G/box: 850 Auto: - PNP switch removal - Page 3

stevepcar · Mar 25th, 2020, 10:07

Still in the process of removing Auto Transmission from my 1996 T5 850. Have a real problem removing the Torx screws to release the Torque converter from the flywheel. Took several hours to remove just 3 of the 6. I have already started to damage the heads of the remaining ones & really don't want to keep on at them, in case I cannot get the Torx bit to engage with them anymore. So this might seem a stupid question, but can I remove the gearbox without detaching the Torque converter from the flywheel? Will it cause damage to anything, or is it almost impossible to re-attach the box without damaging anything, with the converter still attached to the flywheel? I guess I should have used an air tool from the beginning, but I was afraid of shearing the heads off. Any advice gratefully received.

stevepcar · Mar 25th, 2020, 10:19

Please all you sensible people ignore my last post. I now realise that the flex plate is sandwiched between the flywheel & the torque converter & bolted to the flywheel, so the answer to my question is no what a fool.

stevepcar · Mar 25th, 2020, 10:49

Ref my last post. I am not sure if I am being an idiot. Do the Torx bolts go through the flywheel and Flex Plate screw into the Torque converter? If so is it possible to remove the transmission & leave the Torque converter bolted on?
I am really confused.

stevepcar · Apr 2nd, 2020, 15:26

I have managed to get the Torx bolts out of my Torque converter, but they all need replacing as the heads are generally chewed up. As a long shot has anybody any of them in good condition. Just to be sure they are the 6 x Torx head bolts that hold the Torque Converter to the Flywheel on a 1996 850 T5 Auto transmission.

SteveSarre · Apr 3rd, 2020, 08:47

Hi Steve

Surely worth getting new from Volvo?

HTH
Steve

stevepcar · Apr 10th, 2020, 14:06

Thanks I managed to get some Volvo ones from Caffyns in Eastbourne. They seem very reasonable & have had everything I have asked for so far.

stevepcar · Apr 12th, 2020, 17:27

Well after several weeks on and off, I have finally finished fitting the second hand auto box to my 1996 850 T5 Turbo. Quite a hard & sometimes tricky job, but all worth it when I took it for a test drive & no warning light! Now all I need to do is have the manual box out of my 10 V 850 to fix the main oil seal leak. After I have changed the PCV system that caused the leak in the first place. Should be a doddle after wrestling with the auto box.

stevepcar · May 3rd, 2020, 16:04

Continuing story, this point might be of use to anybody that is experiencing trouble with reversing lights not working. After successfully replacing the auto box on my T5 with a second hand one, I started getting problems with the car not turning over in Park or Neutral. So I did the old trick of iperating the ger shift with the engine off about 20-times. This cured it until the next time, I also noticed that the reversing lights were not working. When I got the S/h box it already had the PNP switch in position, so I let sleeping dogs lie & just left it alone. I found a good article on Mathews Volvo site that explained how to adjust the PNP position, by checking when the reversing lights came on. After about 5-attempts, I still couldn't get the lights to come on in any position. So I stripped the original PNP switch off the old gbox dismantled it cleaned it filled it with silicone grease & fitted it to the new box. I had roughly lined it up by eye with the ridge that runs on the PNP cover. Not only does it start in P & N but the reversing lights came on. I will now strip down the one that I took off & service that one as a spare.
Those of you that had been following this thread & the trouble I had getting the original switch off, will smile when I tell you that the reason I couldn't get it off, was because I had not snapped off the 2-little lugs at the back of the electrical connector. Once they have gone the whole assembly comes apart with a small penknife & a small set of mole grips. When you re-assemble the cable ties keep it all together.
This restoration job has improved my mechanical skills enormously & it is a constant learning curve.
Good luck to anybody attempting the same .

Mar 25th, 2020, 10:07	#21
stevepcar Steve Last Online: Yesterday 16:26 Join Date: Jul 2012 Location: Bristol	Auto Transmission warning light Still in the process of removing Auto Transmission from my 1996 T5 850. Have a real problem removing the Torx screws to release the Torque converter from the flywheel. Took several hours to remove just 3 of the 6. I have already started to damage the heads of the remaining ones & really don't want to keep on at them, in case I cannot get the Torx bit to engage with them anymore. So this might seem a stupid question, but can I remove the gearbox without detaching the Torque converter from the flywheel? Will it cause damage to anything, or is it almost impossible to re-attach the box without damaging anything, with the converter still attached to the flywheel? I guess I should have used an air tool from the beginning, but I was afraid of shearing the heads off. Any advice gratefully received.

Mar 25th, 2020, 10:19	#22
stevepcar Steve Last Online: Yesterday 16:26 Join Date: Jul 2012 Location: Bristol	Auto Transmission warning light Please all you sensible people ignore my last post. I now realise that the flex plate is sandwiched between the flywheel & the torque converter & bolted to the flywheel, so the answer to my question is no what a fool.

Mar 25th, 2020, 10:49	#23
stevepcar Steve Last Online: Yesterday 16:26 Join Date: Jul 2012 Location: Bristol	Auto Transmission warning light Ref my last post. I am not sure if I am being an idiot. Do the Torx bolts go through the flywheel and Flex Plate screw into the Torque converter? If so is it possible to remove the transmission & leave the Torque converter bolted on? I am really confused.

Apr 2nd, 2020, 15:26	#24
stevepcar Steve Last Online: Yesterday 16:26 Join Date: Jul 2012 Location: Bristol	Torx Bolts I have managed to get the Torx bolts out of my Torque converter, but they all need replacing as the heads are generally chewed up. As a long shot has anybody any of them in good condition. Just to be sure they are the 6 x Torx head bolts that hold the Torque Converter to the Flywheel on a 1996 850 T5 Auto transmission.

Apr 3rd, 2020, 08:47	#25
SteveSarre Premier Member Last Online: Apr 10th, 2024 17:15 Join Date: Oct 2004 Location: London/West Country	Hi Steve Surely worth getting new from Volvo? HTH Steve __________________ V70 2.5 Turbo AWD Man. 1999 Red V70 2.5 10V Auto 1998 Green C70 T 20V Auto Conv. 2001 Blue, C70 T5 Auto Conv. 2000 Blue V70 2.5 Turbo AWD Auto 1998 Green, V70 2.5 10V Auto BiFuel 1999 Red (scrapped) V70 20v Auto 1999 Green (scrapped)

Apr 10th, 2020, 14:06	#26
stevepcar Steve Last Online: Yesterday 16:26 Join Date: Jul 2012 Location: Bristol	Auto Transmission warning light Thanks I managed to get some Volvo ones from Caffyns in Eastbourne. They seem very reasonable & have had everything I have asked for so far.

Apr 12th, 2020, 17:27	#27
stevepcar Steve Last Online: Yesterday 16:26 Join Date: Jul 2012 Location: Bristol	Auto Transmission warning light Well after several weeks on and off, I have finally finished fitting the second hand auto box to my 1996 850 T5 Turbo. Quite a hard & sometimes tricky job, but all worth it when I took it for a test drive & no warning light! Now all I need to do is have the manual box out of my 10 V 850 to fix the main oil seal leak. After I have changed the PCV system that caused the leak in the first place. Should be a doddle after wrestling with the auto box.

May 3rd, 2020, 16:04	#28
stevepcar Steve Last Online: Yesterday 16:26 Join Date: Jul 2012 Location: Bristol	PNP Switch Continuing story, this point might be of use to anybody that is experiencing trouble with reversing lights not working. After successfully replacing the auto box on my T5 with a second hand one, I started getting problems with the car not turning over in Park or Neutral. So I did the old trick of iperating the ger shift with the engine off about 20-times. This cured it until the next time, I also noticed that the reversing lights were not working. When I got the S/h box it already had the PNP switch in position, so I let sleeping dogs lie & just left it alone. I found a good article on Mathews Volvo site that explained how to adjust the PNP position, by checking when the reversing lights came on. After about 5-attempts, I still couldn't get the lights to come on in any position. So I stripped the original PNP switch off the old gbox dismantled it cleaned it filled it with silicone grease & fitted it to the new box. I had roughly lined it up by eye with the ridge that runs on the PNP cover. Not only does it start in P & N but the reversing lights came on. I will now strip down the one that I took off & service that one as a spare. Those of you that had been following this thread & the trouble I had getting the original switch off, will smile when I tell you that the reason I couldn't get it off, was because I had not snapped off the 2-little lugs at the back of the electrical connector. Once they have gone the whole assembly comes apart with a small penknife & a small set of mole grips. When you re-assemble the cable ties keep it all together. This restoration job has improved my mechanical skills enormously & it is a constant learning curve. Good luck to anybody attempting the same .

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