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These transmissions had an almost 100% failure rate, especially the T6 XC90. XC90 is 6000#’s compared to
S80 at 4000#’s. Supposedly Chevy told Ford that the 4T65 would not hold up to the turbo torque and car weight.
The tran driver side end aluminum plate held some of the shaft end bearings. Over time, torque and wear started to work on the aluminum case. This caused aluminum case dust to get into the tran oil. Over time aluminum gunk blocked the solenoid shift valves. TCM-002B was a tran death code. Some of the first trans replacements were returning with shift flare, TCM codes. Another gearbox was installed. Volvo realized that aluminum dust had traveled into the external oil cooler, radiator oil cooler and lines. Now we replaced the tran, radiator, external cooler and lines. Volvo stepped up and covered tran shift issues for quite a few years past 2006 MY. If you were a 3 party buyer with shift issues, on a case by case basis, Volvo would replace the gear box or Volvo pay for parts, customer pays labor. Remove your tran dipstick, wipe it on white paper. If you see any metal debris, you need replace the radiator, cooler and lines. Or, try to flush the cooler lines and somehow install a filter in the external cooler lines before the return oil goes back into the transmission.
Remove the top tran cooler line going into the radiator. Bump the starter or start and shut off. Watch how the tran oil flows to determine where to install an in line tran oil filter. Tran adapt should be carried out. TCM learns shifts as the tran gets older and tries to adapt some. You could get harsh shifting until the TCM can adapt to the new gear box. Below is a parts pic for tran cooler and lines. The tran replace PDF is the best with old-school real-time photo pictures. Make sure that the rebuilt tran mating surface to engine block is bare metal and not painted. Some of the first Volvo trans, the rebuilder painted the complete case and mating surface.
We did not know that it would be a thing, it was a big thing. Some, no starter crank to many TCM shifting and codes issues. We ran a separate ground cable from the tran case to the engine block, no help. We had to remove the trans, whizz wheel the mating surface paint, install and all good. As rebuild gear boxes arrived, we whizz wheeled the mating paint off until they started showing up with a clean mating surface.
As mentioned, keep us posted. We love progress or wholly crap I messed up and need help pics.
We are all here to help.
These transmissions had an almost 100% failure rate, especially the T6 XC90. XC90 is 6000#’s compared to
S80 at 4000#’s. Supposedly Chevy told Ford that the 4T65 would not hold up to the turbo torque and car weight.
The tran driver side end aluminum plate held some of the shaft end bearings. Over time, torque and wear started to work on the aluminum case. This caused aluminum case dust to get into the tran oil. Over time aluminum gunk blocked the solenoid shift valves. TCM-002B was a tran death code. Some of the first trans replacements were returning with shift flare, TCM codes. Another gearbox was installed. Volvo realized that aluminum dust had traveled into the external oil cooler, radiator oil cooler and lines. Now we replaced the tran, radiator, external cooler and lines. Volvo stepped up and covered tran shift issues for quite a few years past 2006 MY. If you were a 3 party buyer with shift issues, on a case by case basis, Volvo would replace the gear box or Volvo pay for parts, customer pays labor. Remove your tran dipstick, wipe it on white paper. If you see any metal debris, you need replace the radiator, cooler and lines. Or, try to flush the cooler lines and somehow install a filter in the external cooler lines before the return oil goes back into the transmission.
Remove the top tran cooler line going into the radiator. Bump the starter or start and shut off. Watch how the tran oil flows to determine where to install an in line tran oil filter. Tran adapt should be carried out. TCM learns shifts as the tran gets older and tries to adapt some. You could get harsh shifting until the TCM can adapt to the new gear box. Below is a parts pic for tran cooler and lines. The tran replace PDF is the best with old-school real-time photo pictures. Make sure that the rebuilt tran mating surface to engine block is bare metal and not painted. Some of the first Volvo trans, the rebuilder painted the complete case and mating surface.
We did not know that it would be a thing, it was a big thing. Some, no starter crank to many TCM shifting and codes issues. We ran a separate ground cable from the tran case to the engine block, no help. We had to remove the trans, whizz wheel the mating surface paint, install and all good. As rebuild gear boxes arrived, we whizz wheeled the mating paint off until they started showing up with a clean mating surface.
As mentioned, keep us posted. We love progress or wholly crap I messed up and need help pics.
We are all here to help.
Adaptation data
There is a function for resetting adaptation in the transmission control module (TCM) which can be activated via VIDA vehicle communication. This must be carried out after replacing internal components, such as the valve housing or a solenoid, or when replacing the entire transmission.