automatic transmission VOLVO 960 1982 Service Repair Manual

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Carburettor
Fuel pump
Clutch
Alternator ,­
Steering box
SU
Pierburg
Solex Pierburg
Bosch
AC- oelco
Sofabex
Fichtel & Sachs
Verto/Valeo
Bosch
Cam Gear
Zahnrad Fabrik (ZF)
~
'?' .'" ... .
.
---
" .. u.·.. ,
2
3
5
2
3
4
5
2
3
1
2
3
6 . Fina l drive ratio , part and seria l numbers
Located on rear axle .
7. Gearbox type des ig nation, part numbe r and
serial num ber
A. Manual : On bottom of gearbox .
B. Automatic:
BW 55,
AW 55/70171 /72: On LH side of gearbox.
AW3Q-43:
On RH side of gearbox.
8 . Body number pla te
Located above left head lamp.
780
70019401960 Specifications
Section
0 General
3
6
8
7 B 143980
9. Engine type des ig nation, serial number an d
part number
A. 024, o24T, o24TIC
Stamped on cylinder block, beneath vacuum pump.
B. B28
Located on plate in front of oil filter . On B 28 ElF en­
gines: a
decal on the right rear side of cylinder head
shows
last three digits of part number.
B280
Stamped on cylinder block. (Some models: decal)
Early
type : between cylinder banks, to rear.
Late type: front right side, between
inlet manifold and
water pump.
__ -G.-819, B 23
I
Stamped on left side of engine, behind distributor. Last
three digits of part number are shown
on transmission
gearcase.
O. B 200, B 230
Located on timing gearcase . Also stamped in left side of
cylinder block.
E. B6403
Decal
on timing gearcase. Also stamped in right side of
cylinder block, above water pump housing , between
timing gearcase and
manifold.
7
I
J

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780 1988
Fu se Circuit protected
No.
Rating
1 Main fuel pump ........................... 25 A
2
Central locking, system, hazard
warning
lights, rear fog lamps ................ 25 A
3 Dipped beams, rear
foglamps ............... 15 A
4 Brake
lights .................. ............. 15 A
5
Glove compartment lighting, clock, .......... 15 A
radio, engine compartment
lighting,
interior lighting, boot lighting,
electric aerial,
door courtesy
lights, vanity mirror
6
Electrically-heated front seats ............... 30 A
7
Electronic climate control (ECC) ............. 30 A
8
Electric window winders .................... 30 A
9
Seat belt reminder , direction ................ 15 A
indicators, air conditioning ,
electrically-heated front seats,
electric window winders
10 Electrically-heated rear window, ............. 30 A
electrically -heated rear-view
mirrors,
electric sun roof
11 Fuel pump (tank pi.Jmp), .................... 15 A
electrically-heated oxygen sensor
(Lambdasond)
(B 280 F)
12 Reversing lights, cruise control .. ............ 15 A
ignition on, automatic
transmission disengagement
13 Automatic idling controls ................... 15 A
70019401960 Specifications
Section
3 Electrical System
780 1988
Fu se Circuit protected
No. Rating
14 Power rear-view mirrors, .................... 15 A
cigarette
lighter, radio, heater fan,
air conditioning
15 Horn, windscreen wipers, windscreen ........ 25A
washers
16
17
LH main beam ............................ 15A
18 RH main beam , supplementary main beam ... 15 A
19 LH dipped beam ............. ............. 15A
20 RH dipped beam .......................... 15 A
21 LH parking lights, front and rear, ............ 15 A
number
plate light. Illumination of
ashtray, heater
controls, rear window
heater switch,
electric sunroof switch.
Illumination of instruments and
switches to
left of steering wheel
22 Illumination of seat belt locks ............... 15 A
RH parking lights, front and rear.
Illumination of storage pocket between
front seats.
Supplementary main beams .
23 Relay, power seats ................ .... .... 15 A
24 Power passenger seat .................. ... 30 A
25 Rear fog lamps (USA/CON) ................. 15 A
26 Power driver's seat ................... .. .. . 30 A
N.B. The system also includes a 10 A fuse for the ABS
(anti-lock
braking system) function. This is incorporated in
the transient surge protector at the pedal mounting.
133
·,f' "'I .", '" .",
'" .",
'" .",

70019401960 Specifications
Section
4 Power Transmission
Section 4 Power Transmission
Group 41 Clutch ...... . . . . . . . . . . . . . . . . . . . . . . . .. 138
Group 43
Manual transmission. . . . . . . . . . . . . . . . . .. 138
Group 43 Automatic transmission BW 55 . . . . . . . . . .
140 AW70171/72 ..... 142
AW 30-43 LE. . .. 146
ZF 4HP 22 ...... 149
Group 45
Universal joint. . . . . . . . . . . . . . . . . . . . . . . .. 151
Group 46 Rear axle ............................. 151
Group 41 Clutch
~
~" A ~
-\ . 'I Pressure plate, max out-of-true ............................ 0.2 mm (0.008 in) /\'~\ dl'?
Clutch fork free travel: , ~-
hydraulic ... ", ........................................ not adjustable ... ~mm
clutches w!th return spring. (A) ............... , ........... 1:3 mm (0.04-0.12 !n) (to fro!:),t) . ~ . IllJ
clutches without return sprlng ............................ 1 3 mm (0.04-0.12 In) (to rear)-~"
Clutch pedal travel ............ ........................... 160 mm (6.23 in)
• Spring (8) attached to pedal carrier as illustrated . 1
-if. B .. ru~'
Group 43 Gearbox
Manual gearbox
Reduction ratios:
1st gear
................................................... , .
2nd gear .
............................... ................... .
3rd gear
................................................... .
4th gear
......................... ........... ............... .
Overdrive
(M 47 : 5th gear) ................................... .
Reverse ..
.......................................... ........ .
• In some cases 3.71:1
Clearances
Clearance: reverse gear to gear selector ................ mm (in)
Axial clearance : input shaft ............................ mm (in)
countershaft.
........... ............... mm (in)
main shaft ............................ mm (in)
138 5th gear synchronizer hub .............. mm (in)
M46
4.03:1'
2.16 :1
1.37 :1
1
:1
0.79 :1
3 .
68:1
0.1-1 .0
(0.004-0.040)
0.01-0 .20
(0.0004-0.0079)
0.03 (0.0012)
to
preload of 0.05
(0.0019)
0.01-0 .
20
(0.0004-0 .0079)
I@ ' " '..,,~ W 7 '\. /_-
\ 136763
M47/M47 II
4 .03:1
2 .16 :1
1 .
37:1
1: 1
0 .83:1 (M 47 II: 0.82 :1)
3.68:1
0 .1-1.0
(0.004-0.098)
0 .
01-0.20
(0.0004-0 .0079)
0 .01-0.10
(0.0004-0 .0004)
0.01-0.20 (0.0004-0.0079)
0 .
01- 0.20
(0.0004-0.0079) (M 47)

70019401960 Specifications
Section 4 Power Transmission
Automat ic transmission BW 55
Make and type .. ............................................ .
Reduction ratios, 1 st gear ..
................. ................. .
2nd gear
................................... .
3rd gear
................... ................. .
Reverse
.................................... .
Torque converter, type ratio
................................ .. .
Lubricant.
........................... ....................... .
Fluid capacity .................... ........................... .
* ATF = automatic transmission fluid.
1.45:1 x Converter ratios
Borg
Wirner type
55
2.45 :1
1 : 1
2.21 : 1
1-approx 2:1
ATF, type G (or F)*
6.9
litres = 7.2 US qts (inc!. approx 2.5 litres = 2 .6
US qts in torque converter)
.~ Engine type Normal
stall speed*
rls (r/min)
Type
designation
Type plate
colour
....... WAOIIHUH
55 e:> ~~D ~~~I~ f'"OUTUTAUS
B28A 38.3 (2300) 029 SERIAl~ Light brown 131755 * At sea level.
Stall speed drops 2 rls (120 rpm) for each 1000 m increase in altitude .
Throttle cable setting
Distance between adjusting sleeve and stop
at idling .................................................. .
kick -down
........................ ........................ .
C leara nces
Oil pump: pump body -outer cog wheel ....................... .
arc segment -
large cog wheel ...................... .
axial clearance .................................... .
Clutch C2, brakes B1 and B2:
clearance between
clutch assembly pressure plate and
locking ..................................................... .
Input shaft, clutch C1 axial clearance .......................... .
Output shaft,
axial clearance ................................. .
Line pressure
Idling D .................................................... .
R ..................... .... ........................... .
Stall speed, D .................. .............. ...... ........ .
R .............................................. .
140 0.25-1
.0
mm 51 +1.6mm -0.6
0.07-0.30 mm
0.11-0 .50 mm
0.02-0.10 mm
0.3-1 .2 mm
0.20-0 .55 mm
0.20-0.55 mm
(0.001-0.040 in) (2 +0.63 in) (-0.024Ih)
(0.0027-0.118 in)
(0.004-0 .019 in)
(0.0008-0.004 in)
(0.0118-0 .0472 in)
(0.0078-0.0216 in)
(0.0078-0.0216 in)
0.53-0.63 MPa (75-90 psi)
0.74-0.91 MPa (105-129 psi)
1 .12 -1.37
MPa (159-195 psi)
1.54-1.96
MPa (219-279 psi)

70019401960 Specifications
Section
4 Power Transm ission
Automatic transmission AW 70171/72
13B 733
Engine Type Stall speed1 Volvo PIN Plate
rls (rpm) colour
B19E AW70 36
.7 (2200) 1208314 Silver
B23E AW71 35.0 (2100) 1208300 Orange
B23FT AW71 41.7
(2500)2) 1208334 Pink
B28A AW71 35.0 (2100) 1208360 Yellow
B28E AW71 35.0
(2100) 1208310 Black
B28F AW71 33.0
(2000) 1208248 Blue
B200K AW70 38.0
(2300) 1208332 Red
B200E AW70 35.0
(2100) 1208415 Green
B200F AW70 37.0 (2200) 1208659 Pink
B230A AW71 35.0 (2100) 1208304 Black
B230K AW71 -1986 42.0 (2500) 1208371
Pink
AW71
1987-42 .0 (2500) 1208417 Blue
B230F AW70 USNCDN
5-door, Japan, 33.0 (2000) 1208563 Dark brown
Australia 1988
AW70
USNCDN Japanl 33.0 (2000) 1208604 Pink
Australia
AW70 Others 33.0 (2000) 1208652 Red
I
B230FB AW71 33.0 (2000) 1208682 White
B234
FIG AW72 USNCDN 30 .0 (1800) 1208637 White
41.0 (2450) 1208666 Orange
Europe 30.0 (1 800) 1208638 Black
41.0 (2450) 12086673
) Green
B230FT AW71 45.0
(2700)2) 1208334 Pink
45.0 (2700)2)
1208661
Yellow
USNCDN/Japanl
Australia 1990 42.0
(2500)2) 1208642
Others 1990 42,0 (250W) 1208643
B280E AW71 Scandinavia 35
(2100) 12085333
) Green
AW71
Others 35 (2100) 1208534 Orange
B280F AW71 35 (2100) 1208532 Purple
AW71 35 (2100) 12085333
) Green
1) At sea level. Stall speed drops 2 rls (120 rpm) for each 1000 m increase in altitude. 2) Start-stop . 3) With kick-down inhibitor.
AW70/71 AW72
Reduction ratios, 1 st gear .................................... 2.45 :1 2.83:1
2nd gear .................... ....... ......... 1.45 :1 1.49:1 x Converter
3rd gear
..................................... 1:1 1 :1
ratios
Overdrive .
........ ............... ............ 0.69:1 0.73:1
Reverse
...... . .............................. 2 .21 :1 2.70:1
Torque converter :
reduction ratio
....... .......... ............. ............... 1-2:1 approx
Lubricant,
fluid capacity ....................................... see page 13
142

70019401960 Specifications
Section 4 Power Transmission
Automatic transmission AW 30-43 LE
Engine Type Notes Normal stall speed1
) Volvo PIN Decal rl s (r/min) colour
B6304 F AW3Q-43 35 (2100) 1208657 Black
1) At sea level. Stall speed drops 2 rls (120 r/min) for each 1 000 m (3300 feet) increase in altitude.
Reduction ratios, 1 st gear .................................... .
2nd gear .
.................... ' .............. .
3rd gear
.................................... .
4th gear .
........ ... ................... ..... .
Reverse
................................... . .
Torque converter, K-factor
.................................... .
diameter
............ ....................... .
reduction ratio .
............... ... ........... . 2.80
:1
1.53:1
1 :1
0.75:1 2 .
39:1
177
254
mm (10 in)
1 :
1-2.1:1
Lubricant, fluid capacity ...................................... .
type
........ ...................................... . approx
7.7
litre (8.1 US qt)
ATF-fluid Dexron II 0
Line Press ure
Engine Transmission Idling, position
D Idling, position R
Pressure MPa (psi)
Pressure MPa (psi)
B6304F AW3Q-43 0.41-0.45 (58-64) 0.61-0.67 (87-95)
Line Pressure at stall speed
r
Engine Transmission Idlin
g, position D Idling, position R
Pressure MPa (psi)
Pressure MPa (psi)
B6304F AW3Q-43 1.24-1.34 (176-191)
1.44-1.74 (205-248)
146

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Automatic transmission ZF
70019401960 Specifications
Section
4 Power Transmission
·~~7i6~3:9:91 SERI.AL NO. ~
1043010153 MODEL NO. ~
4HP-22 Q -~ IF Gelriebe GmbH ~ Saarbrilcken
Type and designation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ZF 4HP 22
Reduction ratios, 1 st gear .................................... .
2nd gear ................................... .
3rd gear .................... ................ .
4th gear (overdrive) .......................... .
Reverse
... ................................. .
Torque converter, type
....................................... .
reduction ratio
............................................ .
size
................. ........................... .
Lubricant
.......... ......................................... .
Oil fill quantity ............. ................................. .
Part numb er, stall speed
E ngine ,/ Volvo P/N °
B23E, B230E 1208375 1208502
1208391 1208662
B230ET 1208376 1208503
1208480 1208609
B
230 F Europe 1987-1208518 1208601 1208680
B 230 F Others 1208301 1208501
(not estates 1987)
B230FB 1208686
B 230 FT Europe 1987-88 1208517 1208610
D24 1208407 1208594
1208505
D24 T Europe 1208317 1208506 1208664
1208389 1208595
D 24 T USNCanada 1208365 1208507 1208665
Austria 1987-
1208390 1208596
D24
TIC 1208397 1208663
0) ZF and Volvo part numbers stamped on type designation plate. Last three digits of Volvo number also stamped on rear of gearbox .
024,024 TITle
2.73:1
1.56 :1
1:1
0.73:1
2.09:1
024
218K
Other e ngin es
2.48:1
1.48:1 x converter-
1:1 ratio
0.73:1
2.09:1
Other engin es
195K
1-approx 2.57 1-approx 2.3
260
mm
ATF oil type Dexron II D'
7.5 litres incl oil cooler and tubes (2.5 litres = 2.6 US
qts approx in torque converter)
Stall speed1
rls (rpm )
36.0 (2150)
33.3-41 .0 (2000-2450) 2
35.0 (2100)
35.0 (2100)
33.0 (2000)
33.3-41.0
(2000-2 45W
36.0 (2150)
31.7-39.0 (1900-2350)2
30.0-33.3 (1 800-200W
31.7-40.8 (1900-2450)2
I) At sea level. Stall speed drops 2 rls (120 rpm) for each 1000 ·metre (3300 feet) increase in altitude . 2) Start-stall.
149
I
III til' 'IIt til ' ,lit
lit
,lit til ,III