Warning about 2003 Volvo S60 trans

[Sugarfryz]

I know this isn't the right place to post this but I know there's a lot of technicians on this forum, who should not make the grave mistake i did. I had the task of draining and filling a 2003 Volvo 2.4 liter s60 transmission today. Going to fill it through the dipstick I noticed there was no way I was gonna fit a funnel down there, I started looking for elsewhere to fill it.

I saw a bolt on top of the transmission I could easily fill the transmission up with, it's on many cars and I've done that before without issue.

Big mistake.

I don't work on volvos often at all, and just took it out and filled it through the hole. Got the fluid level right tool it for a test drive. No third gear whatsoever, transmission was slipping pretty badly.
Apparently this bolt on this particular transmission, holds the b4 transmission band 4 anchor. The bolt is threaded not only into the transmission case but into that band which provides for 3rd gear. The band fell down into the trans and will be next to impossible to thread back in without removing and rebuilding the transmission. No one in my shop had a clue, actually our master tech with many years of experience and is quite good at his job told me to just fill it there.

I'm not proud of it, so please don't come at me saying I don't know what I'm doing. I've done many trans drain and fills with a bolt at the top without issue. I will be removing and replacing the trans.

I just want everyone here to know and not make the same mistake I did.

Sources
http://www.volvoxc.com/forums/showt...0-Transmission-Nightmare-EVERYONE-PLEASE-READ!


https://www.thevolvoforums.com/thre...00-v70-se-i-think-they-killed-my-******.6737/

 

[jd_1138]

Bummer. You guys have a computer in the shop for reference? But don't worry, we all make mistakes. It's just a car and no one was hurt.

Also, you can go on ebay and buy PDF versions of factory repair manuals for like $5 or so that would've told you exactly how to service that ******. You guys must be a general repair shop that works on a lot of makes?

 

[SuperCheyenne]

I got huge respect for someone who "owns it' when they make a mistake.

 

[Sugarfryz]

Yeah we have a computer, and yeah we work on everything. I was reading it trying to figure it out and it said to use a funnel and a long tube to fill it through the dipstick, I didn't have that so I just took out the bolt. There was no warning about it, I'm not saying that makes it any better. Me just being a tech on a really busy day in the shop with a boss yelling at you to get cars done and just made a mistake. Lesson learned the hard way.

 

[Skin]

Hindsight is 20/20 but its always good to call a dealer and/or post on iATN.

I actually thought you were going to say someone drained the differential and filled the transmission. I've seen that more than once. Bad things happen.

 

[jrockford]

A smaller funnel can be made, but it takes forever. It's in a terrible location too, which makes checking the level a treat. Why did the customer bring the car to do you for service? Slipping, harsh shifts etc.? (If the transmission needs taken apart and if slipping was a symptom, a new valve body unit may be in order.)

Anyways, lesson learned. Congrats for admitting your mistake.

 

[Sugarfryz]

Tons of things I could should and would have done differently. Everything was perfect for this to happen, long frustrating day, not enough time to get the car done, wanted to go home. Most important thing now is taking care of the customer, getting him his car back. Just don't want this to happen to anyone else.

 

[Sugarfryz]

A smaller funnel can be made, but it takes forever. It's in a terrible location too, which makes checking the level a treat. Why did the customer bring the car to do you for service? Slipping, harsh shifts etc.? (If the transmission needs taken apart and if slipping was a symptom, a new valve body unit may be in order.)

Anyways, lesson learned. Congrats for admitting your mistake.

Honestly he came in for tires and asked requested it. Customers never been here before. Never mentioned any symptoms, I truly believe he was just trying to take care of his car.

 

[Sugarfryz]

Hindsight is 20/20 but its always good to call a dealer and/or post on iATN.

I actually thought you were going to say someone drained the differential and filled the transmission. I've seen that more than once. Bad things happen.

Yes I've seen that all the time

 

[mlum6969]

ouch. Usually when im servicing something really odd, i'll just run up to the computer to make sure i've got the right kind of fluid, where to fill it and how much while its draining. Also get a long flexible funnel. it makes filling all kinds of trannys easier.

 

[LXCam]

Bummer, that's blows when things like that happen. But it's all part of growing up and gaining experience. Are you sure that senior tech wasn't Fn with ya? I have a couple trans that are like that and the worst part is a complete refill is 14qts. I'd suggest you look into the IV bag trick. It's the only way to go on these sealed units.

 

[Sugarfryz]

Bummer, that's blows when things like that happen. But it's all part of growing up and gaining experience. Are you sure that senior tech wasn't Fn with ya? I have a couple trans that are like that and the worst part is a complete refill is 14qts. I'd suggest you look into the IV bag trick. It's the only way to go on these sealed units.

Yes he actually helped me remove it. We had no idea.

 

[LXCam]

Yes he actually helped me remove it. We had no idea.

Reminds me of the first time I went to put a high stall converter in a Nag1 behind a Hemi. I didn't realize the cooler lines where held in with spring clips, thought it was a flange/flare nut connection. So while unscrewing the adapter it gawled and cracked the case. So then in my mind it was a oh ****, but no biggie I'll just get a new bell housing and bolt it on. What I didn't know is that required a complete disassembly of the trans. **** by the time I was done there was 8ft of parts laid out on the bench and I didn't own any of the special tools to line up the clutch packs.


You have no idea how happy my ******* was when it worked after getting it all back together.

 

[loljesse]

This happened in my shop as well, if you remove the snap ring on the cap right behind it you can push the band back in place and thread the bolt back in.

 

[mudflap]

Dont beat yourself up...stuff happens.. Sounds like your a good honest Tech..that made a mistake..(who hasnt...?) and had a bad day...This world needs more like you.... And thanks for the heads up...I have worked on Volvos..but only big ones...but you probably saved somebody from making the same mistake...

 

[LXCam]

This happened in my shop as well, if you remove the snap ring on the cap right behind it you can push the band back in place and thread the bolt back in.

Ya live n learn, I've done a couple hundred since then. Haha

 

[VRStrickland]

As the owner and lead tech of a small general service shop that will take on almost any job, I have to say thanks for the heads up. Could have happens to me or one of my guys on any given day. Then I would have been fixing it after hours to keep from killing the schedule.


Sent from my iPhone using Tapatalk

 

[bdelmar2]

Its a terrible location for the strut.

There are other transmissions where the fill plug is right next to the strut/anchor making a mistake even more likely.

I don't know all the models right off hand, but its definitely something else to watch out for - even if you think you have the right fill plug.

 

[bigredjeepone]

Volvos and Saabs are two brands that I cringe when they come around. Had a guy bring an overheating Saab to me because it had been leaking coolant and I asked him what he did to stop it. Said there was a hole on the block that had coolant coming out and he figured a plug came out. Said he just packed it full of JB weld. I told him that was the weep hole for the water pump. He asked if I could fix it. I said sure . . . if I replace the engine block. $1500 block on a $2300 used car . . . another mechanic game him $500 for it because he happened to have a used engine from his wrecked Saab of the same generation.

It can be hard to maintain enough knowledge of multiple brands to not make mistakes. Doesn't make you a bad mechanic . . . makes you human. I try to stick with only Chrysler products now unless the maintenance is simple and straight forward.

 

[Tim C]

When I was working at the local Ford dealer I had two different escorts towed in from a jiffy lube across town about a month apart. They would drain the transmission from the plug on the bottom, then instead of removing the fill plug on the side that looks exactly like the drain plug, a 7/8" hex, they would pull a t45 torx bolt out that was about an inch or two from the fill plug. I honestly don't know how they didn't see the fill plug right there, even taking the same wrench they just used on the drain.

The t45 bolt is the pivot for the internal reverse shift fork actuator. The reverse lever would fall down into the case and wedge into the gears. I had to fully disassemble those transmissions to put it back together. The e clip holding the lever on the t45 pivot stud would be ruined but that was about all the damage done. Still a bunch of labor for a $0.10 e clip.

Sent from my XT1254 using Tapatalk

 

[Rico.]

I try to stick with only Chrysler products now unless the maintenance is simple and straight forward.

You're a very wise man..... Good to keep ones self busy.

 

[Sugarfryz]

Update, this morning we called the customer and just told him straight up what happened. He obviously wasn't thrilled, but definitely appreciated that we were honest. Gave him a ride to enterprise and got him a car for the day. we had a very busy schedule and many customers to take care of today, so we decided it would be best to call our usual transmission shop to see what he could do. Before my boss finished the sentence about what happened, the transmission guy knew what happened. That I mistaked it for a fill plug. All in all the customer took it well, ended up only costing us a few hundred bucks and a tow. The customer left happy and that's what truly matters.

I surely will be paying more attention to correct service procedures, when working on a car I am very unfamiliar with. Also someone up here suggested a flexible funnel and it's already ordered. Thanks for that.

Hopefully this helps someone out one day!! Don't make the same mistake I did!! One day hopefully this will be a funny story, and I can pass the knowledge onto someone else.

 

[shockwave]

That ***** definitely Volvo are a pain to work on had issue somewhat like this on cam seals leaking on s60 and you have to hold motor on transmission side

I can blame you on this one it's good to look at all data or Mitchell on procedures if you question any plugs a look can save time too

 

[jd_1138]

Update, this morning we called the customer and just told him straight up what happened. He obviously wasn't thrilled, but definitely appreciated that we were honest. Gave him a ride to enterprise and got him a car for the day. we had a very busy schedule and many customers to take care of today, so we decided it would be best to call our usual transmission shop to see what he could do. Before my boss finished the sentence about what happened, the transmission guy knew what happened. That I mistaked it for a fill plug. All in all the customer took it well, ended up only costing us a few hundred bucks and a tow. The customer left happy and that's what truly matters.

I surely will be paying more attention to correct service procedures, when working on a car I am very unfamiliar with. Also someone up here suggested a flexible funnel and it's already ordered. Thanks for that.

Hopefully this helps someone out one day!! Don't make the same mistake I did!! One day hopefully this will be a funny story, and I can pass the knowledge onto someone else.

I'm glad it worked out ok. Yeah you techs at general repair shops kinda have it hard. If you worked at a Volvo-only place, you would've known all the quirks and tricks of Volvos.

 

[jimmy-ray]

Tons of things I could should and would have done differently. Everything was perfect for this to happen, long frustrating day, not enough time to get the car done, wanted to go home. Most important thing now is taking care of the customer, getting him his car back. Just don't want this to happen to anyone else.

I hate those days.

You did the right thing though, first owning it. We run though the guys pretty quick who blame others or try to shy out of ******* up. You can never train them because they never make mistakes, big no no in our shop. Own it and learn from it. The shop foreman and i are both master techs so you arent fooling us anyway. Second spreading the word on what could be a honest mistake for another tech and third being honest and doing right by your customer. Ive never worked in general repair shops, i have worked in multi line bike shops where you basically work on anything that comes in the door. Every day was an adventure at those places lol, was fun though. Definitely tougher than the specialized stuff imo.

I fucked up recently, wasnt a huge one and ive been on a good streak, maybe only one other **** up in the last year and only one comeback. Anyway i was training a new guy, i was also tired and short on hours so rushing a bit on a big job to try to get it flagged. all no excuses but it sets the scenario. Anyway long story short i forgot to install some clamps on his oil cooler lines. They shot off ofcourse and got oil all over the vehicle. He noticed before he lost oil pressure or any damage occurred. So really it was just a mess for the wash guys to clean up. i put all new lines and better clamps on and did an oil change

As soon as i saw the lines i noticed the clamps were on but not over the *******. my heart sank, the customer was right next to me and i blurted out **** i didnt install the oil cooler clamps, god dammit. he wasnt happy but he understood **** happens, i thought no way in hell will that guy ever be back, hes been back a few times since though, really surprised me.

It will definitely be a funny story...cause all worked out. Many times I yell out in the shop, hey Rob remember that time I..always gets a laugh.

 

[Sugarfryz]

I hate those days.

You did the right thing though, first owning it. We run though the guys pretty quick who blame others or try to shy out of ******* up. You can never train them because they never make mistakes, big no no in our shop. Own it and learn from it. The shop foreman and i are both master techs so you arent fooling us anyway. Second spreading the word on what could be a honest mistake for another tech and third being honest and doing right by your customer. Ive never worked in general repair shops, i have worked in multi line bike shops where you basically work on anything that comes in the door. Every day was an adventure at those places lol, was fun though. Definitely tougher than the specialized stuff imo.

I fucked up recently, wasnt a huge one and ive been on a good streak, maybe only one other **** up in the last year and only one comeback. Anyway i was training a new guy, i was also tired and short on hours so rushing a bit on a big job to try to get it flagged. all no excuses but it sets the scenario. Anyway long story short i forgot to install some clamps on his oil cooler lines. They shot off ofcourse and got oil all over the vehicle. He noticed before he lost oil pressure or any damage occurred. So really it was just a mess for the wash guys to clean up. i put all new lines and better clamps on and did an oil change

As soon as i saw the lines i noticed the clamps were on but not over the *******. my heart sank, the customer was right next to me and i blurted out **** i didnt install the oil cooler clamps, god dammit. he wasnt happy but he understood **** happens, i thought no way in hell will that guy ever be back, hes been back a few times since though, really surprised me.

It will definitely be a funny story...cause all worked out. Many times I yell out in the shop, hey Rob remember that time I..always gets a laugh.

lol I got a funny story. Awhile ago I was training a new guy who had never touched a car before, just started school and was working part time mostly just cleaning. Anyways, I showed him how to do an oil change, letting him help in small ways. I got caught up and realized we didn't have a filter when I lowered the car down (it was a canister filter on the top). I started giving him a speech on how you Must always check the oil level after you change the oil. Got pulled off for a minute to knock something out for a customer. Came back, pretty much gave the speech again, got on the car and started it. I hear a lot of splashing, sure enough I left the damn oil filter off bc I was stopped in the middle and so focused on teaching him how to check the oil level lmao. My boss comes up behind us and says, "most people are nice enough to show you the right way, but few people are kind enough to show you the wrong way". Every time we get a new guy and I show them how to do something everyone in the shop makes fun of me.

 

[jimmy-ray]

Lol yeah thats a good one. Sounds like we share the same luck.

we have a good sense of humor at our shop. Our shop foreman not to long ago put the wrong gas tank on a bike and didnt notice it until he was done with the test ride. He rarely messes up and hes been doing it for like 30 years, so that was a good laugh. The bike was black and tank bright red lol. He was a little pissed at first but as soon as he blurted out, **** i put the wrong tank on, the whole shop burst out laughing so he couldnt help but laugh.

 

[jrockford]

That ***** definitely Volvo are a pain to work on had issue somewhat like this on cam seals leaking on s60 and you have to hold motor on transmission side.

Usually, the owner is to blame here. Turbo Volvo's have a sophisticated positive crankcase ventilation system that needs properly maintained, cleaned and/ or replaced. A neglected system combined with using cheap non synthetic oil will cause things to plug up. Excess pressures cause oil consumption, cam seal leaking and eventual failure.

 

[Strouty]

We have a teeny tiny funnel that has a hose for an extender. Yes it takes longer, but as you now know........

 

[-OSIS-]

You're a very wise man..... Good to keep ones self busy.

Muwhahahahhaha

 

[FlushingDIYer]

There are so many 00-04 Volvos with "questionable" transmissions for sale around here for a song. Considering that they're luxury vehicles that cost a hell of a lot more, I bet a lot of folks roll the dice on them. Only to find out it'll cost $3K+ to get it running again...

Volvos are pretty cool. If you can find one that hasn't been abused... My wife always wanted an older manual transmission Volvo and I finally found one for sale but man, getting that car back into tip top shape has taken a long time!

It's a shame that most, if not all, these "turn of the century Volvos" went down the tubes because of that bolt. For those who haven't seen the bolt... Look at it! It looks like a fill bolt!

Wording to stay away from in CL ads:

- "Only needs a transmission flush to be perfect!"
- "Only needs a software update from dealer, but I've been driving this way for years! LOL!"
- "Only have trouble between 1st and 2nd gears, other than that, the ******'s perfect!"

 

[Roberts210]

I got huge respect for someone who "owns it' when they make a mistake.

Absolutely!! You're a good guy in my book too.

 

[American Locomotive]

I recall that they later changed the design of the bolt head to something non standard, because so many people kept dropping their bands into the case.

 

[48548]

I recall that they later changed the design of the bolt head to something non standard, because so many people kept dropping their bands into the case.

I am not a mechanic by any means, but does that ever happen on tH400's(3l80, 4l80e)? Or 700r4s (4l60e)? Being a GM guy, I have never heard anything like that... on a GM product, but maybe nobody mentioned it.

 

[Strouty]

On the rear wheel drive autos, they don't have fancy bolts that look like fill plugs, just the dipstick tube.

 

[48548]

On the rear wheel drive autos, they don't have fancy bolts that look like fill plugs, just the dipstick tube.

That is true... I forgot about t transmissions on gm's(4t60e).... All of the GM's I have owned and even my wifes car were rear wheel drive and her car had a 6l80e... My bad. I just hate front wheel drive for some reason....

 

[Sugarfryz]

I recall that they later changed the design of the bolt head to something non standard, because so many people kept dropping their bands into the case.

Yeah after researching it they later changed it into a 5 sided bolt head. I don't think I'll live this one down for awhile