I am working on an 05 S60 2.5T AWD with 160K miles on it. It's a constant WIP with me identifying the next worn component and planning the next rebuild. The current issue is teenager induced. I am now hearing a clunk from the trans when coming off the gas and decelerating. The fun started after my teenage daughter thought she was in drive, she was in heutral, she revved the engine, freaked and slammed it into reverse. I am fairly certain that moved up the rebuild date for the trans a good bit. The trans is shifting fine both up and down the gears. It shifts harder into reverse but doesn't bang. It is due for a fluid change but I am fairly certain that I am looking at hardware damage that fluid won't fix. Amazon has an order on the way of the required 3309 fluid regardless. There is also some extra slop in the parking pawl now that wasn't present prior to the big bang. So to the question.

Since I likely need a rebuild, is there a way to beef up this trans so that it can handle the unrestricted torque of the engine in 1st and 2nd with some mild mods (exhaust, down pipe, intercooler upgrade and retune planned assuming the car survives the teen years). Or, has volvo improved these 5 speeds from the factory such that buying a dealer sourced trans will cover the bases.

I do not have the tools or clean room to successfully rebuild this trans and given the hit I know it's taken I would prefer a remanufactured or new unit to put in its place.

Gotta love the learning experience that comes with a teen driver and a learners permit.

 

did you check the motor mounts/torque rods? You may want to drop the pan when doing the drain&fill to inspect for any clutch bits...

 

I wish it was the torque rod or a motor mount. I just replaced them all during a front end rebuild and they still look brand spanking new.