I have a '96 960 with a shot transmission. I am looking to replace with used, but I can't find any information about interchangeablity. Do I have to find a transmission from a '95-'98, or can I use earlier? I've found a lot of conflicting information. Any help is much appreciated!

Dear asg1986,

Hope you're well. If your 960 was marketed in North America, it came with an Aisin-Warner 30-40 (AW30-40) transmission.

According to Volvo VADIS - the now-superseded Volvo Dealer parts and service database - the AW30-40 was used in 960s (1992-1997) and the S/V 90 (1997-1998).

As in all things Volvo, there are sure to be a couple of exceptions.

I'd seek a tranny from the latest model year, especially if a low-miles unit can be found. I'd be sure to take the transmission computer, along with the actual transmission.

When shopping for a used transmission, first check the fluid (ATF). If it is other than rich, clear, rosy red, move on. Milky/cloudy fluid means water has contaminated the ATF: move on. Brown/black fluid bespeaks neglect: move on!! An orange tinge evidences over-heating: move on!!!

AW trannies are pretty durable, so you should be able to find one in a salvage yard. Thus, do not seek a re-built unit. That is a huuuuuuuge waste of money.

If your car's tranny failed and the fluid is milky/cloudy, the in-radiator ATF cooler has failed, allowing coolant to contaminate the ATF. Replace the radiator before replacing the tranny. There's no way to fix a failed in-radiator ATF cooler: radiator replacement is required.

Because a cooling system is pressurized, coolant is forced into the ATF, as it passes through the in-radiator cooler. Water in the coolant - when it reaches the tranny's innards - dissolves the adhesive, that bonds clutch-pack facings to the steel substrate. Clutch pack fibers, freed when the adhesive dissolves, clog fluidways. Further, water becomes steam at normal transmission operating temperatures. Water does not lubricate.

Once you find a good salvage yard tranny, flush it with Wal-Mart fluid. Drive 1,000 miles (1,500 Km) and re-flush with Mobil 1 Synthetic ATF or similar.

Hope this helps.

Yours faithfully,

Spook

Thanks Spook,

I bought this car for a steal with only 110,000 miles on it. I knew (or thought I knew) what I was getting into when I bought it: a warped head/blown head gasket, and a transmission that doesn't shift. My assumption about the transmission's decline was that, similar to an 850, the fluid was never changed and it died. As I've looked into what years will work I've read a lot about radiators causing transmission failures. The radiator was replaced shortly before I purchased the car (along with the water pump- hence the warped head), so I think this is how the transmission met her demise. When I've searched ebay they show AW30-40's that are for years: '92, '93, '94, and '95; and others for '96's and '97's.

I know they are the same transmissions, but my concern is that I will have to mess with computer wiring. I really just want a direct swap.

Do you know if I replace the transmission with an older one, and replace the computer that matches the vintage if there will be any glitches?

Thanks for you reply!

Andy

Dear asg1986.

Hope you're well. You're welcome!!!!

The only sure way to know if AW30-40 trannies will interchange - as to wiring harnesses - is to consult the wiring diagrams from each model year.

I do not operate 960s and do not have these wiring diagrams. A review of Volvo VADIS indicates each model year's AW30-40 tranny had its own electronic control module. However, neither the diagrams nor the parts lists show the wiring harnesses in much detail. I can't know whether a module from, say, a 1998 AW30-40: (a) will connect with the harness present in a '96 960 and (b) even if the module will connect with the harness, whether the wires that comprise that harness go to the same places, as did the wires on the donor car.

The bottom line: to be sure that the control modules will interchange, you'll need to get the wiring diagrams for your car ('96 960) and for a potential donor car.

A possibility: a transmission shop might know whether there is "plug-and-play" compatibility as between AW30-40s, installed in various model years.

Hope this helps.

Yours faithfully,

Spook

I think I can find the wiring diagrams on MVS. I know they have them on the newer (late 90's, early 2000's- new for me) cars. I'll see if I can find pin out and wiring information. Good call. Thanks for the help!

I bought a transmission the other day at a local junk yard. It's off of a '95 with 120,000 miles that was recommended to me by the guy who owns the yard. I wanted to make sure it would work on my 1996. At first I was told "no", it has to be a tranny from a '96 or '97. Then the guy delved deeper into his computer system and concluded that any tranny from a '92-'97 WILL WORK AS LONG AS THE REPLACEMENT TRANSMISSION COMES WITH ITS TORQUE CONVERTER. So if anyone is wondering in the future: here's your answer! Thanks for the help!

Dear asg1986,

Hope you're well. I presumed that the tranny and torque converter would stay together. My concern is whether there are any differences in the transmission control modules (TCM) - and the wiring that connects the TCM to the engine control module - between model years.

Volvo is infamous for having parts that seem identical, but do not interchange.

Volvo assigns different part numbers to the TCMs. That part number change usually means some change has been made. Whether that change (or those changes) matters you'll determine, when you install the '95 tranny in your '96.

If you find there's no difference, i.e., the '95 TCM fits perfectly into your '96, then that should be included in the site's FAQs.

Hope this helps.

Yours faithfully,

Spook