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

Steering Linkage

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REMOVAL & INSTALLATION



All vehicles are equipped with rack and pinion steering (manual or power). Rack and pinion systems save space and weight, improve steering response and eliminate most of the rods and linkage under the vehicle.

Tie Rod Ends

See Figures 1, 2, 3, 4, 5 and 6

  1. Raise and safely support the vehicle.
  2.  
  3. Remove the wheel(s).
  4.  
  5. Measure the length between the end of the tie rod and the steering rack housing, and mark the position of the tie rod end on the rack.
  6.  

Another way to remove the tie rod end and not drastically change the alignment is to loosen the locknut on the steering rack, but do not turn it any more than the initial loosening. Remove the tie rod end from the spindle as usual, but unthread the tie rod end from the steering rack without moving the locknut. When installing the tie rod end, thread the tie rod end onto the rack until it bottoms against the locknut, then turn the tie rod end so that the ball joint is ready to be connected to the spindle. Place the tie rod end in the spindle and tighten the retaining nut, then install the cotter pin. Tighten the locknut on the steering rack; the toe on the side you worked on should be very close, if not the same, as when you started.

  1. Loosen the locknut on the steering rack and pinion.
  2.  
  3. Remove the cotter pin (if equipped) and the retaining nut from the spindle.
  4.  
  5. Separate the tie rod end from the steering arm using an appropriate puller.
  6.  
  7. Unthread the tie rod end from the steering rack.
  8.  

To install:
  1. Thread the tie rod end onto the steering rack until it aligns with the marking made earlier.
  2.  
  3. Tighten the tie rod locknut to 52 ft. lbs. (70 Nm).
  4.  
  5. Connect the tie rod end to the steering arm.
  6.  
  7. Tighten the retaining nut.
    1. 850 series and C70/S70/V70: tighten to 52 ft. lbs. (70 Nm).
    2.  
    3. 240, 700, 940 and 960 series, and S90/V90: tighten to 44 ft. lbs. (60 Nm).
    4.  

  8.  
  9. Install the cotter pin (if equipped).
  10.  
  11. Install the wheels.
  12.  
  13. Lower the vehicle and check the front wheel alignment.
  14.  



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Fig. Fig. 1: Measuring the distance from the steering rack housing to the tie rod ends ball joint



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Fig. Fig. 2: Loosen the locknut on the steering rack



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Fig. Fig. 3: Remove the retaining nut from the tie rod end where it fastens to the spindle



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Fig. Fig. 4: The use of an appropriate puller is recommended, especially if the tie rod end is only being removed and not replaced



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Fig. Fig. 5: After the tie rod end is separated from the spindle, unthread it from the rack and pinion



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Fig. Fig. 6: After the tie rod end is removed, inspect the threads on the steering racks inner tie rod

Inner Tie Rod

If a steering boot or inner rod is damaged on the rack and pinion assembly, they are easily replaced after tie rod end removal. DO NOT allow a torn boot to go unattended, as steering rack damage will likely occur.

  1. Raise and safely support the vehicle.
  2.  
  3. Remove the wheel.
  4.  
  5. Remove the outer tie rod end from the spindle.
  6.  
  7. Remove the steering rack boot.
  8.  
  9. Using appropriate tools, hold the rack and loosen the inner tie rod by turning the hex on the ball.
  10.  
  11. Remove the inner tie rod assembly with the tie rod end attached.
  12.  

To install:
  1. Mark the position of the tie rod end on the inner tie rod, and remove the tie rod end.
  2.  

An alternative method is to measure the length of the assembled inner tie rod and tie rod end before removal. Then, assemble the new inner tie rod and tie rod end to the same length.

  1. Install the tie rod end onto the inner tie rod.
  2.  
  3. Compare the marks and assemble to the same length.
  4.  
  5. Clean the tie rod threads on the rack assembly.
  6.  
  7. Thread the new inner tie rod end onto the rack and tighten.
  8.  
  9. Using a punch, stake the inner tie rod assembly to the rack by hitting the inner tie rod lip.
  10.  
  11. Install the steering rack boot.
  12.  
  13. Fasten the tie rod end to the spindle.
  14.  
  15. Install the wheel.
  16.  
  17. Lower the vehicle.
  18.  

 
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