1982 VOLVO 940 gearbox

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 -------------------------------------------------------------
Oil pressure, overdrive
Direct drive .............................................. .. . .
Overdr ive engaged
D 24 TmC, with asbestos-free friction linings ................... .
Gasoline turbo with asbestos-free friction linings ................ .
Gasoline turbo with old type friction linings ..................... .
Remaining, with
old type friction linings ........................ .
All ......................................................... .
Early type friction linings (1987) ............................... .
Asbestos -
free linings (1988-) ................................. .
( Tightening torque data
8ellhousing ................................................. .
Gear
lever mounting bracket bolts ............................. .
Gearbox cover
bolts ......................................... .
Countershaft, M 47
.......................................... .
Drive
flange nuts, M 47, M 16 ................................. .
M20 ...................................... .
M46 ...................................... .
Rear cover, M 46
............................................ .
Rear cover,
5th gear synchronization, M 47 II ................... .
Oil drain plugs .............................................. .
Lubricant
/ Type ....................................................... .
Capacity, M46,
early type, -1990 Litres (US qts) ............... .
late type, 1991-Litres (US qts) ................. .
M
47, early type, Litres (US qts) ...................... .
late type, Litres (US qts) ....................... .
• On complaints about gearbox noise, Volvo Thermo oil (PIN 1161 243-9) can be used. Volvo Thermo oil is only recommended for vehicles driven in areas where
ambient temperature seldom drops below -10°C (+14°F), or high mileage vehicles such as taxis. NOTE: Do not mix oil types.
Section 4 Power Transmission
approx 0.15 MPa (21.3 psi)
Type J
2.8--3.1 MPa (400-440 psi)
2.8--3.1 MPa (400-440 psi)
3.9-4.2
MPa (555-600 psi)
3.7-4.0
MPa (525-570 psi)
Type P
2.8--3.1 MPa (400-440 psi)
Type J/P-hybrid
3.7-4.0 MPa (526-569 psi)
2.7-29
MPa (384-412 psi)
Nm ft Ib
35-50 (25-35)
40 (30)
15-25 (10-20)
35-45 (25-30)
70-90 (50-65)
90-110
(65-80)
165-180
(120-130)
12-18 (9-13)
120 (87)
27-40 (20-29)
Litres U S qts
ATF* type F or G
2 .3 (2.4)
2.6 (2.7)
1.3 (1.4)
1.6 (1.7)
139
I
.til I! II I! II I! ·1 , I!

Regulator press ure
Final drive ratio 3.31:1
At 30 km/h (19 mph) ........................................ .
At 60 km/h (38 mph) ....... ................................. .
At 110 km/h (69 mph) ....................................... .
Gea r ch anging speeds
Limits for kick -down shift points , km/h (mph)
1-2 ........................................................ .
2 - 3
......... ............................................... .
3-2 ............................. ........................... .
3-1 ...................................................... .. .
Tran smiss io n brake an d clut ch pla tes
Min permissible thickness .................................. .. .
( Tig ht enin g to rq ue da ta
Drive plate - torque converter ....................... ......... .
Torque converter casing -engine, M
10 ....................... .
M12 ..................... ..
Center support -transmission housing
tighten
alternately in steps of 7 Nm (5 ft Ib) ................... .
Pump cover -pump housing
.................. ............... .
Pump -transmission housing ...
............................. .
Plate above parking detent ............................ .... ... .
Torque converter casing -transmission housing
4 x M
10 .................................................. .
2xM12 ....... . r. ............... ......................... .
Rear housing -transmission housing .......................... .
Valve bodies -transmission casing ........................... .
Valve bodies, for cam, M 6 ................................... .
Valve bodies, other bolis, M 5 ................................. .
Cover
plate - gearbox housing ............................... .
Strainer -
lower valve housing M 6 ......................... ... .
Oil pan - transmission housing (yellow gasket) ................. .
Oil pan -transmission housing (blue gasket) ................... .
Drive
plate - output shaft .... ............................. ... .
Blind plug, for pressure test ....................... .. ......... .
* Seal with Locking fluid 1 161 053-2 (1 161 054-2) .
0.10-0.13 MPa
0.14-0.18 MPa
0.30-0.36 MPa
71 (44)
128
(80)
117 (73)
approx.
60 (38)
2.1 mm
Nm
41-50
35-50 55-90
24-28
6-9
22-28
6-9
Nm
26-40
47 -60
26-40
8-12
6-9
5-6
5-6
6-9
6-10
8-12
40-50·
9-12
70019401960 Specifications
Section 4 Power Transmission
(14-18 psi)
(20-26 psi)
(43-51 psi)
(0.083 in)
ftlb
(30-37)
(26-37)
(41-66)
(18-21 )
(4-6)
(16-21)
(4-6)
ftlb
(19-29)
(35-44)
(19-29)
(7-9)
(4-6)
(3-4)
(4-6)
(3-4)
(4-8)
(7-9)
(29-37)
(6-9)
141
'", "" '", "" ·11"
"" ·11.· 1111 ,11'

(
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