Removal/Installation, Final Drive Only
NOTE: Special tools: 999 5972, 999 5561, 999 5652, 999 5659, 999 5680
Removing
Note: Position the rear lining arms on the arrows on the sills. This is so the support arm mountings are not blocked.
Adjusting Parking Brake
- Slacken off parking brake adjustment as much as possible.
- Use Torx TX 50.
Removing Floor Hatch
- Remove front floor hatch screws (both sides). Pull back hatch to release it from its front mounting.
- Remove hatch.
Disconnecting Connectors
- Disconnect ABS sensors and fuel gauge sensor connectors.
- Remove connector holders and the front cover. Remove rear cover. Pull cables through hole.
Removing Circlip And Boot
- Remove fuel filler pipe boot circlip.
- Remove boot. Reinstall fuel filler cap.
Removing Rear Wheels
- Undo rear right-hand side of fender liner and splash guard.
Draining Fuel Line
Remove:
- throttle pulley cover.
- cap from valve on fuel rail.
Connecting Fuel Draining Unit
- Connect fuel draining unit adapter 999 5484 to fuel draining unit 981 2270, 981 2273 and 981 2282.
- Connect adapter to fuel rail valve in locked position (Figure 1, valve closed).
- Start fuel draining unit.
- Unlock adapter (Figure 2 valve open). Raise the car.
Draining Fuel System
- Remove fuel filter valve cap.
- Connect venting hose 999 5480 to valve upstream of fuel filter.
- System takes approx. 2 minutes to drain.
- Reinstall components in reverse order.
CAUTION: Remember to reinstall valve caps.
Disconnecting Fuel Lines
- Disconnect front fuel line connectors. Remove fuel line protective cover.
- Note the position of fuel lines in the protective cover.
- Tie fuel lines to the rear of the fuel tank to avoid crushing them.
Removing Exhaust Pipe
- Remove tail pipe and mufflers.
Adjusting Parking Brake
- Slacken off parking brake adjustment Slacken off brake shoe adjustment as much as possible. Turn the brake disc so that one of the wheel stud holes is opposite the brake shoe adjustment gear wheel.
- Turn the gear wheel as far as it will go. Use a screwdriver.
Removing Brake Calipers And Brake Discs
- Remove both brake calipers and brake discs Hang brake caliper in the spring with a hook. Mark position of brake disc in relation to locating pin. Remove brake disc.
Removing Brake Shoes
Remove:
- parking brake shoes.
- parking brake cable mountings on jacking point, control arm and wheel bearing housing.
NOTE: Note routing of brake cable.
- Carefully fold back cables away from rear suspension.
Removing Support Arm Mountings
- Remove support arm mountings from car body Block the brake pedal with a pedal jack. Depress the pedal approx. 2 cm (0.787"). Block it in this position.
- Bring a mobile lack into contact with the support arm mounting.
- Remove lacking point and support arm mounting screws on both sides.
- Remove mobile lack.
- Disconnect front brake pipe from three-way junction on the left jacking point.
Removing Propeller Shaft
- Mark propeller shaft in relation to the flange.
NOTE: Carefully note the length and position of screws on the propeller shaft CV joint. See also Specifications page 2 (Standard screw for front and rear propeller shaft CV joint and balancing screw for rear joint).
- Remove propeller shaft screws. Use counterhold 999 5561. Move the shaft to one side.
Lowering Torque Tube
- Bring mobile lack 998 5972 into contact with torque tube.
- Remove screw and lower torque tube with mobile lack.
NOTE: If only replacing final drive housing bushings reinstall rear suspension assy.
Marking
- Mark flange in relation to the end of the viscous coupling shaft.
- Remove flange. Use counterhold 999 5652.
Removing Torque Tube
Remove:
- four torque tube screws in final drive.
- torque tube.
Removing Viscous Coupling
- Mark up viscous coupling flange in relation to final drive.
- Remove viscous coupling from final drive.
NOTE: Washer at the front of the viscous coupling shaft.
Removing Rear Suspension Assembly
Installing Lifting Table
- Locate lifting table with fixture under fuel tank and control arms. See illustration.
Caution: Tie front of final drive to lifting table. This stops the rear suspension tipping backward when it is lowered.
Removing Fuel Tank Securing Strap Screws
- Remove fuel tank securing strap screws on both sides.
Removing Rear Axle Member Screws
- Remove screws holding rear axle member to car body on both sides.
Lowering Rear Suspension With Fuel Tank
- Carefully lower rear suspension with fuel tank. Check that the fuel filler pipe goes free of the fender liner.
NOTE: Check that fuel line between fuel gauge sender unit and injector pump does not catch in bodywork when lowering the rear suspension.
Removing Final Drive From Member
Remove:
- expansion tank screws.
- fuel filter bracket.
- ABS sensor in wheel bearing housing, both sides. Do not disconnect connector.
- cable clips on track rod.
- cables from clips on rear axle member.
Removing Upper Member
- Remove screws to upper section of member Remove upper section.
Replacing Final Drive Bushings
- Remove Bushings From Final Drive.
NOTE: If only removing final drive bushings: Tap bushings off the lugs. Use a heavy screwdriver.
Installing Bushings
- Install final drive bushings.
- Tap in bushings. Use a rubber mallet.
- If only replacing bushings: Continue with installing upper section of rear axle member.
Removing Final Drive From Rear Axle Member
- Removing Drive Shafts.
- Pull drive shafts out of final drive to release circlip Use a jimmy bar.
Removing Screws And Nuts On Both Sides
- Remove the following on both sides:
- track rod screw. Unhook track rod from locating pin.
- upper control arm mounting nut.
- lower control arm nut and screw. Tap out screw with a drift.
- Tap out bushing lug from upper control arm. Use a copper mallet.
Removing Drive Shaft And Wheel Bearing Housing
- Remove drive shaft and wheel bearing housing from rear suspension on both sides.
Removing Final Drive
- Lift final drive out of rear axle member.
Installing Drive Shafts And Wheel Bearing Housing
- Position final drive in rear axle member.
- Reinstall on both sides:
- drive shafts to final drive. Take care not to damage seals.
- wheel bearing housings to upper and lower control arms. Install new locknuts loosely.
NOTE: Tap out lower control arms screws completely.
- Hook on track rods loosely and install screws loosely.
- Press CV joint housing into final drive so that the snap ring engages in its groove.
- Check by carefully pulling CV joint.
Installing Rear Suspension Assembly
- Install upper section of rear axle member Tighten alternately until the upper section is in contact with the lower section of the rear axle member. Tighten to 50 Nm (37 ft.lb.).
Installing Rear Axle Components
- Install the following on rear axle member:
- expansion tank. Tighten to 25 Nm (18.5 ft.lb..
- fuel filter bracket. Tighten to 25 Nm (18.5 ft.lb.).
- Lubricate sensor holes with wheel bearing grease, 1161241-3. Clean the ABS sensor with a soft brush. Install in stub axle. Tighten to 10 Nm (7.3 ft.lb.).
- Install ABS wiring in clips on rear axle member and cable holders on track rod.
Lifting Rear Suspension With Fuel Tank
- Ensure that the fuel filler pipe goes free of the fender
- liner. Ensure that the fuel line is free of the bodywork and that the fuel gauge sensor cable does not catch on the fuel tank securing strap brackets.
- Take fuel tank unit and fuel pump (FP) cable up through the bodywork (hatch)
CAUTION: Tie front of final drive to lifting table. This stops the rear suspension tipping backward when it is raised.
NOTE: Check that fuel line between fuel gauge sender unit and fuel pump does not catch in bodywork when raising the rear suspension.
Installing Rear Axle Member Mounting Screws
- Install all rear axle member mounting screws Tighten outer screws to 80 Nm (59.0 ft.lb.) and middle screws to 50 Nm (37 ft.lb.).
- Apply a few drops of locking fluid to the screws.
Tightening Fuel Tank Securing Strap Mountings
- Tighten fuel tank securing strap mountings on both sides.
- Remove lifting table.
Installing Fuel And EVAP Lines
- Install fuel and EVAP lines.
- Install fuel lines in protective cover.
Installing Viscous Coupling
NOTE: If the final drive has been replaced or reconditioned and the pinion flange has been removed, measure according to Measuring flange and viscous coupling. Balancing viscous coupling. Service and Repair If it has not been replaced or reconditioned, continue with "install viscous coupling as marked".
- Install viscous coupling as marked. Ensure that the mating surtaxes are absolutely clean.
- Use new screws.
- Lightly tighten screws crosswise. Tighten crosswise to 50 Nm (37 ft.lb.).
Installing Torque Tube
- Install torque tube. Lightly tighten the tour screws crosswise, then tighten to 50 Nm (37 ft.lb.)
NOTE: Check that: The mating faces on the final drive housing and torque tube are clean and that the washer is in place on the viscous coupling shaft
Installing Viscous Coupling Flange
- Install viscous coupling flange as marked Use counterhold 999 5652 and new nut Tighten to 180 Nm (132.8 ft.lb.).
Installing Torque Tube
- Press torque tube up against car body. Use mobile jack 998 5972.
- Install screw and washer. Tighten to 80 Nm (59.0 ft.lb.).
Installing Propeller Shaft
- Install propeller shaft to flange.
NOTE: Install propeller shaft as marked. Use new screws of the same length. Reinstall screws in the same positions.
- Check that viscous coupling and propeller shaft flange mating surfaces are clean.
- Tighten screws crosswise to 8 Nm (5.9 ft.lb.). Then tighten crosswise to 30 Nm (22.1 ft.lb.). Use counterhold 999 5561.
- Start tightening with the same screw both times.
Installing Support Arm Mountings And Jacking Points
- Install front support arm mountings and jacking points to car body.
- Press up control arms into position.
- See Use of tensioner 999 5859 in Normal position.
- Connect front brake pipe to three-way junction on left- hand side.
- Install support arm brackets and jacking points with new screws
- Tighten the three support arm brackets screws to 65 Nm + 60° (47.9 ft.lb + 60°).
- Tighten the screw through the jacking point to 105 Nm + 90° (77.4 ft.lb + 90°).
- Remove pedal jack from brake pedal.
Tightening Wheel Bearing Housing Nuts And Screws
- Tighten nuts and screws on both sides to:
- wheel bearing housing - upper control arm to 115 Nm (84.8 ft.lb.).
- wheel bearing housing - lower control arm to 80 Nm (59.0 ft.lb.).
- track rod screw to 80 Nm (59.0 ft.lb.).
Installing Exhaust Pipe
Install:
- tail pipe.
- mufflers.
NOTE: Check for clearance to heat deflector plates.
Installing Brake Components
- Install on both sides:
- parking brake cable on jacking point, control arm and wheel bearing housing.
- brake shoes.
NOTE: The parking brake adjuster should be screwed as far as it will go and the arrow on the cable gear should point forward.
NOTE: The parking brake cable should be routed over the brake hose.
Installing Brake Discs And Brake Calipers
- Install on both sides:
- brake discs.
NOTE: Ensure that the mating surfaces are absolutely clean.
- brake calipers. Use new screws. Tighten to 60 Nm (44 ft.lb.).
Checking Parking Brake
- Check that the parking brake is not engaged. Turn the brake disc so that one of the wheel stud holes is opposite the brake shoe adjustment gear wheel.
- Adjust until brake disc cannot be turned. Then undo adjuster approx. 6 notches. Use a screwdriver.
Bleed Brakes
NOTE: Check level in brake fluid reservoir.
- Use genuine Volvo brake fluid marked DOT4+.
- Install wheels.
Tightening Wheel Studs.
- This the following applies when installing and tightening wheel studs.
- Ensure that the brake disk and wheel rim mating surfaces are clean. Lubricate hub center rim guide. Use rust inhibitor 1161030-0.
- Tighten studs lightly. Then tighten crosswise to 110 Nm (81 ft.lb.). Torque socket 1158147-7 must be used when tightening with an impact wrench.
- Crosswise tightening and torque tightening is important to prevent tension in the brake disc.
Installing Fuel Filler Pipe
- Install fuel filler pipe to car body with rubber boot and circlip.
Installing Fuel Gauge Sender Unit Hatches And Connections
Install:
- front and rear hatch in car body and connector holders. Ensure that the rubber seal around the wiring is in place when the rear hatch is installed.
- fuel gauge sender unit, fuel pump (UP) and ABS system connectors.
Aligning Floor Hatch Mountings
- Align front edge of floor hatch. Install screws in rear edge. Align hatch with rear floor hatch. Tighten screws.
Adjusting Parking Brake
- Lower the car onto all four wheels.
- Adjust the parking brake so that the lever can be pulled up a maximum of 7-8 notches (the first two notches should be play). Use Torx TX 50. Braking effect should be obtained on the fourth-sixth notches. Reinstall the cover in the center console locker.