Volvo 240/740/760/780/940/960 1990-1998

Sway Bar

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The sway bar, variously called the anti-roll bar or stabilizer bar, serves to control the sideways roll of the body during cornering. While the bar itself rarely fails, the links and bushings around it are prone to wear. If the bar is not rigidly mounted to the vehicle, it cannot do its job properly.

Sway bars of different diameters (thickness) can stiffen or soften the roll characteristics of a vehicle. Bushings are easily replaced and well worth the effort in terms of restoring proper cornering manners to your vehicle.

REMOVAL & INSTALLATION



240 Series
  1. Raise the vehicle and support it safely.
  2.  
  3. Remove the wheels.
  4.  
  5. Remove the underside splash guard panel, if equipped.
  6.  
  7. Remove the upper nut securing the anti-roll bar to the struts.
  8.  
  9. Remove the upper link nut on the opposite side.
  10.  
  11. Remove the bolts for the two retaining brackets and remove the bar.
  12.  
  13. If the link bushings are worn, remove the lower link bolts and remove the entire link.
  14.  
  15. Inspect all the bushings for compression or elongation. Replace as required. The two U-shaped bushings from the front brackets are particularly prone to deforming.
  16.  

To install:
  1. Reconnect the lower link to the arms, if removed.
  2.  
  3. Hold the bar in position and install the front brackets with bushings. Make sure the slot in the bushing faces forward.
  4.  
  5. Install the bar to the link on one side of the vehicle but do not tighten more than a few turns.
  6.  
  7. Connect the bar to the link on the opposite side and install the bushings and nut.
  8.  
  9. Tighten each upper link nut until 1.65 inches (42mm) can be measured between the outer surfaces of the upper and lower washers.
  10.  
  11. Reinstall the underside splash panel, if required.
  12.  
  13. Install the wheel.
  14.  
  15. Lower the vehicle.
  16.  

700 Series, 940 and 1992-94 960 Models

See Figure 1

  1. Raise and safely support vehicle.
  2.  
  3. Remove the wheels.
  4.  
  5. Remove the splashguard from under the engine.
  6.  
  7. Disconnect the anti-sway bar from upper link mounts on both sides.
  8.  
  9. Remove the sway bar clamps on both sides and take the bar off.
  10.  

To install:
  1. Install new rubber bushings on sway bar and attach to subframe with clamps.
  2.  
  3. Connect sway bar to upper link mounts and tighten the nut until the distance between bushing washers is 1.65 in. (42mm).
  4.  
  5. Install the splashguard under the engine.
  6.  
  7. Install the wheels.
  8.  
  9. Lower the vehicle.
  10.  



Click image to see an enlarged view

Fig. Fig. 1: The bushing opening should face towards the front of the vehicle when installed

1995-98 960/S90/V90 Models
  1. Raise and safely support the vehicle.
  2.  
  3. Remove the wheels.
  4.  
  5. Remove the nuts connecting the sway bar to the axle beam.
  6.  
  7. Remove the bolts connecting the sway bar to the support arms.
  8.  
  9. Remove the sway bar.
  10.  

To install:
  1. Attach the sway bar to the axle beam using new nuts. Tighten the nuts to 15 ft. lbs. (20 Nm).
  2.  
  3. Connect the sway bar to the support arms using new bolts. Do not tighten the bolts.
  4.  
  5. Tighten the support arm bolts to 63 ft. lbs. (80 Nm).
  6.  
  7. Install the wheels.
  8.  
  9. Lower the vehicle.
  10.  

850, C70, S70 and V70 Series

See Figures 2, 3, 4 and 5

  1. Install support rails 5033, bracket 5006 and lifting hook 5115, or suitable equivalents. These make it possible to raise the engine in the vehicle.
  2.  
  3. Raise the engine slightly.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Remove the underengine splashguard.
  8.  
  9. Remove the five nuts holding steering gear to the subframe.
  10.  
  11. Disconnect the power steering line brackets from the subframe at the front and rear edges.
  12.  
  13. Position a suitable jack under the rear crossmember.
  14.  
  15. Remove the bolts holding the subframe brackets to the body on both sides.
  16.  
  17. Remove the two subframe bolts, brackets and washers.
  18.  
  19. Lower the subframe at the rear edge approximately 0.59-0.79 in. (15-20mm). Make sure that the steering gear bolts come away from the frame.
  20.  
  21. Remove the sway bar links and subframe brackets.
  22.  
  23. Remove the sway bar.
  24.  

To install:
  1. Install the sway bar and subframe brackets.
  2.  
  3. Install the sway bar links using new nuts and tighten them to 37 ft. lbs. (50 Nm).
  4.  
  5. Raise the subframe up with the jack and push the steering gear mount bolts into the frame.
  6.  
  7. Install the subframe brackets and new M14 bolts, but do not tighten fully.
  8.  
  9. Move the jack to the front edge of the frame and replace the bolts. Do not tighten fully.
  10.  
  11. First tighten the bolts on the left side on the frame to 77 ft. lbs. (105 Nm) and angle tighten 120°. Then do the same to the right side.
  12.  
  13. Tighten the bracket bolts to 37 ft. lbs. (50 Nm).
  14.  
  15. Install new attaching nuts to the steering gear and tighten them to 37 ft. lbs. (50 Nm).
  16.  
  17. Tighten the power steering line brackets on the front and rear edges of the subframe.
  18.  
  19. Install the underengine splashguard.
  20.  
  21. Lower the vehicle.
  22.  
  23. Remove the support rails, bracket and lifting hook.
  24.  



Click image to see an enlarged view

Fig. Fig. 2: Hold the hex head on the ball end of the link with an appropriate size wrench, or the nut cannot be removed



Click image to see an enlarged view

Fig. Fig. 3: If replacing the link, use a new nut; the old nut can be discarded



Click image to see an enlarged view

Fig. Fig. 4: After both nuts are unfastened, remove the link from the vehicle



Click image to see an enlarged view

Fig. Fig. 5: The sway bar bushings are located on the subframe

 
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