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

Power Rack and Pinion

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REMOVAL & INSTALLATION



240 Series and Coupe

CAUTION
On vehicles with air bags, the front wheels must be pointing straight ahead with the steering wheel locked. If this is not done, the contact reel of the air bag system will reach its end position and deploy the air bag.

  1. Disconnect the negative battery cable. Disarm the air bag system, if equipped.
  2.  
  3. Raise and support the vehicle safely on jackstands.
  4.  
  5. Remove the front wheels
  6.  
  7. From under the vehicle, remove the splashguard.
  8.  
  9. With the wheels pointed straight ahead, measure the length from one tie rod end to the steering rack housing.
  10.  
  11. Remove the steering column U-joint by scribing an alignment mark on the shaft.
  12.  
  13. Remove the cotter pin and loosen the nut and bolt securing the joint to the column shaft.
  14.  
  15. Separate the joint and steering shaft.
  16.  
  17. Remove the tie rod ends.
  18.  
  19. With a drip pan placed below the hoses to the steering rack, tag then remove the hoses. Discard the copper sealing washers.
  20.  
  21. Remove the sway bar if equipped.
  22.  
  23. Remove the two steering rack fixing bolts and nuts.
  24.  
  25. Lower the steering rack down from the vehicle frame and out.
  26.  

To install:
  1. Position the steering rack in the vehicle and secure the rack with the fixing nuts and bolts. Tighten the nuts and bolts to 32 ft. lbs. (44 Nm).
  2.  
  3. Install the sway bar if removed.
  4.  
  5. Install the hoses to the rack using new sealing washers. Tighten the hose bolts to 30 ft. lbs. (42 Nm).
  6.  
  7. Install the tie rod ends.
  8.  
  9. Connect the steering shaft and U-joint by aligning the scribe mark on the steering shaft with the mark on the U-joint. Tighten the retainer nut and bolt to 15 ft. lbs. (20 Nm). Install a new cotter pin.
  10.  
  11. Install the splashguard.
  12.  
  13. Fill the steering reservoir and bleed the system.
  14.  
  15. Lower the vehicle.
  16.  

700 Series, 900 Series and S90/V90

See Figure 1

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Remove the splash guard and the small jacking panel on the front crossmember.
  6.  
  7. Disconnect the lower steering shaft from the steering gear.
  8.  
  9. At the lower universal joint, remove the snaprings and loosen the upper clamp bolt.
  10.  
  11. Remove the lower clamp bolt and slide the joint up on the shaft
  12.  
  13. Use a ball joint separator and disconnect the tie rods at the outer ends.
  14.  
  15. Disconnect the fluid lines from the steering gear. Catch the spilled fluid in a pan and install plugs in the lines.
  16.  
  17. Remove the sway bar mounting brackets from the side members and move them out of the way.
  18.  
  19. Remove the steering gear retaining bolts and lower the assembly out of the vehicle.
  20.  

To install:
  1. When reinstalling, position the rack in position and install the retaining bolts. Tighten them to 32 ft. lbs. (44 Nm).
  2.  
  3. Install the sway bar mounting brackets.
  4.  
  5. Use new copper washers and connect the fluid lines to the assembly.
  6.  
  7. Connect the tie rods and tighten their nuts to 44 ft. lbs. (60 Nm).
  8.  
  9. Slide the lower universal joint down the shaft and into position.
  10.  
  11. Tighten the lower clamp bolt first, then the upper. Both bolts are tightened to 15 ft. lbs. (20 Nm).
  12.  
  13. Install the snaprings.
  14.  
  15. Reinstall the jacking plate and the splash guard.
  16.  
  17. Fill the reservoir with the appropriate type of Automatic Transmission Fluid (ATF). For further information, refer to General Information & Maintenance .
  18.  
  19. Start the engine and smoothly turn the steering wheel from lock to lock 3 or 4 times.
  20.  
  21. Bleed the system and recheck the fluid level in the reservoir.
  22.  
  23. Lower the vehicle.
  24.  



Click image to see an enlarged view

Fig. Fig. 1: Unfasten the two attaching nuts/bolts to remove the lower shaft from the steering gear

850, C70, S70 and V70 Series

CAUTION
On vehicles with air bags, the front wheels must be pointing straight ahead with the steering wheel locked. If this is not done, the contact reel of the air bag system will reach its end position and deploy the air bag.

The front subframe must be lowered. The bolts cannot be used again once loosened: new subframe bolts are required.

  1. Disconnect the negative battery cable. Disarm the air bag system, if equipped.
  2.  
  3. Install support rail 5033, bracket 5006 and lifting hook, or their equivalents, over the engine.
  4.  
  5. Lift the engine up slightly so that there is no pressure on the engine mounts.
  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Remove the front wheels.
  10.  
  11. Disconnect the tie rod ends.
  12.  
  13. Remove the splash guard from below the engine.
  14.  
  15. Disconnect the power steering fluid lines brackets and clamps from the front and rear of the subframe.
  16.  
  17. Remove the five nuts holding the steering rack to the subframe.
  18.  
  19. Position a jack below the rear part of the subframe and remove the following:

    4 bolts holding the subframe to the body on both sides
     
    2 bolts and washers holding the bracket to the subframe
     

  20.  
  21. Loosen the front subframe bolts so the frame lowers 0.59-0.79 in. (15-20mm).
  22.  
  23. Lower the subframe using the jack, and place a spacer between the frame and the body at the rear edge so the frame will not pop up.
  24.  
  25. Position a catch pan under the steering rack and disconnect the power steering lines from the rack.
  26.  
  27. Remove the steering column joint bolt and press it up from the steering rack.
  28.  
  29. Remove the bolt holding the rack to the engine mount.
  30.  
  31. Remove rack from the right side.
  32.  

To install:
  1. Transfer the thermal protection plate and center attachment mount, but do not tighten the mounting bolts.
  2.  
  3. Install the protective plugs in the line connection holes.
  4.  
  5. Install the tie rod ends.
  6.  
  7. Install the steering rack from the right side and let it rest on the rear engine mount.
  8.  
  9. Raise the rack up on the right side so that it is straight in relation to the frame and tighten the engine mount bolt to 37 ft. lbs. (50 Nm).
  10.  
  11. Connect the fluid lines and brackets loosely using new O-rings on the lines.
  12.  
  13. Align the fluid lines in the bracket and tighten them in the steering rack.
  14.  
  15. Fit the steering rack onto the steering shaft joint and tighten the bolt to 15 ft. lbs. (20 Nm).
  16.  
  17. Install the bolt lock clip.
  18.  
  19. Lift the rear of the subframe up using a jack and line up the steering rack mount bolts in the frame.
  20.  
  21. Install new subframe bolts loosely.
  22.  
  23. Move the jack to the front and replace the bolts with new ones, but do not tighten.
  24.  
  25. Tighten the bolts on the left side of the subframe to 77 ft. lbs. (105 Nm) plus an additional 120 degrees.
  26.  
  27. Tighten the right side bolts the same way.
  28.  
  29. Finally, tighten the bracket bolts on both sides to 37 ft. lbs. (50 Nm).
  30.  
  31. Install new nuts on the steering rack and tighten them to 37 ft. lbs. (50 Nm).
  32.  
  33. Tighten the steering rack center bolt to 59 ft. lbs. (80 Nm).
  34.  
  35. Install the front and rear steering fluid line brackets and tighten them.
  36.  
  37. Install the engine splashguard below the engine.
  38.  
  39. Install the wheels.
  40.  
  41. Fill the power steering fluid reservoir with fluid.
  42.  
  43. Connect the negative battery cable.
  44.  
  45. Start the vehicle and bleed the steering system.
  46.  
  47. Check the fluid level once again.
  48.  
  49. Lower the vehicle and check the toe-in.
  50.  

 
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