Volvo Volvo XC90 2002-2014 AW55 Transmission Transmission Torque Specifications & Bolt Torque Values
Volvo Volvo XC90 2002-2014

Volvo Volvo XC90 2002-2014 AW55 Transmission Torque Specifications

Comprehensive torque specifications for the AW55 transmission bolts on the 2002-2014 Volvo XC90. Ensure proper installation and longevity with accurate technical details.

Updated

Important Information

Safety guidelines and reference information for proper torque application

Quick Reference Guide
ft-lbs → Nm
× 1.356
ft-lbs → kg-m
× 0.138
Nm → ft-lbs
× 0.738
in-lbs → ft-lbs
× 0.083

Common Torque Patterns

Star Pattern

Used for wheels and other circular bolt patterns

Star Pattern torque pattern diagram showing proper bolt tightening sequence
Cross Pattern

Used for gaskets and cover plates

Cross Pattern torque pattern diagram showing proper bolt tightening sequence
Sequential Pattern

Used for head bolts and other critical components

Sequential Pattern torque pattern diagram showing proper bolt tightening sequence

Common Mistakes to Avoid

Over-tightening

Exceeding the specified torque value can stretch or break fasteners, damage threads, or crack components.

Prevention:

Always use a calibrated torque wrench and follow specifications exactly.

Incorrect Torque Sequence

Tightening bolts in the wrong order can cause uneven pressure distribution and potential leaks or damage.

Prevention:

Follow the manufacturer's specified torque sequence pattern.

Dirty Threads

Dirt, rust, or old thread locker can affect torque readings and proper fastener tension.

Prevention:

Clean and inspect all threads before assembly. Use new thread locker if specified.

Reusing TTY Bolts

Torque-to-yield bolts are designed to stretch and must not be reused.

Prevention:

Always replace TTY bolts with new ones. They are single-use only.

Dry vs. Lubricated

Not accounting for whether torque specs are for dry or lubricated fasteners can lead to incorrect tension.

Prevention:

Check if specs are for dry or lubricated threads. Use specified lubricant when required.

Recommended Tools

Torque Wrench (1/4" Drive)

Range: 2-25 ft-lbs
Small fasteners, delicate components

Torque Wrench (3/8" Drive)

Range: 10-100 ft-lbs
Most common automotive fasteners

Torque Wrench (1/2" Drive)

Range: 30-250 ft-lbs
Large fasteners, wheels

Angle Gauge

Torque-to-yield (TTY) bolts

Torque Wrench Care

  • Calibrate annually or after 5,000 clicks
  • Store at lowest setting
  • Keep clean and lubricated

Search Specifications

Search by component name, bolt size, or description

Torque Calculator

Convert between different torque units

Transmission Mounting

This subsystem includes bolts that secure the AW55-51 transmission to the vehicle’s chassis, ensuring proper alignment and preventing movement during operation.

1

Transmission Mounting Bolts

M12 x 1.5
Torque Value
66 ft-lbs (90 N·m)
Important Notes
Ensure proper alignment before tightening. Incorrect torque can lead to misalignment, vibrations, or damage to the transmission.

Oil Pan

This subsystem includes bolts that secure the transmission oil pan to the transmission housing, ensuring a proper seal.

1

Transmission Oil Pan Bolts

M6 x 1.0
Torque Value
7 ft-lbs (10 N·m)
Important Notes
Use a crisscross pattern to avoid distortion or cracking of the oil pan.

Fluid Access

This subsystem includes plugs for draining and filling the transmission fluid, ensuring a proper seal.

1

Transmission Fluid Drain/Fill Plug

M16 x 1.5
Torque Value
30 ft-lbs (40 N·m)
Important Notes
Ensure the plug has a new sealing washer before installation.

Drive Axle

This subsystem includes bolts that connect the drive axles to the transmission output shafts, ensuring secure power transfer.

1

Drive Axle/Half Shaft Bolts

M12 x 1.5
Torque Value
66 ft-lbs (90 N·m)
Important Notes
Use a star pattern for even torque distribution.

Valve Body

This subsystem includes bolts that secure the valve body to the transmission case, ensuring proper hydraulic fluid control.

1

Transmission Valve Body Bolts

M6 x 1.0
Torque Value
7 ft-lbs (10 N·m)
Important Notes
Ensure the valve body is properly aligned before tightening.

Bellhousing

This subsystem includes bolts that secure the transmission to the engine’s bellhousing, ensuring proper alignment and connection.

1

Transmission Bellhousing Bolts

M12 x 1.5
Torque Value
59 ft-lbs (80 N·m)
Important Notes
Ensure proper alignment before tightening.

Torque Converter

This subsystem includes bolts that secure the torque converter to the engine’s flexplate, ensuring smooth power transfer.

1

Torque Converter Bolts

M8 x 1.25
Torque Value
30 ft-lbs (40 N·m)
Important Notes
Ensure the torque converter is properly seated before tightening.

Solenoid Assembly

This subsystem includes bolts that secure the solenoids within the transmission, ensuring proper gear shift control.

1

Transmission Solenoid Retaining Bolts

M6 x 1.0
Torque Value
7 ft-lbs (10 N·m)
Important Notes
Avoid overtightening to prevent damage to the solenoid housing.

Neutral Safety Switch

This subsystem includes the bolt that secures the neutral safety switch to the transmission housing, ensuring proper starting and gear selection.

1

Transmission Neutral Safety Switch Bolt

M6 x 1.0
Torque Value
7 ft-lbs (10 N·m)
Important Notes
Ensure the switch is properly aligned before tightening.

Troubleshooting Guide

Common issues, diagnostic steps, and prevention guidelines

Common Issues

Bolt stretching, stripped threads, uneven torque patterns

Loose Components

Symptoms:
  • Rattling or vibration noises
  • Visible movement in components
  • Uneven panel gaps
Solutions:
  • Clean threads and mounting surfaces
  • Replace damaged fasteners
  • Apply proper torque in sequence
  • Use thread locker if specified

Stripped Fasteners

Symptoms:
  • Unable to achieve proper torque
  • Fastener spins freely
  • Visible thread damage
Solutions:
  • Use thread repair kit if appropriate
  • Install thread insert (HeliCoil)
  • Replace component if threaded hole is damaged
  • Upgrade to higher grade fastener if recommended

Overtightened Components

Symptoms:
  • Cracked or deformed parts
  • Broken fasteners
  • Compressed gaskets or seals
Solutions:
  • Replace damaged components
  • Use new fasteners
  • Follow proper torque sequence
  • Verify correct torque specifications

Diagnostic Steps

Visual inspection, torque verification, thread assessment

1

Visual Inspection

Inspect the affected area for any visible signs of damage or wear

  • Check for cracks or deformation
  • Look for signs of excessive wear
  • Verify proper fastener installation
2

Torque Verification

Verify the torque applied to the fasteners

  • Check the torque wrench calibration
  • Verify the torque specification
  • Compare the applied torque to the specification
3

Thread Assessment

Assess the condition of the threads

  • Check for signs of thread damage
  • Verify the thread type and size
  • Check for proper thread engagement

Prevention Guidelines

Best practices, maintenance tips, tool care

Best Practices

  • Always follow the recommended torque specification
  • Use the correct type and size of fasteners
  • Verify the torque wrench calibration regularly

Maintenance Tips

  • Regularly inspect the affected area for signs of wear or damage
  • Replace damaged or worn-out components promptly
  • Keep the work area clean and organized

Tool Care

  • Regularly clean and maintain the torque wrench
  • Store the torque wrench in a dry and secure location
  • Verify the torque wrench calibration before each use

Frequently Asked Questions

Find answers to common questions about torque specifications

Q1

What are the consequences of incorrect torque application on the AW55 transmission?

Incorrect torque application can lead to fluid leaks, improper sealing, component failure, or even transmission damage. Over-tightening can strip threads or crack components, while under-tightening may result in loose fasteners and potential component separation.

Q2

How often should transmission pan bolts be checked for proper torque?

Transmission pan bolts should be checked during every transmission service interval, typically every 30,000 to 60,000 miles, or whenever the transmission fluid is replaced. Always refer to your vehicle's specific maintenance schedule for precise intervals.

Q3

Can I reuse the transmission pan gasket after removing the pan?

No, the transmission pan gasket should not be reused. It should be replaced with a new gasket to ensure proper sealing and prevent leaks. Reusing an old gasket can compromise the seal and lead to fluid loss.

Environmental Considerations

Temperature, humidity, and seasonal effects on torque specifications

Temperature Effects

Includes: High Heat, Cold Weather, Thermal Cycling

Temperature can significantly impact torque values and fastener behavior

Cold Weather

Effects:
  • Increased material brittleness
  • Higher torque required due to thread contraction
  • Reduced thread lubricant effectiveness
Recommendations:
  • Allow components to warm to room temperature when possible
  • Consider using winter-grade thread lubricants
  • Check torque values more frequently during winter months

Hot Weather

Effects:
  • Thermal expansion of components
  • Decreased friction in threads
  • Accelerated lubricant breakdown
Recommendations:
  • Check torque when components are at normal operating temperature
  • Use temperature-resistant thread lockers
  • Consider re-torquing after heat cycles

Humidity and Corrosion

Covers: Rust Prevention, Salt Exposure, Moisture Control

Moisture and corrosion can affect fastener integrity and torque values

High Humidity

Effects:
  • Accelerated corrosion formation
  • Reduced friction coefficient
  • Potential thread seizing
Prevention:
  • Use corrosion-resistant fasteners
  • Apply appropriate anti-seize compounds
  • Maintain proper protective coatings

Salt Exposure

Effects:
  • Rapid corrosion development
  • Thread damage
  • Seized fasteners
Prevention:
  • Regular underbody washing
  • Use of sacrificial anodes where appropriate
  • Application of protective coatings

Seasonal Maintenance

Spring, Summer, Fall, and Winter maintenance schedules

Spring

  • Inspect for winter damage
  • Clean and protect exposed fasteners
  • Check torque on critical components

Summer

  • Monitor heat-affected components
  • Check expansion-related loosening
  • Inspect cooling system mounts

Fall

  • Prepare for winter conditions
  • Apply corrosion protection
  • Verify all fasteners are properly torqued

Winter

  • More frequent inspection of critical fasteners
  • Check for salt damage
  • Monitor suspension component torque

Related Resources

Tools, service procedures, and technical bulletins

Recommended Tools

Torque Wrench

A precision tool used to apply specific torque values to bolts.

  • Adjustable torque settings
  • Durable construction
Learn more

Socket Set

A set of sockets in various sizes for bolt tightening.

  • Includes metric sizes
  • Compatible with torque wrench
Learn more

Thread Locker

A chemical compound used to secure bolts in place.

  • Prevents loosening due to vibration
  • Medium strength formula
Learn more
Service Procedures

AW55 Transmission Bolt Torque Application

Detailed procedure for applying correct torque to AW55 transmission bolts.

  • Identify the specific bolts requiring torque application.
  • Clean the bolt threads and apply thread locker if recommended.
  • Set the torque wrench to the specified torque value (e.g., 35 Nm for transmission pan bolts).
  • Tighten the bolts in a crisscross pattern to ensure even pressure.
  • Verify the torque values with a second pass if necessary.
View full procedure
Technical Service Bulletins

AW55 Transmission Bolt Loosening Issue

2010-05-15

Bulletin addressing reports of transmission bolts loosening over time.

2002-2008 Volvo XC90

Resolution: Ensure proper torque application and use thread locker on all transmission bolts.

AW55 Transmission Fluid Leakage

2012-09-20

Bulletin addressing fluid leakage caused by improperly torqued transmission pan bolts.

2005-2012 Volvo XC90

Resolution: Re-torque the transmission pan bolts to the manufacturer's specifications and inspect for leaks.

About the Author

Expert automotive knowledge and experience

Alan Montanye - Automotive Technical Specialist
ASE

Alan Montanye

Automotive Technical Specialist

ASE Master Certified Technician with over a decade of hands-on experience in automotive repair and diagnostics.

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