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REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Volvo S40 / V40 (from 1996 to 2000, the year of issue)

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Volvo S40 / V40
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S40 / V40
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Removing the gearshift and replacement parts



To change the details of the mechanism, do the following:

Removing the rods 1 of 2 scenes
Fig. 5.50. Removing the rods 1 of 2 scenes


a) Disconnect the shift rod and the rocker (Fig. 5.50):
- Remove the axle bolt and remove the shift rod;
- Machined parts anticorrosive composition.
Be careful with sealing rings and plastic sleeves;

Details of fastening of the gearshift, and a protective cover (indicated by arrows)
Fig. 5.51. Details of fastening of the gearshift, and a protective cover (indicated by arrows)


- Remove the protective cover from the tunnel (Fig. 5.51);
- Remove the bolts along with the rings;
- Remove the gear selection by turning it up to 90 ?�.
b) replace the rubber sealing element supports the shift lever:
- Pull down the entire casing of the mechanism;
- Extract the rubber fingers from the housing and remove the rubber element;
- Install the new rubber element in the casing and press in the rubber in his fingers;

Installation rubber fingers (shown by arrows)
Fig. 5.52. Installation rubber fingers (shown by arrows)


- Lift the cover and press in the rubber fingers (Fig. 5.52);

Removal of the bottom plate
Fig. 5.53. Removal of the bottom plate 1 - a nut, 2 - bottom plate; 3 - rubber element


c) remove the bottom plate 2 (Fig. 5.53):
- Remove the rubber element 3 from the plate of the gearshift;
- Remove the rubber element of the gearshift lever;

Removing lever lock
Fig. 5.54. Removing lever lock


d) Remove Gear lever lock (Fig. 5.54):
- Mark the position lock of 5th transfer;
- Remove the bolts and remove the bollards;
- Loosen the nut;
- Remove the plate and spring;

Removing the gear lever
Fig. 5.55. Removing the gear lever


d) Remove the gearshift lever from the central casing (Fig. 5.55):
- Unscrew the nut and remove the bolt;
- Remove the cover;
- Remove the gearshift lever;

Removing the gear lever bearing
Fig. 5.56. Removing the gear lever bearing


e) remove the bearings the gear lever (Fig. 5.56): plastic sleeves, rubber element and O-rings;

Removing the central bearing housing
Fig. 5.57. Removing the central bearing housing


g) Remove the bearing housing center (Fig. 5.57):
- Remove the bolt, and then remove the rubber grommet;
- Remove the casing from the central hub of the bearing;
- Remove the rubber grommet;
- Clean and check the parts, replace culled;
h) collect nodes in the reverse order of removal. Note the installation lock 5th gear: the installation, perform exactly the mark made during disassembly;
i) check the adjustment of the gear lever: Set the gearshift lever to position of 1st transfer; the gear lever must pull over to the top right Locking;

Adjusting the gearshift
Fig. 5.58. Adjusting the gearshift


- Set the length of the protruding portion of the lever of about 8 mm;
- Lightly press the lever to the right;
- Insert the bolt rod gear and tighten its moment of 24 Nm.




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