XC70: Gearbox Worrying gearbox problem XC70

[Alecm]

I have a 2010 (MY 2011) XC70 D5 geartronic. Bought it nearly 18 months ago at 4 years old, 60,000 miles, one owner, supplied and serviced annually by same Volvo dealer. All fine until a week ago. Driving at about 40mph suddenly a clunk from the gearbox and lottsa warning lights ("DSTC Service required" etc). Finished journey 1 mile, kept appointment, and when returning to car all OK. Volvo dealer said wait for it to happen another time, it might not. It did a few days later so took it in to main Volvo dealer. They advised there are error messages about changing 4/5/6 gears. They took sample of gearbox oil and said it "contaminated" and smells burnt. Charged me £97 for the diagnosis, and advised a flush of gearbox oil. They say it *might* improve things, but if it doesn't then they suspect "internal pressure solenoids", which are not separately replaceable, so I'd need an exchange gearbox at around £5,000.

The car is booked in for a gearbox oil flush (they drain and fill it, run it, empty it and refill it a second time) which will cost me a further £386.

Obviously I am most unhappy about this.

Some background:

The car hadn't been used for towing by it's first owner (4 years). I had a towbar fitted and have since done about 1,000 - 2,000 miles towing a very small caravan (under 900kg, so tiny).
The car had an annual service by the same Volvo dealer in October, at 66,00 miles. I asked whether the gearbox oil should be changed and they showed me a sample. They said it looked a bit dirty, but not excessively, and didn't smell burnt. I was advised that there's no need to change the oil, but to check again at the next annual service. Since then I have done about 1,500 miles, not towed at all. It's puzzling that this apparently serious fault should occur out of nowhere, in that time. Present mileage is 68,000.

Does anyone have any thoughts?
Many thanks,
Alec

[Simon Jones]

Interesting that Volvo now seem to recognise that transmission fluid does need checking and replacing. They've been telling us P2 owners that the boxes are sealed for life which many of us have found not to be the case. Hope you get it sorted.

[Tannaton]

Volvo do not include any oil changes in their services schedules for the automatic gearboxes yet other manufacturers who fit the same gearbox have done so, some at 36k. I think it's factual to say that the general consensus amongst the mechanics on this forum is for heavy use cars (taxi work, lots of heavy towing) the oil should be changed at 36k otherwise it should be done at around every 70k. This is viewed as a maintenance schedule - not when to expect problems.

The towing you have done, unless you have been competing in a top gear style caravan race, shouldn't have bothered it at all and is routine for many owners.

I would suggest you get the oil flushed as suggested by the dealer - most people who change the fluid do report improvements in gearbox manners. If you still have problems and do need a new gearbox I would push the dealer hard for a contribution from Volvo of minimum 50-60%. If you can't secure a contribution then seek out a reputable transmission specialist and get the gearbox repaired, this will be much cheaper. The Volvo dealer will not open up the gearbox, I believe their scope us limited to swapping them.

Good luck, the TF80 box that you have is generally reliable and if it has a fault you have been very unlucky - 250k miles should be possible.

[luggsey]

Originally Posted by Alecm

I have a 2010 (MY 2011) XC70 D5 geartronic. Bought it nearly 18 months ago at 4 years old, 60,000 miles, one owner, supplied and serviced annually by same Volvo dealer. All fine until a week ago. Driving at about 40mph suddenly a clunk from the gearbox and lottsa warning lights ("DSTC Service required" etc). Finished journey 1 mile, kept appointment, and when returning to car all OK. Volvo dealer said wait for it to happen another time, it might not. It did a few days later so took it in to main Volvo dealer. They advised there are error messages about changing 4/5/6 gears. They took sample of gearbox oil and said it "contaminated" and smells burnt. Charged me £97 for the diagnosis, and advised a flush of gearbox oil. They say it *might* improve things, but if it doesn't then they suspect "internal pressure solenoids", which are not separately replaceable, so I'd need an exchange gearbox at around £5,000.

The car is booked in for a gearbox oil flush (they drain and fill it, run it, empty it and refill it a second time) which will cost me a further £386.

Obviously I am most unhappy about this.



Some background:

The car hadn't been used for towing by it's first owner (4 years). I had a towbar fitted and have since done about 1,000 - 2,000 miles towing a very small caravan (under 900kg, so tiny).
The car had an annual service by the same Volvo dealer in October, at 66,00 miles. I asked whether the gearbox oil should be changed and they showed me a sample. They said it looked a bit dirty, but not excessively, and didn't smell burnt. I was advised that there's no need to change the oil, but to check again at the next annual service. Since then I have done about 1,500 miles, not towed at all. It's puzzling that this apparently serious fault should occur out of nowhere, in that time. Present mileage is 68,000.

Does anyone have any thoughts?
Many thanks,
Alec

As already said, these gearboxes are very repairable, there are us companies that supply service kits for the solenoids, replacement solenoids, complete valve blocks including solenoids....
Find a good auto box repair shop.

[Tannaton]

Originally Posted by luggsey

As already said, these gearboxes are very repairable, there are us companies that supply service kits for the solenoids, replacement solenoids, complete valve blocks including solenoids....
Find a good auto box repair shop.

I agree 100% but would suggest perseveering with the dealer at the moment to maximise the chances of Volvo taking some responsibility for the repairs. If they don't - then you're better off with a reputable gearbox specialist.

[luggsey]

I read on honest john that the solenoid problem was caused by lack of greece during manufacture?
That must be the older style solenoids that haven't got the holes in the cover.
I wonder if that problem was officially acknowledged?

[Alecm]

Thank you so much Tannaton for this helpful and informative reply.
Alec

[Alecm]

Thanks. I'll do that.
Alec

[keithC70]

I think if you read through the posts you will find that the consensus is that the solenoids are electro magnets that attract and collect metal swarf from the transmission fluid.

This eventually builds until the solenoids become sticky in operation, sometimes working ok and at others causing banging, jerky gear changes.

The solution for diyers, is to remove valve body, remove the solenoids and either replace them or dismantle them and clean the bore with a drill bit until the pintles are free to move again.

It's quite an arduous task but if it saves the cost of a new gearbox ......

There are many you tube videos showing what to do.

[Alecm]

Originally Posted by keithC70

I think if you read through the posts you will find that the consensus is that the solenoids are electro magnets that attract and collect metal swarf from the transmission fluid.

This eventually builds until the solenoids become sticky in operation, sometimes working ok and at others causing banging, jerky gear changes.

The solution for diyers, is to remove valve body, remove the solenoids and either replace them or dismantle them and clean the bore with a drill bit until the pintles are free to move again.

It's quite an arduous task but if it saves the cost of a new gearbox ......

There are many you tube videos showing what to do.

Thanks for this. Not sure how relevant it is. Sounds like what you're describing will cause a progressive deterioration. In my case the car was perfect one day and started failing the next. And unfortunately I don't do DIY repairs!
Let's see how it is after the gearbox oil change. I'll report.
Alec