'04 Volvo S60 - Manual Shift Knob & Boot R&R - 21 years and 220k Miles

[Devo242]

After two decades and nearly the distance to the moon traveled, the shift knob and boot in my 2004 S60 was looking tired and bringing down the rest of an otherwise clean car- the stitching on the knob was coming apart and the boot was delaminating. Searching for replacement parts proved somewhat elusive, as the age of the car combined with the fact that not many 5 speed S60s were imported into North America.

I managed to locate the new shift boot at FCP Euro on closeout which I jumped on along with some other parts I needed, but finding the leather covered shift knob proved difficult. This part was discontinued and I was left with a few straightforward options: recovering it via an auto leather service, going with the many Chinese knockoffs floating around on ebay/amazon, or wait and keep instigating OEM options.

The leather service could recover the knob but not reproduce the shift pattern, and the knockoff versions looked awful, so I spent time continuing to look. Through a stroke of luck, I found a similar aluminum version at Skandix in Germany as NOS. This aluminum knob was available on the S80 models apparently up until 2006 (non-North American spec). It looked like a fit from the photos and so I took a risk, I paid for the part along with the rather steep shipping charge and crossed my fingers.

Upon successful arrival about 2 weeks later I checked the contents, packed very well but the box glue had delaminated and was flimsy, evidently from sitting so long on the shelf. The knob was sealed in a bag and otherwise in new condition.

With all this settled I got to work removing the old boot and knob with the help of a Genuine Volvo weatherstrip bone tool I've had for years and gets used far more than I ever expected, it's fantastic for giving leverage to pry while not scratching or gouging around delicate surfaces. The process from here went smoothly, the old shift knob releases with the push tabs pinched in and once removed the boot pulls up next.

Installation was a bit tricky with the new boot being firmer than the old piece, and it required some fine motor skills to mount up and press the new knob into place, which it did click right in (phew!).

Overall, I am very happy with the results and plan to get many more miles from the car, it's not a quick car by any means but the 5 cylinder and simplicity of everything make it an enjoyable vehicle to drive.

 

[Ronsant]

Save the Manuals!

 

[Racer4]

Very nice job, I know it makes you feel like you accomplished something, and you will enjoy it every time you drive it!

 

[Kira]

A rewarding job, yes.
May I share my recent experience?

Replaced mine last week; '07 V70 auto.
My release trigger pivot broke. The lever often worked but could jam. Then you'd have to jiggle it.
I admit to using rubber bands to hold the trigger. Had it broken 'the rest of the way', I could've been stranded.
I too am glad mine was available. My seller corrected my order with the VIN. GREAT. Volvo 9463564, $137, not bad.

My boot exhibits some wear, but It's still good to go.

3rd picture down: There's a noteworthy difference in the boots' necks. The retaining ring appears to be part of the manual style boot.
In my automatic, there was an internal ring which held the boot against the bottom of the knob.

You gently pry -at the 3 and 9 o'clock positions- where the knob and boot material meet.
You pull the boot down the shaft a bit AND THE RING SLIDES DOWN AND CHANGES ORIENTATION. It's unavoidable.

Pulling up hard, releases the original knob. My assembly was a bit over 9" long complete (including the rod).
The most demanding part of the job is messaging the retaining ring ALL THE WAY UP to the boots end.
You'll see the catches at 3 and 9 and square guides which are fore and aft. THE GUIDE WITH THE NOTCH GOES STRAIGHT AHEAD.
Square it up...put your hand atop the knob and reach down with two fingers 'hooking' at the 3 and 9 and the catches will pop obediently into place.
THERE CAN BE NO BUNCHED-UP MATERIAL AT THE NECK.

Then you can land the new lever. I padded the top with some leather and struck it several times with my hand.
The pain got me to resort to a 2 lb. blacksmith's hammer with the head held in my hand. Think thud.

Getting the ring all the way up the narrow boot is easily the most tedious / hardest part.

Look at pictures 1 and 4 and the OP's new knob looks much bigger.

 

[Oillover]

After two decades and nearly the distance to the moon traveled, the shift knob and boot in my 2004 S60 was looking tired and bringing down the rest of an otherwise clean car- the stitching on the knob was coming apart and the boot was delaminating. Searching for replacement parts proved somewhat elusive, as the age of the car combined with the fact that not many 5 speed S60s were imported into North America.

We also had a 5 speed, 04 S60. It was naturally aspirated.
In the Canadian market, it was called the "SE" version, as it had leather and all the appointments of the fancier models but without the auto trans or turbo engines. A real "pipe and slippers" kind of car.

When we sold it a few months after purchase (about the time of the 08 market downturn), I had many calls from older gentlemen who simply couldn't comprehend that Volvo still made a manual transmission car. They thought I was mistaken until I pointed out the "three pedals" in the drivers footwell, lol.

We ended up getting something a little more nimble and fun to drive (I think it was a late model Focus hatchback, also with a 5 speed transmission).

 

[wings&wheels]

That is such a Swedish design shift knob! Excellent...love older Volvo's and miss SAAB too.

 

[KevinMalone]

Great find OP, I love all of the little differences between the P2 models.

The plastic internal mechanism in our V70's auto shifter also exploded. Fortunately it was still functional, and there were many used replacements in excellent condition on eBay for reasonable prices.

 

[Devo242]

Save the Manuals!

lol trying to do my part

Very nice job, I know it makes you feel like you accomplished something, and you will enjoy it every time you drive it!

Probably the least challenging and involved project I've taken on with the cars in quite awhile, but one of the more rewarding ones as most of the work I'm doing is either under the hood or under the car and rarely seen. This one is front and center.

Look at pictures 1 and 4 and the OP's new knob looks much bigger.

Looks that way, but pic #3 shows them side by side and they are essentially identical. Pic #1 and #4 were just taken at different distances. I will say the new aluminum version seems to have more weight to it so it will be interesting to see the difference in gear changing feel.

In the Canadian market, it was called the "SE" version, as it had leather and all the appointments of the fancier models but without the auto trans or turbo engines.

Nothing fancy about this one. Cloth seats and slick top (no moonroof) make this one bare bones and doesn't advertise any model designation, which is fine for me. I prefer simplicity for the purpose of ease of ownership and longevity.

That is such a Swedish design shift knob! Excellent...love older Volvo's and miss SAAB too.

Agree, the Swedes have a certain appeal to their designs which makes them unique. Saabs are interesting for sure, I remember them from friends and family having them growing up, though never owned one myself.

 

[tbm5690]

You should have put a 6-speed knob on it...cheapest way to add a gear by far. Jokes aside, looks good! OE appearance parts is always the best look.

 

[Astro14]

The shift knobs for my R model are no longer made. They came either smooth (shown) or with the six speed pattern embossed in the leather.

Believe it or not, this one is only three years old. I got one of the last ones made. I don’t need the shift pattern on this, as you can see it’s already displayed on the console.

I might have to get an aftermarket one just to fit to the transmission while I get this one redone with black leather and blue stitching to match the R trim.

 

[Devo242]

You should have put a 6-speed knob on it...cheapest way to add a gear by far. Jokes aside, looks good! OE appearance parts is always the best look.

2004 was the final year of the 5 speed from Volvo as far as I am aware. The car's 5th gear is not an overdrive ratio and this car spent a lot of miles on the highway sitting between 3k and 4k RPM. Luckily the 5 cylinder is pleasant to listen to, otherwise it would be badly in need of a 6th forward gear.

The shift knobs for my R model are no longer made.

Skandix still has a few in stock, though I hesitate to even mention this since their asking price is astronomical:

https://www.skandix.de/en/spare-par...-control/gear-lever-leather-charcoal/1041032/

I might have to get an aftermarket one just to fit to the transmission while I get this one redone with black leather and blue stitching to match the R trim.

In case it helps, I had spoken with Redline Goods about the shift knob recovering as well as the shift boot in the event I was not able to find my 1st choice OEM replacements. They were very responsive and as they had not done one of these yet they offered me a price of $120 with a $30 refund if I sent them pictures of it installed. The only thing deterring me here was that they could not reproduce the gear numbering on the leather face.

No experience with the end product as you know what I ended up doing, though they were pleasant to communicate with and I would have gone down this route had I not been successful with the OEM option.

https://www.redlinegoods.com

 

[Kira]

In post #10 the shift pattern (silk screened?) seems crooked.
The 1-3-5 and 2-4-6-R on the bezel, for me, is a first.