How to remove S90 engine/gearbox?

[Robert Holden]

Have a 2017 S90 which I am rebuilding after a front end shunt. The starter motor must have take a knock as there is a 1" crack in the bell housing next to one of the starter retaining bolts. Does anyone have any advice on the best way to replace the bell housing? Engine out, gearbox out or both together, from above or below? Its a D4 engine with the auto box and I have a ramp, would like to keep AC system intact if possible. There is not much info out there on these newer models.
Any hints or tips much appreciated.
Thanks, Rob

[Clan]

Originally Posted by Robert Holden

Have a 2017 S90 which I am rebuilding after a front end shunt. The starter motor must have take a knock as there is a 1" crack in the bell housing next to one of the starter retaining bolts. Does anyone have any advice on the best way to replace the bell housing? Engine out, gearbox out or both together, from above or below? Its a D4 engine with the auto box and I have a ramp, would like to keep AC system intact if possible. There is not much info out there on these newer models.
Any hints or tips much appreciated.
Thanks, Rob

Cant you weld the crack in place , it would save a lot of work and the bell housing is an integral part of the gearbox casing ,

[Robert Holden]

Don’t think so. Apart from access being limited the crack is open and the area will get a lot of stress during starting. Car was making a squeaking noise on start which I think is due to an alignment issue between starter and the ring gear because the starter mounting has moved. Would like to weld from both sides and then skim the face which bolts to engine to ensure flat and starter correctly aligned. Unfortunately Volvo don’t sell the bell housing as a spare part and want £7.5k for a new gearbox.

[Clan]

Originally Posted by Robert Holden

Don’t think so. Apart from access being limited the crack is open and the area will get a lot of stress during starting. Car was making a squeaking noise on start which I think is due to an alignment issue between starter and the ring gear because the starter mounting has moved. Would like to weld from both sides and then skim the face which bolts to engine to ensure flat and starter correctly aligned. Unfortunately Volvo don’t sell the bell housing as a spare part and want £7.5k for a new gearbox.

Maybe you can find a used gearbox .... there are a few different types with different final drive ratios of course .. they don't sell the bellhousing as it is mated to the other half before machining so no two boxes are identical for alignment reasons ..

[Robert Holden]

A second hand box is plan b if the welding option doesn’t work. Still looking for advice on the easiest way to get the gearbox out...