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

Upper Control Arm

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REMOVAL & INSTALLATION



1992-94 960 Sedan
  1. Raise and support the vehicle safely. Make sure the front supports are placed as far forward as possible.
  2.  
  3. Remove the wheels.
  4.  
  5. Remove the brake caliper without disconnecting the brake hose. Tie it with wire out of the way. Do not allow it to hang by the hose.
  6.  
  7. Remove the bolt holding the lower support arm to the wheel bearing housing and tap the support arm loose.
  8.  
  9. Remove the nut and bolt holding the lower control arm (intermediate arm) to the wheel bearing housing.
  10.  
  11. Remove the bolt attaching the track rod to the wheel bearing housing.
  12.  
  13. Use a small bearing puller to disconnect the track rod.
  14.  
  15. Remove the nut which holds the upper control arm to the wheel bearing housing.
  16.  
  17. Collect and note the location of the spacers between the upper control arm and the bearing housing. They are alignment shims and must be reinstalled properly.
  18.  
  19. Remove the nut holding the rear upper control arm to the rear axle member (support).
  20.  
  21. At the front of the upper control arm, remove the nut and bolt which holds it to the rear axle member.
  22.  
  23. Use a pair of adjustable pliers to remove the control arm from the vehicle.
  24.  

To install:
  1. Install the arm to the rear axle member and secure with nut and bolt.
  2.  
  3. Install both the front and rear mounts.
  4.  
  5. Install the spacers at the wheel bearing housing, and install the nut holding the arm to the housing.
  6.  
  7. Inboard at the rear axle support, tighten the rearmost nut to 62 ft. lbs. (85 Nm).
  8.  
  9. Tighten the front nut and bolt to 51 ft. lbs. (70 Nm) plus an additional 60 degrees of rotation.
  10.  
  11. Pull the top of the wheel bearing housing outwards away from the center of the vehicle. This is essential for correct wheel alignment. Tighten the upper control arm nut at the bearing housing to 84 ft. lbs. (115 Nm).
  12.  
  13. Pull the wheel bearing housing outward and install the lower control arm with the bolt and nut, but do not tighten it.
  14.  
  15. Pull the wheel bearing housing inwards towards the center of the vehicle. Tighten the control arm nut to 37 ft. lbs. (50 Nm) plus and additional 90 degrees of rotation.
  16.  
  17. Reinstall the support arm; tighten the mount to 44 ft. lbs. (60 Nm) plus an additional 90 degrees of rotation.
  18.  
  19. Install the track rod and tighten to 62 ft. lbs. (85 Nm).
  20.  
  21. Install the brake caliper.
  22.  
  23. Install the wheels.
  24.  
  25. Lower the vehicle.
  26.  
  27. Check and adjust the rear alignment if necessary.
  28.  

1995-98 960/S90/V90
  1. Raise and safely support the vehicle.
  2.  
  3. Remove the wheel.
  4.  
  5. Install compression tool J-41470 or a suitable equivalent. Apply light pressure to the link arm.
  6.  
  7. Disconnect the shock absorber from the support arm.
  8.  
  9. Remove the sway bar bolts from support arm on both sides.
  10.  
  11. Turn the compression tool up to its fully compressed position.
  12.  
  13. Remove the brake caliper and hang it safely out of the way so that the brake hose is not damaged.
  14.  
  15. Remove the nut connecting the upper control arm to the wheel bearing housing.
  16.  
  17. Using a brass drift, tap the bolt out to release the upper control arm bushing from the wheel bearing housing.
  18.  
  19. Remove the bolt connecting the track rod to the wheel bearing housing.
  20.  
  21. Separate the track rod from the wheel bearing housing.
  22.  
  23. Remove the nut connecting the lower control arm to the wheel bearing housing. Use a brass drift to tap out the bolt.
  24.  
  25. Separate the wheel bearing housing from the upper control arm. Allow the wheel bearing housing to rest on the lower control arm.
  26.  
  27. Remove the front and rear bolts from the upper control arm.
  28.  
  29. Pull the upper control from the rear axle beam and remove it.
  30.  

To install:
  1. Install the upper control arm in the rear axle beam and attach it with new front and rear bolts. Tighten the bolts to 18 ft. lbs. (25 Nm).
  2.  
  3. Push the wheel bearing housing up and connect it to the upper control arm.
  4.  
  5. Install a new attaching nut, but do not tighten.
  6.  
  7. Connect the support arm to the wheel bearing housing and install a new attaching bolt, but do not tighten.
  8.  
  9. Connect the lower control arm to the wheel bearing housing. Install the through bolt and a new nut, but do not tighten.
  10.  
  11. Install the track rod and attaching bolt, but do not tighten.
  12.  
  13. Tighten the attaching bolts and nuts in the following sequence to the indicated specifications:

    upper control arm nut-92 ft. lbs. (120 Nm)
     
    lower control arm nut-63 ft. lbs. (80 Nm)
     
    support arm bolts-63 ft. lbs. (80 Nm)
     
    track rod bolt-63 ft. lbs. (80 Nm)
     

  14.  
  15. Install the brake caliper and new attaching bolts. Tighten the bolts to 47 ft. lbs. (60 Nm).
  16.  
  17. Install the shock absorber and a new attaching bolt. Tighten the bolt to 63 ft. lbs. (80 Nm).
  18.  
  19. Release the pressure on the compression tool.
  20.  
  21. Connect the sway bar to the support arm using new bolts, but do not tighten.
  22.  
  23. Install the wheels.
  24.  
  25. Lower the vehicle.
  26.  

 
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