Volvo S60 T20 automatic, 2002 with 115,000 miles covered. Service history unknown.


I have an issue with the transmission, namely that I have an error message stating 'Transmission service required' with an accompanying orange engine service light.
The transmission is fine for about 10 or fifteen miles then reverts to a 'dash' instead of the gear reading 'D'rive, '4'fourth, 'N'eutral etc. If in 'D'rive this generally leaves me in fourth gear as it seems to usually downshift to fourth from Drive, but not always. When I come to a stop at red lights or whatever the transmission will slip until I got up to a suitable speed in fourth gear. I can manually change through the box to alleviate this slipping. If I stop and turn off for a few minutes the transmission will work correctly for another few minutes. A longer stop extends the transmission's correct function to at least ten or fifteen miles. When the software is giving me the correct reading e.g. 'D' for drive the transmission seems to be working very well , being quiet, shifting effortlessly, good kick-down etc.
Last Friday I had booked into my local Volvo appointed dealer. I duly arrived at the appointed time waited more than two hours before they gave my poor little car a brief once over, no diagnostics were employed and then they blithely informed me that they could replace the transmission fluid at a cost of € 225 and if that didn't work they would have to replace the gearbox. This startling analysis was arrived at without even downloading any error codes or asking me about what symptoms were evident. That dealer won't be seeing me ever again.



An online Volvo expert gave me this advice :
' Hello! What you are describing sounds like a network communication failure. The TCM transmission control module is on a digital communication network wit several other modules in the car. When the dashboard display goes to a dash, this is usually a sign of this. Without communication to and from the engine, ABS, instrument cluster, etc, the TCM and Central Electronic Module go into a limited function mode. If you read the ECM and TCM codes and find one in the TCM complaining of no network communication, this would be confirmed. There may be a bad connection where the TCM plugs in inside the black box near the right front wing. Unfortunately you need a special tool to operate the violet plastic sliding cal latched that retain the TCM in the box. If you remove the TCM and clean the terminals with electrical contact cleaner, and work the latch back and forth several times to scrape off the oxidation, function will be restored at least temporarily. Another possibility is a bad PNP switch on the trans. This is the switch that tells the TCM what gear has been selected by the driver. This would also show up as a code in the TCM when the codes are read out. '



I'm new to Volvo's (ex Mercedes man), does anyone have any thoughts or experience of this matter, as a little help and guidance would be appreciated.
Gerry
Wexford
Ireland

 

I then took it to an auto trannie expert who checked the fault codes and determined that it is an internal error. Namely (lock-up and service clutch low pressure). It's an 'aisin Borg and Warner' converter and he says it needs to be re-built at € 1600 plus € 400 for removal and re-fit.
Should I try a transmission re-fill, though expensive it would be better than writing off the car. It seems a bit daft the transmission that is, in that for the last 20 years I have driven automatic Mercs, clocking up 250,000 miles on several cars with no transmission problems.
Any ideas welcome
Gerry
Wexford
Ireland

 

I am new to Volvos having had 20 years of driving automatic Mercs (190, 190E, 350slc, E 230) none of which gave any transmission problems with a cumulative total of about 800,000 miles. I am a bit disappointed that having done some research on the S60 before buying, that no review site warned of the soft auto box. Further disappointment in that the Toyota owned 'Aisin Warner transmission' is so poor, whatever happened to the 'best built cars etc.' and Japanese quality control.
However I like this Volvo S60 and will give it another chance, I'm obstinate like that. Having looked through most forums, looked at the likes of 'Howard's Volvo maintenance' and even tried 'Justanswer' (rip off), and talked to a transmission repair guy, this is what I've decided to do.
In that the box seems to be working well until it gets hot, I am going to get a reconditioned torque converter, and a new B4 servo cover. Then I'm going to get my local repair shop to remove the box fit the new parts and replace the ATF with a recommend synthetic. The cost of this I reckon will be about € 350 on parts and € 400 on workshop fees. I'm wondering while the box is out should I replace any solenoids (part numbers ?) and is there a gasket set or such like. Any thoughts or advice would be most welcome.



The only viable alternative would be to get a second hand transmission at about € 500 , but only after fitting this would risk the same or possibly worse problems.


Gerry
Wexford

 

Is there anyone out there ?

 

Well after exhaustive research in the forums, Sonnax.com (USA) etc. I have decided to proceed in this order with my dodgy transmission. Any comments, tips, personal experiences etc. are most welcome.
In view of the fact that my trannie works well (once warm), but starts to play-up when hot or if I give it the wellie (3000 rpm and above), and the fault codes indicate low pressure in the lock-up and service clutches, this seems to be a sensible route to follow.
Firstly I'll take it to my local garage (a small quality outfit who do service and repairs) and get them to replace the ATF with a recommended synthetic (maybe Mobil, Toyota or even Volvo, depends on price).
At the same time I'd like them to replace the B4 servo cover as this appears to be a faulty part, given the model and age 2002 of this car. Does anyone know where is the best place to get a B4 servo cover in Ireland or the UK, and possibly the transmission solenoids (Sonnax) but more of that later ? This I suppose will cost me in the region of € 200 → € 300 but if it gets me out of the mire it's money well spent.
Then with a bit of luck I'll be sucking diesel, well hope not in that it's a petrol but you know what I mean.
If this doesn't sort me out I'll be getting despondent and a little angry so the next step would be the transmission solenoids and since the sub-frame etc. has to come off possibly a re-con torque converter as well. Sigh, another € 800 down the tube. Also various rubber suspension mounts need replacement. Starting to look a bit uneconomical at this juncture. Maybe I'll just go back to my erstwhile beloved Mercs, but I do like the the S60 T20 and if I spend this cash will it remain a garage Queen with umpteen other expensive faults and failures.



Gerry
Wexford

 

Is this forum dead or is it just me you don't like ?

 

dead for answers..look over and ask at swedespeed.com..

 

Thanks for the contact, much appreciated.

I find these forums very good and active :
http://www.matthewsvolvosite.com/forums/index.php
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regards
Gerry
Wexford
IRELAND