Auto gearbox problem

[bish789]

Hi all

I have a 2002 S60 T5 Auto. It's started to clunk into gear sometimes but not all of the time.

I've seen in the forums that by sometimes flushing the box and putting new ATF in cures it.

Can anybody confirm that this has worked for them in their car before I take on the new gearbox route.

Any replies would be gratefully received.

[scooter]

check the gearbox dip stick if it is black fluid a change should do the fix

[princepugh]

Don't forget the software update too. I'm sure you'll get plenty of testimonials from folk on here regarding both the flush and s/w update.

[bish789]

Thanks for that.

Spoken to a couple of Auto gearbox specialists and they weren't particularly keen to touch it unless I was going to pay for a recon.

Will try the flush and s/ware update.

Thanks again.

[MattM]

I have the same problem. I've had the software update but haven't had the ATF flush. I assume you've seen this? http://www.volvoxc.com/forums/showthread.php?t=5668 I'd be very keen to know if this fixed the issue.

[mds]

Hi bish 789,
This is a well documented issue with the AW 55-50/51 gearboxes fitted to Volvo's (I have 2 with this gearbox) My dealer proposed a new box and quoted £3500 then I found the USA forum link Matt has passed on. The symptoms I had were clunky changes and flaring 2-3 changes. I discovered that Volvo's schedual indicates changing the ATF at 48000 miles all 3 of our Volvo's have full service histories and on checking the one with the problems discovered its never been done?

So following the thread I flushed the box (There are several sources for JWS3309 ATF now last time I used Carlube ATF-U from EuroCarParts £6.96 per litre) using ATF from the GM dealer 1/3 the price Volvo wanted (GM use the same box as do Saab and Toyota). The difference is chalk and cheese I then had the Volvo dealer reset the Fluid counter and upgrade the software £50 about from memory that was a year back and its still like a new box total including the ATF and other stuff was about £150 much cheaper than a rebuild or new box as a starting point. I have flushed all 3 Auto boxes and it is now a home maintenance job I use a good Independant for major services (cam belt etc) but do all standard services oil filter changes myself, then I know its been done. My 1997 V70 had the original plug leads (they have date on them) and a full dealer history they should have been changed at the first major service?? Someone paid for that I bet.
Many others have had these problems and will tell you Flush the box the difference is massive.

[bish789]

Thanks everybody.
I'm starting to feel a lot better now after reading your replies. Obviously not using the beast while the white stuff is around, as far too much torque and low profile tyres on, but am going to do the change as soon as it's warm enough before I start using it full time.

[BigJC]

This is exactly what mine 'still' needs before I sell it! Might print the article and hand it to my local garage to do though as its still a bit parky out there...

[thebadger]

Did a flush of my autobox in July, it removed some of the clunking, but left the revving between 2nd & 3rd.

Needs the update to sort that....

[mds]

The flaring between 2/3 and sometimes 3/4 can be caused by the B4 solonoid again well documented.
Once you have flushed the box it can take about 100 miles for everything to settle down there is an adaption sequence that should be followed I think I have it somewhere, if it doesnt after the software is upgraded then it could well be the B4 solonoid Volvo sell what they call a "Piston Repair Kit" its about £15 cheaper if you contact RUFE I think.

[BigJC]

Is there a knack to removing the pipe with the green clip? Had a mare with the garage today, took it in 9am (2 weeks to get slot), gets a phonecall to say they're having a problem at 4.30.... They want to refill it through gear box dip stick but haven't got the right tool so I printed the article detailing how to fix it and took it down. Agreed that if pipe with green clip could had ATF in, they would fill through there. Could we get pipe and green clip out? No.
There's a chap supposed to be coming on Saturday to view the car and I'd much rather the gearbox be happy and not clunky...
Argh!!