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

Pinion Seal

Print

REMOVAL & INSTALLATION



Except Multi-Link Suspension

See Figure 1

  1. Raise and safely support the vehicle.
  2.  
  3. Disconnect the driveshaft at the final drive unit (differential).
  4.  
  5. Loosen and remove the large center nut in the center of the pinion flange. The use of a counterhold device is highly recommended (Volvo 5149 or similar).
  6.  
  7. Use a puller to remove the flange from the housing.
  8.  
  9. Remove the old seal from the inside of the casing and discard it.
  10.  
  11. Clean and check the sealing surfaces. Replace the coupling flange if the sealing surface is worn.
  12.  

To install:
  1. Prepare the new seal by greasing the lip area and greasing the small spring to hold it in place during installation.
  2.  
  3. Install the seal using suitable drivers; do not crimp or gouge the seal during installation.
  4.  
  5. With an installation tool (Volvo 5156 or similar), reinstall the flange in the housing.
  6.  
  7. Install the center nut and tighten it to 145-180 ft. lbs. (197-245 Nm). Use a counterhold device to hold the flange while tightening.
  8.  
  9. Axles denoted by the S prefix in their serial number contain a compression sleeve within the differential housing. On these vehicles, install the center nut and finger-tighten, or carefully tighten to 16 inch lbs. (2 Nm). Make sure that the brakes are not applied and turn the flange at about 1 revolution per second so as to tighten the nut. As an alternative, the nut may be tightened with a wrench to at least 130 ft. lbs. (177 Nm).
  10.  
  11. Reinstall the driveshaft.
  12.  
  13. Check the oil level within the final drive and top up as necessary.
  14.  
  15. Lower the vehicle.
  16.  



Click image to see an enlarged view

Fig. Fig. 1: Steps to replace the pinion seal

Multi-Link Suspension

See Figure 2

  1. Raise and safely support the vehicle.
  2.  
  3. Matchmark the driveshaft flange and the final drive (differential) flange.
  4.  
  5. Remove the bolts and separate the shaft from the final drive.
  6.  
  7. Loosen and remove the large center nut in the center of the pinion flange. The use of a counterhold device is highly recommended. (Volvo 5149 or similar). Remove the 1 additional bolt from the flange. This bolt is a weight which serves to balance the rotational forces of the driveshaft.
  8.  
  9. Matchmark the flange and its center shaft for reassembly.
  10.  
  11. Drain the oil from the housing.
  12.  
  13. Use a puller to remove the flange from the housing.
  14.  
  15. Remove the old seal from the inside of the casing and discard it.
  16.  
  17. Clean and check the sealing surfaces. Replace the coupling flange if the sealing surface is worn.
  18.  

To install:
  1. Prepare the new seal by greasing the lip area and greasing the small spring to hold it in place during installation. The use of a seal puller such as Volvo 5069 is highly recommended.
  2.  
  3. Install the seal using suitable drivers; do not crimp or gouge the seal during installation.
  4.  
  5. Position the flange so that the marks align.
  6.  
  7. With an installation tool (Volvo 5156 or similar), reinstall the flange in the housing.
  8.  
  9. Install a new, lightly oiled center nut and tighten it to 132-145 ft. lbs. (180-197 Nm).
  10.  


WARNING
Do not overtighten the center nut. The pinion bearings will become overadjusted and fail prematurely.

  1. Install the bolt for weight in its original position.
  2.  
  3. Install the driveshaft, observing correct placement as shown by the matchmarks. Use new nuts and bolts and tighten them to 36 ft. lbs. (49 Nm).
  4.  
  5. Refill the final drive unit with oil.
  6.  
  7. Lower the vehicle.
  8.  



Click image to see an enlarged view

Fig. Fig. 2: Removing the pinion seal using puller 5069 or equivalent

 
label.common.footer.alt.autozoneLogo