G/box: TF-80SCAWD: Geartronic stuck in 4

[jjkenya]

After a fault was reported on our dashboard (Transmission Performance Low), and the car wouldn't drive, we took it to Volvo. They replaced the TCM and said "We have fitted new module to car and module is working ok, but car still has no drive due to internal fault in auto box that requires replaced"

They quoted £4500 for a new box so I took it to a highly recommended independent (and in fact Volvo use them) who specialise in auto boxes. They refurbed it and it's working fine.... in automatic.

When you select the geartronic function with the gear stick, it selects 4th gear and won't change.

The independent suspects it is an electronic issue with the "selector module".
If anyone has any experience of similar please let me know.

I'm specifically interested in:

1. The name of the module / box that selects the gears (i.e. the name of the part that one might suspect is faulty)
2. The suitability of an independent carrying this repair out rather than Volvo
3. Any thoughts on whether this fault could have been caused by Volvo when they changed the TCM in the first place?

[Tannaton]

You don’t say what year or engine is in your car, that it critical as there were three entirely different auto boxes fitted to the XC90 variants.

However I’m guessing it is a early (pre 2006) 163 bhp car with the five speed AW box.

The selector modules is the gear-lever itself and a few parts in the bottom of it. They might also be referring to the actuator which is another switch that sits on top of the gearbox. They are very reliable and as cheap as chips second hand.

If you want to refurb a gearbox then you have no choice but to use a independent as Volvo will only replace faulty gearboxes with new ones. Your own experience is a good indication of why they have this policy - the last thing they want is the car going back several times.

I think there is a conclusion to be drawn by your specific specialist returning the car not in full working order.

[jjkenya]

@ Tannaton

Sorry, it's a 2009 model. I ran the car in auto for a short run and it does go through the gears using the "automatic shift", but the display doesn't change and you are unable to make manual shifts. Not sure if that's any use.

[SwissXC90]

In auto mode the dashboard display just shows a D.
If you move the gear lever from Auto to Manual mode, the D will change to the current selected gear (1...6), this is a good way of checking what gear you are currently in, you can select Manual mode briefly when driving as a quick gear monitor.

You can also check the gear selection functions as follows:

• Move the lever through P-R-N-D, the display should show P, R, N, D respectively
• Press the W button on the transmission tunnel (by the gear selector), the display should show W for Winter mode
• Move the lever to Manual mode (+/-), the display will show 1...6 depending on the current gear selected
• At standstill, in manual mode, you can select gears 1, 2 and 3. Nothing higher than 3 is allowed so as to protect the engine (it would struggle to start in 4th).

Do the above and let us know what works, what doesn't work.
It will help us to help you

[jjkenya]

Move the lever through P-R-N-D, the display should show P, R, N, D respectively - it does this. Note that to then move across to Manual Mode, I can't go directly left from D, I have to click in to one more position further down from D. The Dash shows 4 at this position (i.e. PNRD4). When I then move from this position to Manual Mode (moving the lever to the left),
the display remains in 4 unless Winter Mode is selected in which case it says W
Press the W button on the transmission tunnel (by the gear selector), the display should show W for Winter mode - W is displayed on the dash in both Manual and Automatic Modes, when stationary.
Move the lever to Manual mode (+/-), the display will show 1...6 depending on the current gear selected - When moved to Manual Mode (+/-) it always displays 4, and does not change from this number no matter what I do (apart from W). However when pulling away, it feels like it's in 1. If you then drive, it appears to go through the gears normally both up and down (and I confirm that this is in Manual Mode). Does this mean that it's not using the manual mode, or do all XC90s automatically shift in Manual Mode to prevent over-stressing the engine/gearbox?
At standstill, in manual mode, you can select gears 1, 2 and 3. Nothing higher than 3 is allowed so as to protect the engine (it would struggle to start in 4th). - as per previous answer, only 4 is displayed although it feels like I'm driving away in 1

Hope that helps some, but I can clarify further if required?
Thanks in advance

[gmonag]

Note that to then move across to Manual Mode, I can't go directly left from D, I have to click in to one more position further down from D.

There are no more positions other than PRND! You have a major mechanical issue with the selector.

[jjkenya]

@gmonag - thanks for your feedback. I have booked the vehicle in to the local dealership on Thursday and will see what they say... :-(

[gmonag]

Unfortunately, I know exactly what they will say... it will end in several zeros. If the
gear selector assembly is toast, consider fitting used parts. Obviously the dealer will not do that.

[jjkenya]

Volvo looked over the fault and have confirmed it is not the lever, or the TCM, or anything electronic. They checked the linkage and all was in order. They did identify a cable going in to the box that (and this is now beyond my level of knowledge), when the gearbox is in manual mode, is not actuating as it should: it appears too be too short when it is in a certain position, i.e. it is being snagged or is unable to travel freely in the gearbox. They therefore persist that the issue is mechanical and that it should be resolved by Charlie Butler in Forfar, who did the refurb on the box. They seem to be happy to take it in and have a look, which is my Monday taken up... Any thoughts on the above are welcome.

PS - Volvo were particularly helpful / caring / understanding and did not charge for the work, given the history. I think it's important to pat people on the back when they deserve it.

[jjkenya]

For what it's worth this has now been resolved. My understanding is that there were 2 problems:
1. A simple mechanical issue in the gear lever/shift stick mechanism where a small bit of plastic needed re-seating, which solved the "extra position" problem
2. A loose electrical contact on the solenoid which controls the mechanism releasing the gears when the brake pedal is applied. Once the contact was repaired/made good, everything worked fine. We now have a normal box again.