G/box: 4T65AWD: Can you replace the clutched in the car?

[NMB]

Hi All,

My Volvo XC90 T6 (petrol) SE AWD with the GM 4 speed gearbox is slipping and producing an error code of "Transmission Service Urgent".

I have looked at the clutch packs from the US and I'd probably need to spend £300 on gaskets, clutches and solenoids for an "In-Car" rebuild.

This can be accessed by removing the N/S endplate of the gearbox - the question though is this:

"Is there enough clearance inside the wheel arch to do this job?"

There are videos on the repair being done on larger US cars but I don't know if this can be done on the XC90 - does anyone have an idea?

[XJSDriver]

All the videos I have watched on repairing aisin warner and similar boxes show the tear down which is a big process so cannot see how this could be achieved with the box in the car - cannot possibly see how you can access the clutch packs otherwise. Also, most likely there will be other worn components that should be replaced as well.

These are complicated gearboxes designed with many precision parts crammed into a small space so I would get the box out and let a specialist recondition it for you, then refit and forget. The alternative is you are continually chasing faults in the box as bits wear out and break. I did consider buying a second hand box and rebuilding it ready to replace mine when it develops a fault as like you can find the parts in the USA, but on studying the videos I can see it will be too easy to fit something in the wrong place or wrong way around and then you have to start again having refitted the box to find it does not work properly. A good specialist will have a test rig to test rebuilt boxes so you know you are getting a working box back.

[NMB]

Originally Posted by XJSDriver

All the videos I have watched on repairing aisin warner and similar boxes show the tear down which is a big process so cannot see how this could be achieved with the box in the car - cannot possibly see how you can access the clutch packs otherwise. Also, most likely there will be other worn components that should be replaced as well.

These are complicated gearboxes designed with many precision parts crammed into a small space so I would get the box out and let a specialist recondition it for you, then refit and forget. The alternative is you are continually chasing faults in the box as bits wear out and break. I did consider buying a second hand box and rebuilding it ready to replace mine when it develops a fault as like you can find the parts in the USA, but on studying the videos I can see it will be too easy to fit something in the wrong place or wrong way around and then you have to start again having refitted the box to find it does not work properly. A good specialist will have a test rig to test rebuilt boxes so you know you are getting a working box back.

I know its a long shot but I have watched video showing the removal and replacement of clutch bands which would cost me a weekend and a couple hundred pounds as opposed to a couple of thousand pounds on a car not worth that.

Oh what to ponder!

[NMB]

What do people do when the clutches go? A straight gearbox out?

There must be a way to replace the clutches in a car in situ?

[XJSDriver]

Afraid so - they are not designed for easy maintenance. The only way is to remove the box and strip it down. The good news is that if it is just the clutches then the repair cost will be reasonable if you can remove the box yourself. You need a repairer who can test the operation to make sure all the solenoids are fine as these too can start sticking if the oil is contaminated.

[Tannaton]

I've not done a T6 box but I believe one of the issues with them was the modifications that Volvo made so the box sits behind the engine with a chain drive from the torque converter. That layout isn't going to make it any easier I think...

[NMB]

Originally Posted by Tannaton

I've not done a T6 box but I believe one of the issues with them was the modifications that Volvo made so the box sits behind the engine with a chain drive from the torque converter. That layout isn't going to make it any easier I think...

As I understand it, the clutch pack comes out from the nearside wheel end. If you look at other post people have made in America about the GM gearbox, they have removed the clutch packs and drive bands and also replace the solenoids by taking the gearbox end off.

They do this, by taking the front strut off to gain access to their gearbox, driveshaft, hub, wheel arch liner etcetera, and they then lower the subframe/tilt the engine/gearbox to allow access to all bolts on the end plate. They then can then remove the end cover which allows access into the solenoid pack and valve body. This in turn allows the removal of the clutch discs and drive bands.

On American cars with the GM Gearbox, these typically have more space and this is why I am wondering whether it is possible to do it in a Volvo.

Of course, I understand that if the gearbox is worn there will be other Components which will be worn but I am just looking at the possibility of installing new clutch disks and looking for any obvious failings in the drive bands and valve body/solenoid replacement.

Comments would be welcome as I quite fancy having a go at this before I scrap the car As it wouldn’t take too long to see whether access is possible. With the gearbox failing the car is scrap anyway!

An interesting project – thoughts welcome!