Volvo Transmission Adaptation Procedure

A Solution That Eliminates The Need For Costly Repair

Here is some reference information contained in a TSB regarding the Adaptive Transmission Procedure that the technicians employ.

A/T - AW55-50 Hard Shifts/Shift Flare

NO: 43-27

DATE: 1-22-2004
MODEL/YEAR:
MY 2001- S60, V70, V70 XC, XC90 2.5T

SUBJECT:
AW55-50 Adaptation Procedure

CHASSIS:
All

Reference:
For all other cars with the AW 55-50, please see TNN 43-20

THIS TNN SUPERCEDES THE PREVIOUS TNN 43-27 DATED 7-15-02. PLEASE UPDATE YOUR FILES. Updated for XC90 2.5T

DESCRIPTION:

The AW55-50 gearbox relies on adaptive data to properly adjust its shift pressure. This data is collected and memorized by the TCM and then used to adjust shift feel/quality. If the adaptation is not complete, it may result in: - Shift Flare: Engine RPM increases during a shift. This symptom often feels like the car has temporarily lost drive or the transmission is slipping. It is usually the 2-3 upshift that flares the most.

- Harsh Down Shifts: Harshness felt during a coast-down shift (zero throttle downshift).

- Harsh Garage Shifts: Harshness when shifting P-D, N-D, P-R, or N-R while at a standstill.

- Harsh Neutral Control Engagement/Disengagement: After coming to a complete stop in Drive, with your foot on the brake the TCM waits 2 seconds and then disengages drive to reduce emissions and minimize idle vibrations. This disengagement is normally smooth and isn't felt by the driver. If adaptation is not complete then a "thud" can be felt in the car 2 seconds after coming to a complete stop. When the brake pedal is released, the re-engagement of Drive should be relatively smooth. A harsh re-engagement can be felt if the adaptation is not complete. Neutral Control is present on all 2001 MY S60s and V70s. It is also present on non-turbo 2002 S60s and V70s produced before January 2002.

The TCM can sometimes take many miles to fully adapt. To assist in the process, a function called "Control Module Adaptation" has been included in VADIS. This mode is useful when the car is new, the gearbox, valve body or TCM have been replaced, or anytime you want to be sure that the transmission is fully adapted. The picture shows where to find the function. There is no need to "Reset the adaptation to zero", unless a piece of hardware, such as the valve body or gearbox has been replaced.

ADAPTATION MODE:
When you follow the procedure, you will first be directed to check which software version is in the TCM. This is because some cars need to be loaded with the latest software for the function to work (Please refer to TNN 43-24). Once you have checked the software, you will be directed to the procedure. After reading through the procedure and using VADIS to put the car into Adaptation Mode, you can begin the adaptive test drive.

When the transmission oil reaches 65̊Celsius (150̊F.) a text message will appear in the DIM to confirm that you are in Adaptation Mode. It will remain in this mode until the car is shut off. If the transmission oil temperature exceeds 110̊Celsius (230̊F.), Adaptation Mode will be suspended and the text message will disappear until the temperature comes down.

The transmission does not adapt while in Geartronic or Winter mode; do not use those modes at any point in this procedure. While the car is in Adaptation Mode the orange triangle in the center of the instrument cluster (DIM) will flash just after a "perfect shift". A perfect shift is one where the TCM has reached its adaptation target for that particular shift.

To adapt the Upshifts:
1. Use 'D' range. The TCM does not adapt while in Geartronic. From a standstill, accelerate lightly (about 1400 RPM) up to 4th gear. Keep the throttle steady during the acceleration. Come to a stop and repeat this maneuver until the orange triangle flashes after each of the three shifts. It may take several accelerations to complete this. You will not reach 5th gear at this small throttle opening.

2. Perform another steady acceleration, all the way up to 5th gear. This time use a higher throttle position (about 1800 RPM). Repeat the maneuver until you see the orange triangle flash after each of the four shifts. Remember to keep the throttle steady.

3. Again accelerate up to 5th gear from a standstill; this time at an even high throttle opening (about 2500 RPM). Repeat the maneuver until you see the orange triangle flash after each of the four shifts. Remember to keep the throttle steady.

NOTE: The TCM is continuously adapting. Not every shift will be a "perfect shift". For example, you will not see the triangle flash after every 1-2 shift. You only need to see it flash once for the 1-2 shift at each throttle opening to know that the adaptation has reached its target.

To adapt the Downshifts:
1. Use 'D' range. The TCM does not adapt in Geartronic. Drive along at about 45 MPH in 5th gear. Release the throttle and gently brake until you are at a standstill. Use very light pressure on the brake pedal.

2. Repeat this maneuver until the orange triangle flashes after each of the four downshifts. It will take several decelerations to adapt all of the shifts. If you are having difficulty, increase or decrease the pedal pressure you are using.

NOTE: The TCM is continuously adapting. Not every shift will be a "perfect shift". For example, you will not see the triangle flash after every 3-2 shift. You only need to see it flash once for the 3-2 shift during this maneuver to know that it has reached its target.

To adapt the Garage Shifts:
1. With the engine idling and your foot on the brake, shift to 'N'. Wait 5 seconds; shift to 'R'. Wait 5 seconds and shift back to 'N'. The adaptation has reached its target when the orange triangle flashes after you shift to 'R'. If the triangle flashes once, you do not need to see it every time after that. This is because the TCM is continuously adapting.

2. With the engine idling and your foot on the brake, shift to 'N'. Wait 5 seconds; shift to 'D'. Wait 5 seconds and shift back to 'N'. The adaptation has reached its target when the orange triangle flashes after you shift to 'D'. If the triangle flashes once, you do not need to see it every time after that. This is because the TCM is continuously adapting.

To adapt the Neutral Control:
NOTE: This only applies to certain cars. They are listed in the "Description" section of this document.

1. Drive along slowly (about 5 MPH) in 'D' range. Gently bring the car to a complete stop. Repeat this maneuver until the orange triangle flashes a few seconds after you stop the vehicle. This tells you that the Neutral Control engagement is adapted.

2. With the engine idling and your foot on the brake, shift to 'D' range. Wait about 25 seconds and you will see the orange triangle flash, telling you it is ready to adapt. After it has flashed, release the brake pedal and allow the car to crawl forward. Repeat this maneuver until the triangle flashes just after releasing the brake pedal. This tells you that the Neutral Control disengagement is adapted.

NOTE: The TCM is continuously adapting. Not every shift will be a "perfect shift". For example, you will not see the triangle flash every time you release the brake pedal. You only need to see it flash once to know that the neutral control adaptation has reached its target.

Once you have adapted the Upshifts, Downshifts, Garage Shifts and Neutral Control, the procedure is complete. When the ignition is switched off, the TCM automatically exits adaptation mode.

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Volvo S60 Transmission Problems

- flush your fluid every 20-30k miles. Volvo manual says don't do it, which has been proven to be wrong. If you haven't ever flushed and you're at or less than 60k, then flush now.
- use Mobil 3309 or Dexron IV for all s60s, takes anywhere from 8-10qts (avlube.com ~$50+shipping is best deal)
- use the radiator flush method not the drain pan drop method

- if you have more than 60k miles and you're asking if you should flush, you need to. But instead of using the radiator method, remove the drain plug on the bottom of tranny (19mm if I remember, and brass-colored) and that will drain about 4qts of the fluid. Fill up to correct marking
- if you don't flush your fluid ever, you're not "gambling" if your transmission will fail. You guarantee it. What's a gamble is if it happens today, tomorrow, or 6 years from now. 

- ALWAYS get the software updates. It's silly to say that you think the dealership is trying to screw you out of your warranty. one of the main reasons the tranny was so faulty was the many software issues the TCU had


If your transmission still flutters after doing all this there are 2 more known issues with the 2001-2004 transmissions:
1) B4 servo cover: this will cause flares shifting in/out of 3rd gear. It is a very simple, cheap fix. It's literally a cover with some o-rings that has been redesigned many many times. www.ipdusa.com has it for sale under s60/transmission/b4 servo
2) valve body solenoids: you basically have to remove the existing ones, clean it out, and replace with new ones. There's no fix for this. It comes down to the fact that some of the workings of the automatic transmission before MY2004 were sized too small, and clog up too easily (so flush your fluid frequently!)

My recommendations:
- do the b4 servo even if you don't need it if you have a MY2001-2004 s60
- flush your fluid every 15k with mobil 3309
- get a transmission cooler (quick, easy, cheap install)
- get a transmission temperature gauge (easy) and monitor your temperatures
- get the latest software

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