Gearbox removal & installation: Volvo S40, V40 M56 1.9 (B4204T, B4204T2, B4204T3, B4204T5)

🧭 Before you start

Fits: platform codes 2.0, 16V, LPT, |, TURBO

• Opens: clutch fluid, gearbox oil

Don't miss

• When moving the front axle do not over-stretch any hoses or wires

🔧 Engine codes this applies to

📐 20 workshop diagrams for B4204T

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

1. Refit all parts in the reverse order of removal
2. Gearbox support to gearbox:
3. Remove the battery with the battery holder
4. Loosen the clamp(s)
5. Remove the air hose between the turbo and the intercooler

6. Intermediate drive shaft support
7. Gearbox support centre nut:
8. Remove the gearbox support centre nut
9. Disconnect the selector mechanism from the gearbox
10. Remove the selector cable bracket from the gearbox
11. Disconnect the reversing light switch
12. Disconnect the earth cable from the gearbox
13. Unclip the clutch hydraulic line
14. Disconnect the clutch hydraulic line
15. Note: Plug the ends of the hydraulic lines
16. Remove the cable support bracket
17. Remove the three upper gearbox attaching bolts
18. Remove the starter motor bolt(s)
19. Raise the vehicle
20. Remove both front wheels
21. Remove the lower splash guard
22. Remove the front left splash guard
23. Drain the gearbox oil
24. Refit the drain plug
25. Disconnect the bracket
26. Remove the lower intercooler hose
27. Disconnect the brake hoses from the suspension strut
28. Disconnect the ABS wires from the suspension
29. Remove the upper bolt connecting the suspension strut and the wheel bearing housing
30. Loosen the lower bolt connecting the suspension strut and the wheel bearing housing
31. Note: When moving the front axle do not over-stretch any hoses or wires
32. Left-hand side
33. Remove the shock absorber lower bolt
34. Remove the drive shaft from the gearbox and attach to the suspension strut
35. Temporarily secure the wheel bearing housing to the suspension strut
36. Fit the special tool to support the engine
37. Remove the heat shield(s)
38. Remove the lower cross member bolts
39. Remove the lower cross member
40. Right-hand side
41. Remove the drive shaft bearing support bolts
42. Remove the shock absorber lower bolt
43. Disconnect the right-hand drive shaft from the gearbox
44. Secure the drive shaft to the vehicle
45. Temporarily secure the wheel bearing housing to the suspension strut
46. Remove the front gearbox mount
47. Remove the rear gearbox support
48. Disconnect the exhaust pipe mount
49. Lower the engine slightly
50. Support the gearbox
51. Remove the engine to gearbox bolts
52. Remove the gearbox

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