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

Axle Shaft, Bearing and Seal

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REMOVAL & INSTALLATION




CAUTION
This procedure requires removal of the rear brake pads or shoes. Brake pads and shoes may contain asbestos, which has been determined to a cancer causing agent. Never clean the brake surfaces with compressed air! Avoid inhaling and dust from brake surfaces! When cleaning brakes, use commercially available brake cleaning fluids.

Except Multi-Link Suspension

See Figure 1

  1. Raise the vehicle and safely support it on jackstands.
  2.  
  3. Remove the applicable wheel.
  4.  
  5. Remove the brake caliper mounting bolts and remove the caliper. Secure the caliper, with a piece of stiff wire, to the rear springs.
  6.  

Do not allow the caliper to hang by the brake line.

  1. Remove the brake disc and parking brake shoes.
  2.  
  3. Remove the thrust washer bolts through the holes in the axle shaft flange.
  4.  
  5. Using a puller (slide hammer), remove the axle shaft, bearing and oil seal assembly. If a slide hammer is not available, the brake disc may be bolted onto the axle backwards (remember to mount the nuts tapered side out) and used to pull the axle free.
  6.  
  7. Remove the inner oil seal using a suitable puller or small prybar.
  8.  
  9. Clean the inside of the rear axle tube.
  10.  
  11. Press off the toothed wheel. Use 2 V-blocks.
  12.  
  13. Raise up the seal and pressure plate on the axle shaft so that the divided press plate can be placed on the bearing.
  14.  
  15. Place the press yoke over the press plate.
  16.  
  17. Removing the bearing together with the snapring. Use press tool 5212 or equivalent.
  18.  

To install:
  1. Pack the new bearing with grease before installation. The preferred method is with a bearing packer (a low cost tool available at most automotive supply shops) but it may be done by hand if necessary. The bearing must be packed from one side until the grease comes out the other side.
  2.  
  3. Fill the space between the lips of the new oil seal with wheel bearing grease.
  4.  
  5. Position the new seal on the axle shaft.
  6.  
  7. Using a press, install the bearing with a new locking ring, onto the axle shaft.
  8.  


WARNING
When reinstalling the additional toothed gear on axles, the gear must be installed precisely 116mm onto the shaft. The acceptable margin is plus or minus 0.1mm. If at all possible, use Volvo tool 2412 which will allow precise location of this gear. If this gear is not properly located, the vehicle may not run properly.

  1. Install the inner oil seal in the axle shaft housing using a seal installation tool (such as Volvo 5009 or similar) and drift.
  2.  
  3. Install the axle shaft into the housing, rotating it so that it aligns with the differential.
  4.  
  5. Install the bolts for the thrust washer and tighten to 29 ft. lbs. (40 Nm).
  6.  
  7. Install the parking brake shoes, brake disc, caliper and pads. Use new bolts and tighten to 43 ft. lbs. (58 Nm). Make sure the brake disc rotates free of the brake pads.
  8.  
  9. Install the wheel and adjust the parking brake.
  10.  
  11. Lower the vehicle.
  12.  



Click image to see an enlarged view

Fig. Fig. 1: Removing the axle shaft using the brake disc

 
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