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

Axle Housing Assembly

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REMOVAL & INSTALLATION




WARNING
This operation requires removal of a substantial amount of weight from the rear of the vehicle. Position the jackstands at the front end, under the control arm brackets, and at rear, under the jack mounts. If the vehicle is not supported as described, it may become front heavy.

Except Multi-Link Suspension

See Figure 1

  1. Raise the vehicle and support it safely.
  2.  


WARNING
This operation requires removal of a substantial amount of weight from the rear of the vehicle. Position the jackstands at front end, under the control arm brackets and at rear, under the jack mounts. If the vehicle is not supported as described, it may become front heavy.

  1. On the 240 Series, remove the rear axle vent hose and the brake line brackets. Do not loosen any brake lines; they will be left intact.
  2.  
  3. Remove the brake calipers and secure them to the upper spring mount with a piece of stiff wire.
  4.  
  5. Remove the axle shafts, as outlined in this section.
  6.  
  7. Position the jacks or cradle below the rear axle so that the axle is supported.
  8.  
  9. If the exhaust system runs under the axle housing, disconnect the first joint forward of the axle, disconnect any hangers or brackets behind the axle and remove the rear section of the exhaust system.
  10.  
  11. Disconnect the reaction rods or torque rod from the axle housing.
  12.  
  13. Disconnect the Panhard rod from the rear axle.
  14.  
  15. Remove the parking brake cables and mounting brackets from the rear axle.
  16.  
  17. Detach the connector for the speedometer transmitter and, if equipped, the connectors for the ETC system.
  18.  
  19. Loosen and remove the bolts attaching the driveshaft to the pinion flange.
  20.  
  21. Double check that the axle assembly is firmly supported by the jacks or cradle. Remove the bolts which hold the lower mount of the shock absorber.
  22.  
  23. On the 240 Series:
    1. Remove the adjacent bolt which holds the anti-roll bar (sway bar).
    2.  
    3. Loosen, but do not remove the trailing arm bolts at the front of the trailing arm.
    4.  
    5. Lower the jacks or cradle and allow the axle assemble to pivot downwards on the trailing arms. When clear of the vehicle and well supported on the jacks or cradle, remove the trailing arm mounts at the axle housing.
    6.  
    7. Remove the rear axle assembly.
    8.  

  24.  
  25. On the 700 and 900 Series:
    1. Remove the front brackets for the support arms. Pry the support arms loose from the front mounts.
    2.  
    3. Remove the rear axle assembly.
    4.  
    5. Once the axle assembly is clear of the vehicle, remove the anti-roll bar (sway bar). Mark the support arms for the left and right sides and remove the arms from the axle housing.
    6.  

  26.  

To install:
  1. On the 240 Series:
    1. Position the axle unit under the vehicle and attach the trailing arm mounts. Tighten the bolts only enough to hold and still allow motion.
    2.  
    3. Raise the axle and align the springs to their upper mounts. Install the anti-roll bar bolts and the bolts for the lower shock absorber mounts
    4.  
    5. Attach the torque rods to their mounts and attach the Panhard rod to its mount. Tighten these bolts only enough to hold and still allow motion.
    6.  

  2.  
  3. On the 700 and 900 Series:
    1. Make sure the left and right markings are observed. Fit the bushings within the clamps and fit the clamps.
    2.  
    3. Tighten the clamps in a crisscross pattern to 33 ft. lbs. (45 Nm) and reinstall the anti-roll bar if so equipped.
    4.  
    5. Position the axle on its jacks or cradle and elevate it so the support arms align with both their front mounts and the spring seats.
    6.  
    7. Install the front brackets for the support arms and tighten the two bolts to 35 ft. lbs. (48 Nm). Tighten the nut to 62 ft. lbs. (84 Nm).
    8.  
    9. Install the lower shock absorber bolts and tighten to 62 ft. lbs. (84 Nm).
    10.  

  4.  
  5. Reinstall the driveshaft to the pinion flange.
  6.  
  7. Connect the wiring for the ETC sensor and/or the speedometer sensor, as required.
  8.  
  9. Install the parking brake cables and brackets. Adjust the parking brake.
  10.  
  11. Reinstall the exhaust system, as necessary.
  12.  
  13. Complete installation by reversing the removal procedure.
  14.  
  15. Check oil level in differential.
  16.  
  17. Lower the vehicle.
  18.  



Click image to see an enlarged view

Fig. Fig. 1: Points of reference for solid rear axle removal

Multi-Link Suspension

See Figure 2

Because of the nature of the multi-link suspension, component position and bolt tightening values (torque) are critical to ride quality and rear wheel alignment. When installing components, exact location must be achieved; close doesn't count. Tightening specifications must be followed exactly or component function will be impaired.

  1. Raise the vehicle and support it firmly with stands. Locate front lifting arms as far forward as possible. Make sure the rear lifting arms do not interfere with the support arms.
  2.  
  3. Remove the rear wheels.
  4.  
  5. On one side only, remove the bolt holding the support arm to the wheel bearing housing.
  6.  
  7. Drive out the support arm.
  8.  
  9. Remove the nut and bolt holding the lower link arm to the wheel bearing housing.
  10.  
  11. Remove the bolts holding the track rod (Panhard rod) to the wheel bearing housing. Use a small claw puller and an M12 bolt 50mm long to move the rod away from the housing.
  12.  
  13. Remove the bolts joining the upper and lower sections of the rear axle housing.
  14.  
  15. Swing the lower part of the wheel bearing housing outwards and swing down the lower part of the axle housing. It will still have the arms attached to it and will be attached to the vehicle by the arms on the opposite side.
  16.  
  17. Matchmark the flanges at the rear of the driveshaft.
  18.  
  19. Remove the four bolts and lower the driveshaft.
  20.  
  21. Place a jack or cradle under the center of the final drive (differential) unit.
  22.  
  23. Raise the jack and support the unit.
  24.  
  25. Remove the bolts holding the final drive to the upper housing.
  26.  
  27. Lower the final drive slightly. Remove the wiring to the impulse sender.
  28.  
  29. Remove the bolts holding the axles to the final drive.
  30.  
  31. Carefully lower the final drive unit and remove it from under the vehicle.
  32.  

To install:
  1. Raise the final drive unit almost to its final position under the vehicle and connect the impulse sender cable. Tighten the bolt to 7 ft. lbs. (10 Nm).
  2.  
  3. Raise the unit to its final position and install the three bolts to the upper housing. Tighten the bolts. When the bolts are secure, the jack or cradle may be removed.
  4.  
  5. Attach the halfshafts to the final drive. Tighten the bolts to specifications.
  6.  
  7. Install the driveshaft to the pinion flange. Remember to observe the matchmarks made earlier and position the driveshaft properly.
  8.  
  9. Raise the lower section of the axle housing. Loosely install the bolts which retain it to the upper housing. Before tightening the mounting bolts, install two 12mm long bolts (or 12mm drifts) in the centering holes and align the panel. This is essential to insure correct wheel alignment when finished. Tighten the mounting bolts to specifications.
  10.  
  11. Position and install the lower link arm on the wheel bearing housing. Before tightening the nut and bolt, pull the housing in towards the center of the vehicle. When all the play is out of the mount, tighten the link bolt to specifications.
  12.  
  13. Install the support arm and track rod.
  14.  
  15. Install the wheels.
  16.  
  17. Check the oil level in the final drive and top up as necessary.
  18.  
  19. Lower the vehicle.
  20.  



Click image to see an enlarged view

Fig. Fig. 2: Torque Specification

 
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