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

Leaf Spring

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REMOVAL & INSTALLATION



1995-98 960/S90/V90

See Figure 1

Multi-Link suspensions require alignment any time the suspension components are disassembled. Installation tightening and torque procedures are critical to correct alignment.

  1. Raise and support the vehicle safely. Make sure the front supports are placed as far forward as possible. Check that the rear supports will not interfere with the support arm.
  2.  
  3. Remove the rear wheels.
  4.  
  5. Remove the sway bar from the vehicle.
  6.  
  7. Install compression tool Kent-Moore® No. J-41470 (or equivalent) as follows:
    1. Attach one end of the tool yoke into the boss on one side of the axle support beam.
    2.  

  8.  

There is a boss cast into the support on either side of where the spring is visible from underneath.

  1. Slide the tool into the boss on the other side of the axle support beam to fully engage the yoke.
  2.  
  3. Make sure the tool is seated between the retaining tabs before any suspension components can be removed.
  4.  
  5. Make sure the rollers on the ends of the tool are positioned inside the lower control arms.
  6.  
  7. Turn the handle to raise the control arms and compress the leaf spring.
  8.  


CAUTION
Do not tighten the tool after the pegs have contacted the axle support beam.

  1. Once the spring is compressed, components can be removed.
  2.  
  3. Compress the suspension slightly.
  4.  
  5. Removed the shock absorber mounting bolt from the rear support arm.
  6.  
  7. Press the suspension up to normal position, as if the vehicle were on the ground.
  8.  
  9. Remove the bolts at the front of the support arm bracket.
  10.  
  11. Remove the support arm-to-wheel bearing housing bolt.
  12.  
  13. Loosen the support arm bracket nut a few turns.
  14.  
  15. Tap the support arm off the wheel bearing housing.
  16.  
  17. Remove the support arm bracket nut and the support arm with the bracket attached. Do not remove the support arm-to-bracket through bolt.
  18.  
  19. Remove the track rod-to-wheel bearing housing bolt.
  20.  
  21. Tap the track rod off the wheel bearing housing.
  22.  
  23. Remove the lower control arm-to-wheel bearing housing nut. Tap out the bolt with a brass punch.
  24.  
  25. Loosen the inboard lower control arm mounting nut until approximately 0.04-0.08 in. (1-2mm) of the bolt still protrudes from the nut. Tap the bolt with a brass punch until the nut contacts the lower control arm.
  26.  
  27. Repeat Steps 6-14 to disassemble the opposite side of the suspension.
  28.  
  29. Lower the compression tool and control arms completely. Inspect the spring mountings in the lower control arms. Retain the mountings in the control arms for assembly.
  30.  
  31. Loosen all the lower rear axle support bolts one turn.
  32.  
  33. Remove the two front bolts at the pinion flange.
  34.  
  35. Remove the spacers.
  36.  
  37. Install rear axle retainer 5580 (or equivalent) to the front edge of the differential. Install rear axle retainer 5579 (or equivalent) to the rear edge of the differential.
  38.  
  39. Position a lift or jack against the lower axle support beam.
  40.  
  41. Remove the lower support beam mounting bolts and lower the support beam.
  42.  

Before removing the spring mounting plates, take note of the positioning. Installation must be in the same positions.

  1. Remove the spring mounting plates and remove the spring.
  2.  
  3. Check all spring mountings for damage or wear.
  4.  

To install:
  1. Install the spring. Install the spring mounting plates using new bolts.
  2.  

The leaf spring is marked with a center line.

  1. Make sure the spring is centered. Tighten the spring mounting plate bolts alternately to 37 ft. lbs. (50 Nm).
  2.  
  3. Position the lower axle support beam on a lift or jack.
  4.  
  5. Make sure the lower axle support beam contact surfaces are clean and that the lower differential bushing is in place.
  6.  
  7. Make sure the lower differential bushings are inside the guide flanges of the lower axle support beam.
  8.  
  9. Raise the lower axle support beam into position.
  10.  
  11. Install new mounting bolts except at the pinion flange. Tighten the bolts until there is approximately 0.08-0.16 in. (2-4mm) clearance between the support surfaces.
  12.  
  13. Remove the lift or jack.
  14.  
  15. Remove the differential retainers 5579 and 5580 (or equivalents) from the differential.
  16.  
  17. Install the 2 front spacers between the upper and lower axle support beams.
  18.  
  19. Install new bolts at the pinion flange.
  20.  
  21. Tighten all lower axle support bolts diagonally until snug. Tighten the bolts diagonally to 59 ft. lbs. (80 Nm).
  22.  
  23. Install the compression tool.
  24.  
  25. Install the spring into the mounting in the control arms.
  26.  
  27. Raise the control arms up to their normal position.
  28.  
  29. Install the lower control arm to the wheel bearing housing,
  30.  
  31. Install the track rod to the wheel bearing housing using a new nut and tighten to 59 ft. lbs. (80 Nm).
  32.  
  33. Install the rear support arm using new bolts and nut, but do not yet tighten the bolts and nut.
  34.  
  35. Tighten the rear bolt and front nut to 59 ft. lbs. (80 Nm).
  36.  
  37. Tighten the front bolts to 37 ft. lbs. (50 Nm).
  38.  
  39. Install the shock absorbers.
  40.  
  41. Make sure the washers and bushings on the sway bar links are in place.
  42.  
  43. Raise the sway bar into position and install.
  44.  
  45. Install the wheels.
  46.  
  47. Lower the vehicle.
  48.  
  49. Check wheel alignment.
  50.  



Click image to see an enlarged view

Fig. Fig. 1: Leaf spring compression tool J-41470

 
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