1986-1993 Volvo 240 Manual Transmission Replacement

Attributed iFixit repair guide for 1986-1993 Volvo 240.

iFixit Library 1986-1993 Volvo 240 Moderate No estimate Guide 7633

Licensed iFixit integration

This attributed iFixit guide is displayed through Fixonic's recorded commercial API permission. iFixit remains the independent source and author of the procedure.

Step 1

Repair step

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Lift the bottom of the shift boot to expose the shifting socket.
Use snap ring pliers to remove the circlip securing the shifter to its socket.

Step 2

Repair step

⌕

Remove the set screw securing the shifter yoke pin. This assembly can be located on the underside of the car, above the transmission and directly below the shift lever.
Grab the head of the shifter yoke pin with your hands or pliers and pull it out.
If the pin won't readily come free, try jiggling the shifter while you pull the pin.

Step 3

Repair step

⌕

Remove the shift lever by pulling it straight up.
Remove the plastic bushing in the bottom of the shifter socket.

Step 4

Repair step

⌕

Remove the 6 nuts and bolts securing the drive shaft to the guibo and the back side of the transmission.
Only four nuts and bolts are visible and marked in the first picture. The others are hidden on the other side of the drive shaft.
Take note of how the bolts, washers and guibo are positioned. They are required to go back in the same way.

Step 5

Repair step

⌕

Support the drive shaft with a jack, jack stand, or other prop so it does not fall and get damaged or injure someone when the support is removed.
Remove the 4 bolts securing the drive shaft support.
Do not lose the washers on the 4 bolts or the spring and washer on the opposite side of the support.
Slowly lower the drive shaft and separate it from the transmission.
Remove the guibo and metal separator plate.
The separator may not come out with drive line and will be in the transmission.

Step 6

Repair step

⌕

Remove the bolts securing the transmission to the engine and to the starter.
Support the transmission so it doesn't fall when the final support is removed.
Generally, a jack is recommended for this.
Remove the four bolts securing the transmission support to the chassis.
Lower the transmission out of the car.
In many instances, the transmission may not come free from the engine once the bolts are removed. If this is the case, a pry bar is recommended to help separate the two.