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940 AW71L transmission shifting and locking late

Wrong site. You want gcp.se


Your transmission is column D

filter p/n 1340021-3 and 2x gasket 3520330-6. (kit 271694-2)

Thanks a million!
 
These AW7x transmissions are fairly bulletproof and can put up with a fair bit of abuse and poor maintenance. With any luck, a transmission fluid change using a good synthetic ATF followed by adjusting the kickdown cable may be all that's really needed to make an improvement. Choose a good multi-purpose Dex/Merc ATF like Valvoline Maxlife Multi-Vehicle Dex VI/Merc LV that's reasonably backwards compatible with the original Aisin-Warner specified Dexron II or III. Dex II/III have a slightly thicker viscosity than a single grade Dexron VI ATF formulation.

With an unknown history, ideally you'd want to do a full drain, drop the trans pan to inspect/clean the sludge, inspect/clean/replace the trans filter and follow that by a re-fill then a gentle flush using 2-3 times the normal amount of fluid until it runs out as clear as new fluid. The amount of grey sludge in the filter, on the bottom of the pan and especially on the magnet(s) can give you a clue of the condition of the trans and how well it's been looked after. If you start early and drain the pan a few times over a period of a few days or a week then you can often get an extra litre or so of old fluid out before you drop the pan. If the pan was wall to wall sludge then consider doing another flush after a few months of driving.

Now having said all that, with 940s it's much easier said than done to drop the trans pan. I would highly recommend you at least start with a gentle flush at the transmission cooler return line on the rad to see if that will help. It's very easy to do and doesn't even require the car to be jacked up to drain the pan first, although that may do a slightly better job and cut down on the amount of new fluid used. Give it a few weeks of driving before deciding how much of an improvement that makes. Just to give you an idea of how difficult it can be to drop the pan, the filler tube on the side of the pan is often impossible to get off without damaging the pan. You'll typically be faced with two choices, either removing the top starter motor bolt so you can free the filler tube and drop the pan with the tube in place, or cut the filler tube in the middle of the lower straight section so you can drop the pan with a stub of tube attached (mend it later with a brass double compression fitting, commonly available for under $10). But even worse with the later 940s is an exhaust support bracket blocking access to the rear screws of the pan. The engineer who designed this bracket ought to have been shot. To remove that bracket you need to remove the large cross brace and the entire transmission mount assembly off the back of the trans (requires an impact wrench or use of an extra long breaker bar). Trying to bend the bracket out of the way can easily damage the pan (plus it's hard to bend it back with the bolt lined up again). Putting the pan back on can also be frought with difficulties such as fluid leaks if the pan flange is warped/damaged from prying or the bolts being overtightened, also if a cheap gasket is used or if gasket cement/sealer is used incorrectly.

The main reasons to drop the pan are to replace the transmission filter or replace the kickdown cable. These AW trans filters rarely need to be changed. As long as you do semi-regular transmision fluid changes every hundred Kmiles or so then you can often go the life of the vehicle without needing to replace or even clean it. Although it never hurts to replace the trans filter, it's not a wear item. It's rarely plugged, leastwise to the point of being an issue. Volvo no longer specifies a routine service interval for the AW trans filter (a service bulletin was issued). It's to be replaced if and when needed or when you have the pan off for other reasons. You can usually clean and re-use the existing filter as long as you're careful not to damage the gasket during removal. You can flush it with something like spray brake cleaner if needed. Service manuals call for replacing the filter mostly because it's simply not worth the mechanic's time trying to clean it properly and the gasket can easily get damaged if you're not careful.

Your kickdown cable probably needs to be checked/adjusted. You need to do it in a quiet area and preferably after a tranny flush so there's no (or at least minimal) grunge in the bottom of the kickdown chamber. The proper adjustment is to loosen the cable until you can hear the kickdown pawl on the end of the cable hit the bottom of the kickdown chamber down in the trans when you pluck and release the cable (a faint clunk). You then adjust the cable tighter until the clunk can no longer be heard then secure the lock nut. You can go a few adjuster faces tighter or looser to get a bit more aggressive or slightly smoother shifting. When you pluck and release the cable, if the cable doesn't snap back smoothly all the way then the cable needs replacing (the cable frays, the internal sheathing wears through, binding and rusting). Note that in manuals you may see the kickdown cable adjustment shown as a .001-.04 mm gap between the little ferrule and the end of the adjuster. This should be treated as the initial adjustment. It's also only appropriate for the original factory cable. With replacement cables that little ferrule is clamped on by the installer who may or may not clamp it exactly where the factory would.

In case you're interested in the approximate shift and lockup torque points, here's from the AW70/71/72 section of the Volvo 1991-1997 700/900 Pocket Data Booklet specifications:
1788126709379.png
Note that the lockup torque function is mechanical and speed related, not acceleration/load related. For your B230FK, your observed lockup happening at 100 km/hr is perfectly normal when you consider speedometer error, tire size/wear and the age of your trans.
 
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Thanks for the detailed information! The fact that the transmission might actually be locking at the proper speed is both encouraging and disappointing.. if it is indeed designed to kick in 'round 100km/h that is quite annoying as that is the most common cruising speed for me. Meaning it will constantly be engaging and disengaging while cruising..
 
Thanks for the detailed information! The fact that the transmission might actually be locking at the proper speed is both encouraging and disappointing.. if it is indeed designed to kick in 'round 100km/h that is quite annoying as that is the most common cruising speed for me. Meaning it will constantly be engaging and disengaging while cruising..
You'll soon get used to it and learn to drive at a more steady speed so the trans doesn't "hunt". The size of the gap between the lockup and unlock speeds can make for a minor nuisance "hunting" with rpm suddenly dropping or rising without regard to the gas pedal, acceleration or coasting. Your B230FK has the same gap of 2 km/hr between lockup and unlock as the more common B230F and B230FT engines, while the newer B230FD engine has a more relaxed gap of 4 km/hr.

For the past 35+ years my daily drivers have all had lockup torque. Each one had different lockup points: B230FD (73-77 km/hr), B230FT (98-96, same as yours) and a B234F (86-84). I do frequent driving at highway speeds, both on straight stretches at 100 km/hr and on mountain highways closer to 80 km/hr. No problem on the straight stretches with any of those lockup points.

By far the biggest nuisance with the lockup feature is maintaining lockup at highway speed going up a hill or accelerating in order to pass. You have to punch the pedal all the way to the floor to kick down out of lockup 4th, dropping all the way down to unlocked 3rd gear without passing through unlocked 4th. In that situation you're better off to use the overdrive switch than the gas pedal for downshifting as it's too easy to kick all the way down to 2nd gear. Hunting back and forth between unlocked 3rd and lockup 4th is not ideal. The more powerful the engine then the less you will need to kick down to accelerate or maintain speed going uphill. Your B230FK at 135 bhp is nicely in the middle between the low powered B230F/FD at 114/116 bhp and the higher powered B230FT/B234F at 165/153 bhp.
 
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I guess it is mostly useful on longer (multiple hour) trips, does make me wish it had cruise control though, then you could just set it right after it locks on long journeys with low traffic. As for the other nuisances, going up hills is famously not an issue in (most of) The Netherlands. (Could be for vacations to France or Switzerland though, time will tell.) Overtaking might be more so, but as it is at 100 km/h locked it sits at around 2300rpm, right where the turbo wants to do it's thing. Almost like they thought about it..

I also had a peek under the car to look for that exhaust bracket you mentioned.. and yeah.. it's there. Which I can say makes me less enthusiastic about dropping the pan. Guess I'll just start with the flush through the cooler line next weekend, I bought 16liters of Dexron II-D. Which I assumed would be enough for a decent flush.
 
I bought 16liters of Dexron II-D. Which I assumed would be enough for a decent flush.
Having recently flushed my 90 745 with AW70L, the total of Mobil 1 ATF required was 9 pts/L. You will note the color change when you have completed 100% of the flush.... the entire trans and converter need flushed to do the job properly. To be safe, 10L should be plenty. The IPD flush kit makes this job much simpler.... don't know if they still sell it but you can build your own with transmission cooler hose and the proper fittings.

As 945T states, if you are going into the pan, you might as well install the new throttle cable (unless yours was a low Km vehicle). Clean/replace the filter screen and take care with your gaskets! I included quite a bit of detail in my 745 build thread which might explain some details for you. Regarding the "thunk" you are supposed to hear when adjusting the cable.... while that worked on a previous build, I could never hear it on this wagon. I ended up adjusting the metal ferrule until it was touching the red rubber tip cover of the throttle cable.... then test driving and turning a couple flats until ideal shifting was achieved.

Good luck!
 
I guess it is mostly useful on longer (multiple hour) trips, does make me wish it had cruise control though, then you could just set it right after it locks on long journeys with low traffic. As for the other nuisances, going up hills is famously not an issue in (most of) The Netherlands. (Could be for vacations to France or Switzerland though, time will tell.) Overtaking might be more so, but as it is at 100 km/h locked it sits at around 2300rpm, right where the turbo wants to do it's thing. Almost like they thought about it..
You can add cruise control in with relative ease, all 940s (in the US at least) are prewired for it, it was a dealer option if you didn't have it from the factory. All you need is the different throttle drum, vacuum actuator, vacuum pump and associated lines, brake switch, computer, and turn signal stalk. You can take it from a parts car or find an ebay seller with the full kit and instructions.
 
Over the weekend I ended up flushing the ATF through the cooler line as advised, it's nice and red now (I did not drop the pan because of the exhaust bracket that 945T mentioned, that would make it a little too involved right now). Shifting seems better but not yet as it should be, 1-2 seems normal 2-3 and 3-4 still seem delayed but not as badly as before (under minor acceleration it now shifts around 3000rpm). I thought maybe the governor valve is sticking?

I tried some adjusting on the kickdown cable, but I can't give it more slack without the ferrule touching the rubber cap and there being physical slack in the cable between the ferrule and the throttle pulley. With the ferrule touching the cap I can still clearly feel the kickdown detent towards the end of travel on the throttle and when I pull it out by hand there is still some slight tension.

As stated before, the cable moves freely and doesn't stick or bind.
 
I tried some adjusting on the kickdown cable, but I can't give it more slack without the ferrule touching the rubber cap and there being physical slack in the cable between the ferrule and the throttle pulley. With the ferrule touching the cap I can still clearly feel the kickdown detent towards the end of travel on the throttle and when I pull it out by hand there is still some slight tension.

As stated before, the cable moves freely and doesn't stick or bind.
Glad to hear things are improved. Give it a few more weeks before passing final judgement as the new fluid continues to disloge whatever grunge is remaining.

Seems you weren't able to notice the faint clunk happening when adjusting the kickdown cable. Maybe try again in a quieter area. Start by checking that the cable is fully seated in the trans by pushing down firmly and making sure it doesn't wiggle. Back off the adjuster until the little ferrule is pressing into the rubber cap on the end of the cable sleeve. Now start plucking the cable, pulling the cable fully off to the side until it's at end of travel then releasing it. Listen closely down towards the bell housing and notice the sound when it stops. As you advance the adjuster, at some point you should start hearing the sound change and a faint clunk go away as the pawl on the end of the cable can no longer hit the bottom of the chamber. Refine the adjustment to the point that the clunk just goes away and secure in place.

If you still can't hear the clunk then adjust it as you have it now with the little ferrule almost touching the rubber end cap. If you end up needing to use the ferrule for adustment then it's best to check that it's correctly clamped on the cable. When the cable is disconnected from the spindle and tensioned with your fingers so there's no slack inside the cable there should be less than a 1.0 mm gap as per the service manuals. There is also a way you can measure how far the little ferrule should be from the end of the cable. Refer to the Volvo AW70/AW71/AW72 Specifications manual (TP31642/1) which can be found online in the OzVolvo archives. On page 36 you can find specifications for the amount of cable that should extend beyond the end of the cable sheath. There are different specifications for the nine different cables that were used with variants of these transmissions. Cables can be identified by either p/n or color markings as shown in the table. The ferrule should be clamped about 1.0 mm less than that distance to allow for proper adjustment. The adjustment procedure I've described is in the kickdown cable replacement section that starts on page 78. If you ever need to remove that ferrule, it can be carefully nipped off with small side cutters. A drop of JB-Weld can serve as a replacement ferrule so the cable can't slip down into the transmission when disconnected from the spindle (that's the ferrule's purpose, it's not there for adjustment). Note that the throttle spindle linkage rod needs to be correctly adjusted to make sure the spindle isn't fully up against its stop and that there's a little slack in the kickdown cable. There also needs to be a little slack in the gas pedal cable.
 
Just in case it helps you visualize what's happening inside the transmission:

The kickdown cable is connected to a spool inside the transmission which looks very much like the one up at the throttle body. It is buried in a slot next to the valve body so if you take the pan off you may need a flashlight to see it.

This spool controls a valve which tells the hydraulic logic inside the transmission how hard you are trying to accelerate. The more input it sees, the more it delays shifting.

I forget if it rotates clockwise or counterclockwise, but basically you are trying to adjust it so that when there is no throttle input, the spool is just barely not resting against its stop (i.e the transmission also is showing no throttle input, but there is no slack in the cable and it will see even small throttle inputs).

Check your kickdown cable to make sure the cable sheath has not backed out of the adjuster. I think we had someone in the last couple years with that same issue. Looked OK but the sheath had moved, effectively tightening the cable and making it very difficult or impossible to adjust correctly.

1788995770502.png
 
Even if I take the kickdown cable off the spool, pull it out all the way and release it I can't really hear it clunking or bottoming out, the ferrule just cushions against the rubber cap. I can't see any signs that the sheath has backed off the adjuster, would it be clear to tell if it had?
 
Upon further inspection, I think there might actually be sign that the sheath could in fact have backed off the adjuster:

P_20260910_122014_1.jpg

There is a mark on the sheath a couple of mm above the adjuster.
 
I think there might actually be sign that the sheath could in fact have backed off the adjuster:
My 92 Trans in my 90 745 has begun to pull the sheath out of the steel crumpled connector. Carefully center the sheath and PUSH with some force, see if you can get it back into the steel threaded retainer. Mine is movable but can be pushed back inside.... and function of lockdown is normal. When you begin adjusting, at most turn 2 wrench flats at a time and test drive. I could never hear the "thunk" by plucking the cable on this AW70L, but oddly I could hear it on the AW71 it replaced!
 
I tried to re-seat the sheath, but it really wouldn't budge. Couldn't pull it further out either. Putting vise grips on it seems like a bad idea so I'll just leave it as it is. Instead I ended up removing the ferrule and with it gone if I take the cable of the spool, pull it out and release it I can hear a metallic "clunck", I then adjusted it to the point the clunk went away. This is beyond the point where the ferrule previously was, which makes sense. I can still feel the kickdown detent at WOT.

I'll do a test-drive later today, no time right now.

I do plan on dropping the pan and replacing the filter at some point in the future, I'll add replacing the cable to that checklist.
 
Sounds good. My guess would then be it's a replacement cable and the installer either didn't accurately copy where the ferrule was on the original cable, crimped the ferrule on before adjusting kickdown or the cable isn't fully seated at the far end. A good time to drop the pan would be when you're replacing the rear transmission mount and it's easier to deal with that stupid exhaust bracket. As long as the cable retracts easily and there's no sign of fraying (such as the cable needing to be readjusted again) then I wouldn't be in any rush to replace the cable. It's a bit of a messy job.
 
Could be, the cable does seem to be in good condition otherwise. But it could also just be the sheath that came out of it's crimp slightly, effectively tightening the cable such that the ferrule was no longer in the right position.

I did a test drive with the current adjustment and under light acceleration it now shifts around 2700rpm, much better than where it was before I started this (it was closer to 4000rpm). But it still seems a little higher than I would expect, although I can't really find reliable data as to what is normal. (The only data I can find is listed at WOT.)

I can try some more tweaking, but really I think I need to put some km on it with the new fluid, see if there is further gradual improvement.

In the back of my mind I am a little worried though whether I maybe gave the cable too much slack inadvertently, I've read that this can damage the transmission.
 
These transmissions are all kinda old and tired at this point unfortunately. At a certain point you just kinda have to accept "good enough" and see how long it lasts.


I do plan on dropping the pan and replacing the filter at some point in the future, I'll add replacing the cable to that checklist.
FWIW the "filter" is a mesh screen. Fairly fine mesh but more to catch chunks than particles. I inspected mine but didn't bother changing it.

When I did a kickdown cable replacement it was a lot of messing around with a pickset and swearing to get the transmission end of the cable hooked up. The space is very tight and none of my pliers would fit. Had to use one pick to rotate the spool and one to finagle the cable end onto it. So just be prepared for that. Torque the pan bolts to spec and no tighter - they are small and fragile (beheaded one finding this out) and the pan can get bent too.

In the back of my mind I am a little worried though whether I maybe gave the cable too much slack inadvertently, I've read that this can damage the transmission.

The transmission squeezes the clutches together harder as kickdown cable input increases. If you stress it with the kickdown cable disconnected it can slip and wear the clutches. It seems unlikely that short term bad adjustment has made things worse than any previous owner did.
 
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