1982 VOLVO 940 Service Repair Manual

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Throttl e cable se tting
Distance between adjusting sleeve and cable stop
at idling .............................. mm 0.25-i.O
(in) (0. 001-0.040)
kick-down ............. .... mm 50.4-52.6 (1.99-2.1)
Sol e n o id va lv e
Resistan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 0
C lea ra n ces
Oil pump : pump body -outer gear wheel. ............... mm (in)
arc segment -large gear wheel ...................... mm (in)
axial clearance ................................ ..... mm (in)
Brake BO: clearance between clutch pressure plate
and lock ring ....................................... mm (in)
Clutch C2, brakes B1 and B2
clearance between clutch assembly pressure plate
and lock ring ....................................... mm (in)
Input shaft, clutch CO, axial clearance ........... ... ..... mm (in)
Output shaft, axial clearance ................. .......... mm (in)
B ra ke a nd clutch ring s
0.07-0.15
0 .
11-0.14
0 .
02-0.05
0.35-1.60
0.3--1.2
0 .
3--0.9
0.3--0 .9
Minimum permissible thickness ..................... .... mm (in) 2.1 mm
Line pr ess ure
Engine Tra nsmi ssion Press ure, 0
MPa (psi)
B
19/200 ElF AW70 0.35-0.44
(50--63)
B23E AW71 "
B230K -1986 AW71 "
B200K, B230F AW70 0.46-0.54 (65-77)
B23/230FT AW71 "
B 230 A
, B 230 FB AW71 "
B230K 1987-AW71 "
B28A, E, F AW71 "
B234 FIG AW72 0.44-0
.52 (63--74)
B280
AW71 0.51 (73)
S tall spee d press ure
Engine T
ra n smi ssion Press ure, 0
MPa (psi)
B
19/200 E AW70 1.00--1.20 (142-205)
B23E AW71 "
B230K -1986 AW71 "
B 200 K, B 230 F AW70 1.00--1.20 (142-205)
B23/230 FT AW71 "
B 230 A, B 230 FB AW71 "
B230K 1987-AW71 "
B28A, E, F AW71 "
B234 FIG AW72 1.12
-1.32 (159-188)
B280 AW71 1
.15 (164)
7001940 1960 Specifications
Section
4 Power Transmission
025-10mm
(0.003 -0 .006)
(0.0043--0 .0055)
(0.0008-0.0019)
(0.0138-0.0629)
(0.0118-0.0472)
(0.0118-0.0354)
(0.0118-0 .0354)
(0.083)
Pres sur e, R
MPa (psi)
0.50--0 .64 (71-91)
"
"
0.70--0.82 (106-117)
"
"
"
"
0.64-0.76 (91-109)
0 .
77 (110)
Press ure, R
MPa (psi)
1.37-1.70 (195-242) "
"
1.50--1.90 (213-270)
- -
"
"
"
1 .55-1.95 (220--277)
1 .
74 (247)
-
143
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70019401960 Specifications
Section
4 Power Transmission
Gove rnor pressure
3.54:1
Speed Pressure Speed
35 km/h 0
.11- 0.17 MPa 30 km/h
(22 mph) (15
.
6-24.2 psi) (19
mph)
55 km/h 0.17-0.23
MPa 55 km/h
(34 mph) (24
.
2-32.7) (34 mph)
110 km/h 0.38-0.50 MPa 108 km/h
(69 mph) (54
.1 -71.1 psi) (67
mph)
* Only for AW 72.
Shift speeds km/h (mph)
Eng in e Type Rear ax
le
ratio
B 19 E AW70
3.
91 :1
B23E AW71 3
.73:1
B23FT AW71 3.73:1
B28A AW71 3.54:1
B28E AW71 3.54:1
B28F AW7 1 3 .54 :1
B200 F AW70 4.10:1
B200E AW70 3.91 :1
B200 K AW70 3.91 :1
B230 A AW71 3.73:1
B230K -19 86 AW71
3.91 :1
B230 K 1987 - AW71
3.91 :1
B230 F2
) AW70 4.10:1
B 230 F 1989-3
) AW70 4.10:1
B230FT AW71 3.73:1
B
230 FT/GT 1990 AW71 3.73:1
B234F AW72 4.10:1
B280E AW71 3
.91 :1
B280 F AW71 3.73:1
Throttle
valve opening %
1) Kick-down .
Rear axle r ed uction ratio
3.73:1 3.91:1
P r
essure Speed Pressure
0.09- 0.15 MPa 29 km/h 0 .09-0.15 MPa
(12.8-21.3 psi) (18
mph) (12
.8-21.3)
0.16-0.22
MPa 53 km/h 0
.16-0.22 MPa
(22 .8-31 .3 psi) (33
mph) (22
.8-31.3 psi)
0.41-0 .
53 MPa 103 km/h 0.41-0.53 MPa
(58.3-8.4 psi) (64 mph) (58
.3-8.4 psi)
1
-2 2-3 3-4 4-3
62 (39) 103 (64) 109 (68)
38 (24)
63 (39)
105 (66) 135
(84)
39 (24)
63 (39)
105 (66) 111 (69) 39 (24)
73 (46) 123
(77) 123 (77) 28 (24)
67 (42) 112 (70) 119 (74)
29 (24)
67 (42) 112
(70) 119 (74) 29 (24)
57 (36)
101 (63) 110 (69)
37 (23)
67 (42) 113
(71) 114 (71) 40 (25)
67 (42) 113 (71) 114 (71) 40 (25)
71 (44) 119 (74) 118 (74)
27 (17)
66 (41)
111 (69) 112 (70) 35 (22)
55 (34) 98 (61) 107 (67)
35 (22)
63 (39)
106 (66) 108 (67)
37 (23)
57 (36) 99 (62) 110 (69)
36 (23)
63 (39) 105 (66) 111 (69) 39 (24)
65 (41) 112
(70) 130 (81) 27 (17)
56 (35) 102 (64) 116 (73) 33 (21)
60 (38) 105 (66) 116 (73 )
44 (28)
63 (39) 110 (69) 121 (76)
46 (29)
1001) 1001
) 75 0
2) USA/Canada estate cars -1988, 1989-: other markets . 3) USA/Canada/Japan! Australia 1989-.
Mechanical lock-up B230 K
Engages
at ......................... ... ........... km/h (mph) 85 (53)
Disengages at
.................................... km/h (mph) 83 (52)
* Applies to 1 208652 . 1 208604 77 (48), 73 (46). "Applies to 1208643.
144
B230F
78 (49)
76 (47)
Speed
27 km/h
(17 mph)
25 km/h *
(16 mph)
50 km/h
(31 mph)
45 km/h *
(28 mph)
98 km/h
(61 mph)
95 km/h *
(59 mph)
3-2
97 (61)
99 (62)
99 (62)
115 (72)
106 (66)
106 (66)
94 (59)
107 (67)
107 (67)
111 (69)
105 (66)
91 (57)
100 (62)
93 (58)
99 (62)
106 (66)
93 (58)
99 (62)
104 (65)
1001
)
B230F*
1989-
9230 FB
B234F
86 (54)
84 (53)
4.10:1
Pressure
0.09-0.15 MPa
(12.8-21.3 psi)
0 .
16-0.22 MPa
(22 .8 -
31.3 psi)
0.41-0.53
MPa
(58 .3-8.4 psi)
2-1
49 (31)
50 (31)
50 (31)
58 (36)
53 (33)
53 (33)
46 (29)
55 (34)
55 (34)
56 (35)
55 (34)
44 (28)
52 (32t
45 (28)
50 (31)
54 (34)
41 (26)
49 (31)
51 (32)
1001
)
B230 FT""
95 (59)
90 (56)

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Tightening torques
AW70, AW71, AW72
Converter casing -engine, M 10 ...................... .. ...... .
M12 .................. ......... .. . .
Drive plate
to torque converter ................... ............. .
Centre support to gear case:
tighten alternately
in steps to 7 Nm (5 ft Ib) ............... ... .
Pump cover to pump body .......................... ......... .
Pump assembly to gear case .............. ................... .
Plate above parking pawl ............................. ....... .
Converter casing gear case
4
x M 10 ................................ ................. .
2 x M 12 ..
.............. ................................. .
Rear extension housing to gear case
.......................... .
Valve bodies, for cam M 6 .................................... .
other bolts, M 5 ...
.............................. .
Oil strainer to lower valve body ........... .. ............ ...... .
Cover plate
to gear case, M 6 ................................ .
Valve body to gear case ..................... .......... ..... . .
Oil pan to gear case .......... ........ ..................... .. .
Coupling flange
to output shaW .................... ........... .
Blind plug for pressure test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
... .
Nut, oil cooler to gear case .
.................................. .
Speedometer drive
................... .................. ..... .
Nut, oil dipstick tube
........ ................................. .
Solenoid valve
.................... .. ........................ .
Drain plug
to oil pan ........................................ . .
• Use locking fluid PIN 1161 053-2 (1161 054-0) .
Nm
35-50
55-90
41-50
24-28
6-9
22-28
6-9
27-42
48-68
27-47
6-9
5-6
5-6
6-9
8-12
4-5
40-50
5-9
20-30
4-6
65-70
10-16
18-23
70019401960 Specif ications
Section
4 Power Transmission
ftlb
(25-36)
(40-65)
(30-36)
(17-20)
(4-6)
(16-20)
(4-6)
(20-30)
(35-49)
(20-34)
(4-6)
(3.5-4)
(3.5-4)
(4-6)
(6-9)
(3-3.5)
(30-36)
(3.5-6)
(14-22)
(3-4)
(47-51)
(7-12)
(13-17)
145
II
" II ., II ' . .. • • ..

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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7001940/.960 Specifications
Section 4 Power Transmission
Gear shift speeds, km /h (mph)
Mode selector in position ECONOMY (E). Sh ift selector in position D. Thro ttle opening in %
Engine Type Final drive 1-2 2- 3 3-4
3-4 4-3 3-2 2-1
ratio
(100+KD) (100+KD) (75) (100+KD)
(100+KD) (100+KD) (100+KD)
B6304F AW30--43 3.73:1 58 114
157 180 175 105 45
Mode selector in position SPORT (S). Sh ift selector in pos ition D. Thrott le open ing in %
Eng ine Type F
inal drive 1-2 2-3 3-4 3-4 4-3 3-2 2-1
ratio
(100+KD) (100+KD) (75) (100+KD) (100+KD)
(100+KD) (100+KD)
B6304F AW3D-43 3.73:1 58 114 177 180 175 105 45
Mode selector in position WINTER (W). Shift se lector in pos ition D. Thrott le open ing in %
Eng ine Type F
in al drive 1-2* 2-3* 3-4
3-4 4-3 3-2* 2
-1*
rat io (100+KD) (100+KD) (0-100)
(100+KD) (0-100)
(100+KD) (100+KD)
B6304F AW3D-43
3.73:1 50 100 50 170 40 70 20
* 1st and 2nd gear only used on kick-down .
Mechanica l lock-up (LOCK-UP), km/h (mph). Shift selector in pos ition D. Thrott le open ing in %
ECONOMY (E ) SPORT (S ) WINTER
(W)
Eng
ine Type Fin
al drive 2 3 4 2
3 4 3
ratio
(100+KD) (100+KD) (100+KD)
(100+KD) (100+KD) (100+KD) (15-98)
in out in out in out in out in out in out in out
B6304F AW3D-43 3.73:1
85 1 77 130 1123 180 1175 85 1 77 130 1123 180 1175 50 1 40
147
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III 'II III II III
,II
W · III

700/940/960 Specifications
Section
4 Powe r Transmission
Components
Contro l unit
-Volvo part number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3515646
ShiH position sensor
-Volvo part number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3515639
- Aisin Warner number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9903740153
Mode se lector
-Volvo part number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3515640
Solenoids :
ShiH solenoid
1 (51) and 2 (52)
-Volvo part number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3515643
- Aisin Warner number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9903740040
Resistance at +25°C (7rF). . . . . . . . .. ... . . . . . . . . .. . . . . .. . . . . .. 13±20
Lock-up so lenoid (SL)
-Volvo part number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3515644
- Aisin Warner number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9903740041
Resistance at +25°C (7rF) ............. " . . . . . . . . . . . . .. . . .. . . 13±20
Line pressur e sole noid (5TH)
-Volvo part number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3515645
- Aisin Warner number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9903457389
Resistance at +25°C (7rF). . . . . . . . . . . . . ... . .. ..... . . . . ... .. . . 13±20
Speed sensor
-Volvo part number ... ..-: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3515641
- Aisin Warner number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9903740151
Oil te mp eratur senso r
-Volvo part number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3515642
- Aisin Warner number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9903740154
Resistance at
+160°C (320°F)......... .. .... . ......... ....... .............. 20.7±2.90
-O°C (32°F) .. . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . .. . . .. . . . .. . . . . . . 2067±396 0
20670
Tightening torques
Nm (ft Ib)
Converter casing -engine, starter motor (2 pcs) ................ . 40.0 30 others .............. ............... . 48.0 35
Drive plate -torque converter ................................ . 30.0 22
Coupling flange to output shaft ............................... . 50.0 36
Plug, oil pan ................................................ . 20.0 14
148

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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
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lit
,lit til ,III

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70019401960 Specifications
Section
4 Power Transmiss ion
Thrott le cab le setting
Distance between adjusting sleeve and cable stop
at
idling ......................... ......................... .
kick-down .
.. , ............. ........................... . , .. .
0.25-1 .0 mm 51 +1 .6 mm - 0.6
Line pressure (at id le )
(Measure at plug indicated by arrow) MPa psi
(85-108)
(156-199) Idling , D .................................. 0.6-0.76
Idling , R .............................. .... 1.1-1.4
Line pressure at stall speed, ZF
Engine Position 0
MPa psi
B23E 0
.83-1 .03 118-147
B230E 0 .83-1 .03 118-147
B230F/FB 0 .95-1.15
135-164
B230ET 0.95-1.15 135-164
024 0.86-1.06 122-151
D24T 0.81-1 .01 115-144
Austria 1987-
USA/Canada
Othe rs 0 .99-1 .10 141-156
D24TIC 0 .96-1 .06 137-236
Gear shift speeds km/h (mph)
Engine Ratio
B23E 3.73 :1
B230E 3 .73:1
B23 0F 3.91 :1
USA/Canada
B230F 3 .91 :1
Eur ope 1987-
B23 0FB 3.91 :1
B23 0ET 3.91 :1
3 .
73:1
B230FT 3.73 :1
Europe 1987-
024 3.91 :1
D24T 3.91 :1
Austria 1987-
USA/Canada
Oth ers 3 .73:1
D24TI C 3.73 :1
Throttle valve opening %
* Kick-down ** Late type.
150
1-2 2-3
62 (39) 107 (67)
62 (39)
107 (67)
59 (37) 102 (64)
59 (37) 102 (64)
64
(40) 107 (67)
59 (37) 102 (64)
62 (69)
107 (67)
62 (39)
107 (67)
46 (29)
83 (52)
46 (29)
83 (52)
48
(30) 87 (54)
48
(30) 87 (54)
100 * 100*
Position R
MPa psi
1.51-1 .72 215-245
1.51-1.72 215-245
1.61-1 .
81 229--257
1.61-1 .
81 229--257
1 .57-1.76
223-250
1.48-1 .67 211-238
1 .
61- 1.82 229--259
1 .5
7-1.76 223-250
3-4 4-3 3-2
128 (80) 43 (27) 98 (61)
128
(80) 43 (27) 98 (61)
122
(76) 41 (26) 93 (58)
122 (76) 4
1 (26) 93 (58)
131 (82) 38 (24) 102 (64)
122 (76)
41 (26) 93
(58)
128
(80) 43 (27) 98 (61)
128
(80) 43 (27) 98 (61)
98 (61) 34 (21) 79 (49)
98 (61) 34 (21) 79 (49)
103 (64) 35 (22) 82 (51)
103 (64) 35 (22) 82 (51)
85
0 100
*
2-1
52 (33)
52 (33)
50 (31)
50 (31)
54 (34)
50 (31)
52 (33)
52 (33)
39 (24)
39 (24)
41 (26)
41 (26)
100 *
0.001-0.040 in
2 +0.063 in - 0.024
Mechanical lock-up
E ngages" D isengages"
96 (60) 94 (59)
85 (53) 83 (52)
78 (49) 76 (48)
85 (53) 83 (52)
85 (53) 83 (52)
92 (58) 90 (56)
97 (61) 95 (59)
97 (60) 95 (59)
76
(48) 74 (46)
73 (46) 71 (44)
87
(54) 85 (53)
87
(54) 85 (53)