G/box: 4T65AWD: - Glimmer of hope after transmission service urgent!

400-ascona · Jul 1st, 2010, 22:16

With 90k miles on 2005 T6, I wasn't surprised when gear service urgent light came on and it locked in 3rd gear. I carry a fault code reader because since I fitted a K&N filter and had it converted to gas it has occasionaly had MAF faults. So I reset the gearbox fault code (3rd gear ratio out or something like). Started thinking about selling the car until I spoke today to the Automatic gearbox company in Hilton Derbyshire. Apparently the MAF sensor is used in modern cars to control the gearbox (on automatics) as well as the engine. Advice was to bin the K&N, and fit standard filter with new OE MAF from Volvo. Don't fit pattern part or reconditioned as they may work, but won't work as well as a new one. Apparently if you drive an Audi with the MAF disconnected the box will destroy itself within 10 miles! So far I have swapped the air filter, and on a 15 minute drive the harsh and reluctant kick down seems to have gone, and the hunting motion on constant throttle also seems to have gone. He admitted the gearbox's are bad, and said that rebuilding them isn't worth it (he won't do them). Not many threads link gearbox problems to MAF, but changing the airflow through the MAF, or having a fauty but not failed MAF seems to affect the gearbox performance. Going to change the oil and filter in my gearbox this weekend, and see how it goes. £300 + VAT from volvo for MAF, but Bosch service centres can supply genuine Bosch for around £200 +VAT, which I hope to get tomorrow.

400-ascona · Jul 9th, 2010, 22:39

Got a genuine Bosch MAF from CES in Derby. Smoother changes, seems better. Got the MAF for 189 incl VAT. Going to change the oil this weekend.....

400-ascona · Jul 11th, 2010, 22:13

Getting the oil out the box without covering the drive in oil is difficult. Removed the bolts from the narrow end of the sump, and allowed the majority of oil to drain. Once the oil had slowed I removed the sump from the gearbox, and pulled the filter out of the gearbox. There is a small collar/seal sits inside the gearbox, and you get a new one with the new filter. Removed it with some difficulty and tapped the new one home with a little gearbox oil and a suitably sized socket as a drift. Once it was all cleaned down I put it all back together with new filter and sump gasket from volvo, and filled it through the dipstick hole. Managed to get 7 litres swapped out of the 12+. Checked and adjusted the level with the engine running which I assume is the correct method as its nowhere near on the dipstick when switched off.
The filter and sump gasket were approx £25 from volvo all in. The sump was fairly clean, with a small amount of slime around the magnet which I expected to find. I may change again in a few 100 miles to make sure its as clean as possible.
There is a way to swap the oil in the cooler too, but the chance of creating leaks on the joints, and the risk of having to run the box with them disconnected, i decided the double change option was less risky, but a bit more expensive and time consuming.
Gearbox feels a lot smoother, but need a longer run to get it thoroughly heat soaked to be sure.

400-ascona · Sep 12th, 2010, 21:25

So changing the oil didn't work! I have now changed the gearbox (will write about it another time). The old gearbox was killed by the passenger side front drive shaft. The oil from the box got into the drive shaft and carried the grease back into the gearbox, wrecking the gearbox in the process. I have flushed through the cooler, and swapped the box and torque converter. Just got to rebuild 1 decent drive shaft out of the three I have and I will be able to see if all the work has been worth while. It's one to watch out for though. The end cap at the bottom of the drive shaft splines (gearbox end) had come off, and allowed the oil through. It looks like it was originaly welded on. Result is one knackered box and one knackered drive shaft. I'm also knackered after all the work to swap the box, not a job for the faint hearted!

ianu · Sep 12th, 2010, 23:36

...all I can think of to say is 'blimey' - rather you than me...

ianu · Sep 12th, 2010, 23:37

Quote:

Originally Posted by ianu

...all I can think of to say is 'blimey' - rather you than me...

..oh and thanks for the detailed updates - well done...

Jul 1st, 2010, 22:16	#1
400-ascona Premier Member Last Online: Apr 19th, 2024 10:05 Join Date: Mar 2008 Location: Derby	Glimmer of hope after transmission service urgent! With 90k miles on 2005 T6, I wasn't surprised when gear service urgent light came on and it locked in 3rd gear. I carry a fault code reader because since I fitted a K&N filter and had it converted to gas it has occasionaly had MAF faults. So I reset the gearbox fault code (3rd gear ratio out or something like). Started thinking about selling the car until I spoke today to the Automatic gearbox company in Hilton Derbyshire. Apparently the MAF sensor is used in modern cars to control the gearbox (on automatics) as well as the engine. Advice was to bin the K&N, and fit standard filter with new OE MAF from Volvo. Don't fit pattern part or reconditioned as they may work, but won't work as well as a new one. Apparently if you drive an Audi with the MAF disconnected the box will destroy itself within 10 miles! So far I have swapped the air filter, and on a 15 minute drive the harsh and reluctant kick down seems to have gone, and the hunting motion on constant throttle also seems to have gone. He admitted the gearbox's are bad, and said that rebuilding them isn't worth it (he won't do them). Not many threads link gearbox problems to MAF, but changing the airflow through the MAF, or having a fauty but not failed MAF seems to affect the gearbox performance. Going to change the oil and filter in my gearbox this weekend, and see how it goes. £300 + VAT from volvo for MAF, but Bosch service centres can supply genuine Bosch for around £200 +VAT, which I hope to get tomorrow.

Jul 9th, 2010, 22:39	#2
400-ascona Premier Member Last Online: Apr 19th, 2024 10:05 Join Date: Mar 2008 Location: Derby	Got a genuine Bosch MAF from CES in Derby. Smoother changes, seems better. Got the MAF for 189 incl VAT. Going to change the oil this weekend..... __________________ 1997 V70R AWD, Saffron, Manual; Lotus Carlton; Ascona 400; Mini Cooper S Works; 4.2 Supercharged Range Rover; Land Rover Discovery 4; Suzuki GSF1200N; BMW R80/7; Velocette Venom; Daimler V8 250.

Jul 11th, 2010, 22:13	#3
400-ascona Premier Member Last Online: Apr 19th, 2024 10:05 Join Date: Mar 2008 Location: Derby	Getting the oil out the box without covering the drive in oil is difficult. Removed the bolts from the narrow end of the sump, and allowed the majority of oil to drain. Once the oil had slowed I removed the sump from the gearbox, and pulled the filter out of the gearbox. There is a small collar/seal sits inside the gearbox, and you get a new one with the new filter. Removed it with some difficulty and tapped the new one home with a little gearbox oil and a suitably sized socket as a drift. Once it was all cleaned down I put it all back together with new filter and sump gasket from volvo, and filled it through the dipstick hole. Managed to get 7 litres swapped out of the 12+. Checked and adjusted the level with the engine running which I assume is the correct method as its nowhere near on the dipstick when switched off. The filter and sump gasket were approx £25 from volvo all in. The sump was fairly clean, with a small amount of slime around the magnet which I expected to find. I may change again in a few 100 miles to make sure its as clean as possible. There is a way to swap the oil in the cooler too, but the chance of creating leaks on the joints, and the risk of having to run the box with them disconnected, i decided the double change option was less risky, but a bit more expensive and time consuming. Gearbox feels a lot smoother, but need a longer run to get it thoroughly heat soaked to be sure. __________________ 1997 V70R AWD, Saffron, Manual; Lotus Carlton; Ascona 400; Mini Cooper S Works; 4.2 Supercharged Range Rover; Land Rover Discovery 4; Suzuki GSF1200N; BMW R80/7; Velocette Venom; Daimler V8 250.

Sep 12th, 2010, 21:25	#4
400-ascona Premier Member Last Online: Apr 19th, 2024 10:05 Join Date: Mar 2008 Location: Derby	So changing the oil didn't work! I have now changed the gearbox (will write about it another time). The old gearbox was killed by the passenger side front drive shaft. The oil from the box got into the drive shaft and carried the grease back into the gearbox, wrecking the gearbox in the process. I have flushed through the cooler, and swapped the box and torque converter. Just got to rebuild 1 decent drive shaft out of the three I have and I will be able to see if all the work has been worth while. It's one to watch out for though. The end cap at the bottom of the drive shaft splines (gearbox end) had come off, and allowed the oil through. It looks like it was originaly welded on. Result is one knackered box and one knackered drive shaft. I'm also knackered after all the work to swap the box, not a job for the faint hearted! __________________ 1997 V70R AWD, Saffron, Manual; Lotus Carlton; Ascona 400; Mini Cooper S Works; 4.2 Supercharged Range Rover; Land Rover Discovery 4; Suzuki GSF1200N; BMW R80/7; Velocette Venom; Daimler V8 250.

Sep 12th, 2010, 23:36	#5
ianu Premier Member Last Online: Apr 25th, 2024 18:32 Join Date: Dec 2004 Location: Bicester View Photos By: ianu	...all I can think of to say is 'blimey' - rather you than me...

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