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Thread: AF33 automatic gearbox problem

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    Default AF33 automatic gearbox problem

    hi, i bought 2.2dti auto 2003 from ebay with failty gearbox. The ring oil seal was broken so all oil spilled. i replaced the seal, oil.

    car is running as it should exept the 3 gear which dissapeared.

    when running on D car runs till 3 and then just revs goes up without any response from gearbox. looks like on neutral without any additional strange noises.

    when i entering + 4 gear manually it runs again.

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    Full Member fikse's Avatar
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    Quote Originally Posted by riauba View Post
    hi, i bought 2.2dti auto 2003 from ebay with failty gearbox. The ring oil seal was broken so all oil spilled. i replaced the seal, oil.

    car is running as it should exept the 3 gear which dissapeared.

    when running on D car runs till 3 and then just revs goes up without any response from gearbox. looks like on neutral without any additional strange noises.

    when i entering + 4 gear manually it runs again.
    You might have loosened the big bolt on top of gearbox, for filling oil? There is 2 bolts there, one is for filling ("must" remove gearselector to reach it), and the other one, the biggest one, who might looks like a oil-filler, is actually holding the band for 3d gear. If this is unscrewed, you will have to completely dismantle the gearbox to get it back....
    Bent, my name is Bent
    Mods: I polished it in september...

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    Quote Originally Posted by fikse View Post
    You might have loosened the big bolt on top of gearbox, for filling oil? There is 2 bolts there, one is for filling ("must" remove gearselector to reach it), and the other one, the biggest one, who might looks like a oil-filler, is actually holding the band for 3d gear. If this is unscrewed, you will have to completely dismantle the gearbox to get it back....

    thank's for quick reply. we actually did unscrew that bolt as we though it might be oil filer for differential.

    i think part inside is spining is it possiblle adjust it without dismantle?

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    Quote Originally Posted by riauba View Post
    thank's for quick reply. we actually did unscrew that bolt as we though it might be oil filer for differential.

    i think part inside is spining is it possiblle adjust it without dismantle?
    AFAIK its impossible to do "anything" but dismantle

    You can look at this site (Volvo XC70 use same gearbox), and at sonnax.com
    Bent, my name is Bent
    Mods: I polished it in september...

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    Hmm another 2 days under the car ((, i wonder is there any other tricks on this box if i disasamble my self?

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    Quote Originally Posted by riauba View Post
    Hmm another 2 days under the car ((, i wonder is there any other tricks on this box if i disasamble my self?
    As usual, autogearboxes is extremely sensitive for dirt, and is in general &%¤&¤ complicated to fix.. (you should remove from car and get into a clean room) This gearbox in special, has 2 common faults, both of them related to valve body: Internal leakage and worn surface on some of the pistons. Both faults results in hard shifts, especially between 2-3-2.
    Also, as on many gearboxes, they live a hard life regarding temperature (too weak cooling) and wrong service level: It should be flushed at least every 60.000KMs, provided good enough cooling (in live-word-terms: an external cooler).
    At the Vectra there also is a weak point at the OE cooler (built in to engine radiator), where leakage between cooling water from engine into ATF oil gives water into ATF oil = broken gearbox....

    In general: Get a new / rebuilt one. If not, kill the car
    Bent, my name is Bent
    Mods: I polished it in september...

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    Quote Originally Posted by riauba View Post
    Hmm another 2 days under the car ((, i wonder is there any other tricks on this box if i disasamble my self?
    As 'fikse' has already said, there is the method on the Volvo XC site, in particular this post describing a DIY repair without removing/dismantling the gearbox. Seems that this repair has saved a few Volvo V/XC70 5 speed auto gearboxes without having to dismantle after DIY'ers or even in some cases, dealers have removed this bolt to put oil in. The only way to get oil back in the box is via a funnel on the dipstick tube.

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    Quote Originally Posted by Pete B View Post
    As 'fikse' has already said, there is the method on the Volvo XC site, in particular this post describing a DIY repair without removing/dismantling the gearbox. Seems that this repair has saved a few Volvo V/XC70 5 speed auto gearboxes without having to dismantle after DIY'ers or even in some cases, dealers have removed this bolt to put oil in. The only way to get oil back in the box is via a funnel on the dipstick tube.
    Didnt see that post Sounds like a really plan B, worth a try for riauba!
    BTW: There is a fillerplug, under the gearshift wire. A bolt, with some torx. Easier to fill there, but the dipstick is also OK, if you have a long enough hose
    Bent, my name is Bent
    Mods: I polished it in september...

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    Quote Originally Posted by fikse View Post
    Didnt see that post Sounds like a really plan B, worth a try for riauba!
    BTW: There is a fillerplug, under the gearshift wire. A bolt, with some torx. Easier to fill there, but the dipstick is also OK, if you have a long enough hose
    Yeah, hopefully it will save riauba a lot of unecessary hassle.

    I didn't know there was a filler plug on the 5 speed (AF33 in Vx). Most of the info on the Volvo sites, where it's AW55, is that the only way in is through the dipstick.

    I have the 6 speed model TF-80 (known as AW40 in Vx) in a XC70 and co-incidentally, am planning a ATF change tomorrow using the Volvo fluid, which is just re-branded JWS3309 I think. This one does have a filler plug, with a Torx 55 head to distinguish from other bolts, but as far as I am aware, no dipstick according to the info I can find and I haven't found one on mine, looking from top or bottom.

    It's interesting that Toyota (who, as you have said elsewhere yourself, own Aisin Warner) and Volvo specify the same fluid for 5 or 6 speed versions but GM in Europe specify different ATF's for the two.

  10. #10
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    Quote Originally Posted by Pete B View Post
    Yeah, hopefully it will save riauba a lot of unecessary hassle.

    I didn't know there was a filler plug on the 5 speed (AF33 in Vx). Most of the info on the Volvo sites, where it's AW55, is that the only way in is through the dipstick.

    I have the 6 speed model TF-80 (known as AW40 in Vx) in a XC70 and co-incidentally, am planning a ATF change tomorrow using the Volvo fluid, which is just re-branded JWS3309 I think. This one does have a filler plug, with a Torx 55 head to distinguish from other bolts, but as far as I am aware, no dipstick according to the info I can find and I haven't found one on mine, looking from top or bottom.

    It's interesting that Toyota (who, as you have said elsewhere yourself, own Aisin Warner) and Volvo specify the same fluid for 5 or 6 speed versions but GM in Europe specify different ATF's for the two.
    I was surprised to see it was a trick to fix the anchorbolt. Sonnax states you have to dismantle the box. Cross fingers for riauba :-)

    AFAIK Volvo claimed the gearboxes to be "filled for life", and therefore did not have fillerplug (or was it drainplug?).
    Anyway, I will higly recommend to flush the oil, not only change. There is a huge amount of **** coming out when flushing!
    GM owns the brand "Dexron", Ill guess thats why they have different recommondations for oil. For mine (AF33), I got Dexron VI when I was at my Opel-dealer. Thats a completely wrong oil for the Aisins, and luckily I found several sources that stated that JWS3309 is the correct one. For mine, I now use Royal Purple MaxATF, a JWS3309 syntetic oil. I have heard Valvoline also has started produce a syntetic JWS3309. Most other JWS3309 oils I have seen is mineraloil.
    Bent, my name is Bent
    Mods: I polished it in september...

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