing the seal if the shafts are not contacting them 100%

I found the leak. Oil is dripping from the driver's side driveshaft rubber sleeve.
The seals can be replaced without removing the gearbox, not sure about the bearings though. Anyway, now that I know the cause and how much it leaks I can just keep an eye on the oil level and wait till I get back to Sweden where all my tools are plus my buddies there with even more tools,-plus cheap volvo parts.
I'll check for radial movement . . .

[magnuz]

Is this the volvo gearbox or the renault gearbox ?

[emtor]

Originally Posted by magnuz

Is this the volvo gearbox or the renault gearbox ?

According to the VIN number it is a 5MT gearbox.
After some googling it seems as it's also named M56L.

[emtor]

Edit: Decoding the VIN number seems next to useless. Some decoders say: M58, M3P, M5P while other say: M3P, M5P, M5D.

I have the Vadis software and you need to enter the VIN to get your car.
Inside Vadis one does not get to know which gearbox one has by the VIN number, but you're given the option of choosing between M3P, M5P and M5D.

On some gearboxes there's a sticker with numbers and a barcode and also with the gearbox model number but on mine there's no model number.

[emtor]

I found a german webshop that sells parts for Volvo and Saab.
Entering the VIN number gave the following info: M5P gearbox.
Also, I found that the M5P has reverse off to the left so I'm sure this is the box.
They sell radial oil seals and gaskets that fit other boxes also, but I need some help here. It says fitting position: Right.
What does that mean???

[magnuz]

Looks like you have the renault gearbox.!
The gearbox driveshaft/ diff oil seals differ on each side, the right hand oil seal is a normal one, but the left hand one is more like a boot, & is prone to splitting,& therefore leaking, it also has an additional bearing on the shaft that sits in the small end of the boot, so check that bearing for roughness,play,etc.
This driveshaft has a tripod joint joint where it goes in to the gearbox, so be careful when you pull it out of the gearbox, as they can fall apart,& the needle/pin bearings could end up anywhere!
It should be like this one https://www.ebay.co.uk/itm/VOLVO-V40...cAAOSwldRaPKCY

[emtor]

Originally Posted by magnuz

Looks like you have the renault gearbox.!
The gearbox driveshaft/ diff oil seals differ on each side, the right hand oil seal is a normal one, but the left hand one is more like a boot, & is prone to splitting,& therefore leaking, it also has an additional bearing on the shaft that sits in the small end of the boot, so check that bearing for roughness,play,etc.
This driveshaft has a tripod joint joint where it goes in to the gearbox, so be careful when you pull it out of the gearbox, as they can fall apart,& the needle/pin bearings could end up anywhere!
It should be like this one https://www.ebay.co.uk/itm/VOLVO-V40...cAAOSwldRaPKCY

Right/left . . . is that viewed from sitting inside the car? -In that case it's the left hand seal that leaks in my car, so then I ordered the wrong one.
Checking the webshop again I found this one:

Radial oil seal, Differential
Volvo S40 V40 (-2004)

Position: Differential - Drive shaft
Position: Transmission output
Fitting position: fits left and right

-This one does not look like a sleeve but looks exactly like the right hand type.

[magnuz]

Yes.. the one i described is the left driveshaft when veiwed from inside the car.. If you can get in to a position to view them.. they are quite obviously different !
Assuming that it is the renault gearbox ..?
The oil filler is also on the front of the gearbox (radiator side ) about halfway up the housing ,& is usually a plastic plug which can be loosened with pliers, unless someone has changed it for a metal plug ?