Volvo Cars 1999-05

Lower Ball Joints

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Removal & Installation



  1. Remove the front wheels.
  2.  
  3. Remove the nut from the control arm. Use a Torx wrench as a counterhold.
  4.  


WARNING
Ensure that the tension strap is correctly secured in the control arms.

  1. Pull down the control arms (1) using a tension strap (2).
  2.  
  3. Release the spring strut from the control arm.
  4.  
  5. Remove the bolt from the halfshaft. Use a screwdriver as a counterhold on the brake disc.
  6.  
  7. Remove the halfshaft from the hub. Knock the halfshaft out using a brass drift.
  8.  
  9. Push the spring strut to one side.
  10.  
  11. Remove the bolts from the ball joint.
  12.  
  13. Remove the rubber seal (1).
  14.  


    Click image to see an enlarged view

    Fig. Removing rubber seal-S60, S70, S80, V70

    Removing rubber seal-S60, S70, S80, V70

Installing the inner sleeve (P/N 999 5781-1)



Click image to see an enlarged view

Fig. Guide bolts installed-S60, S70, S80, V70

Guide bolts installed-S60, S70, S80, V70
  1. Install the inner sleeve so that both halves hook securely in the flange (see arrow) on the ball joint.
  2.  
  3. Turn the inner sleeve so that the slit is at right angles to the bolt holes.
  4.  

Installing the outer sleeve (P/N 999 5781-2)



Click image to see an enlarged view

Fig. Guide bolt identification-S60, S70, S80, V70

Guide bolt identification-S60, S70, S80, V70

Click image to see an enlarged view

Fig. Installing outer sleeve-S60, S70, S80, V70

Installing outer sleeve-S60, S70, S80, V70

Click image to see an enlarged view

Fig. Installing inner sleeve-S60, S70, S80, V70

Installing inner sleeve-S60, S70, S80, V70
  1. Install the outer sleeve around the inner sleeve halves. Tighten the bolt (1).
  2.  
  3. Install an M12 nut on the ball joint bolt (2).
  4.  
  5. Screw on the nut so that the ball joint bolt is just protruding from the nut.
  6.  

Installing the guide bolts (P/N 999 5781-3)



Click image to see an enlarged view

Fig. Ball joint removal tool installed-S60, S70, S80, V70

Ball joint removal tool installed-S60, S70, S80, V70

Click image to see an enlarged view

Fig. Support tool installed-S60, S70, S80, V70

Support tool installed-S60, S70, S80, V70
NOTE
The guide bolts have a wrench grip (see arrow) which is asymmetrically positioned. 1. Aluminum wheel spindle: Use the bolt (1) with the greater distance from the wrench grip 2. Steel wheel spindle: Use the bolt (2) with the shortest distance from the wrench grip.

  1. Screw in the guide bolts (1) fully.
  2.  
  3. Install the support (P/N 999 5781) using 3 wheel studs.
  4.  
  5. Screw the guide bolts (1) down until they are in contact with the support.
  6.  
  7. Position the supplementary support (2) (P/N 999 5781-4) on the hydraulic press (1).
  8.  
  9. Screw the connector (3) (P/N 999 5781-5) into place on the hydraulic press.
  10.  
  11. Install the connector on the nut on the ball joint.
  12.  
  13. Press off the ball joint.
  14.  
  15. Remove the tool and the ball joint.
  16.  


WARNING
Use protective goggles.

  1. Clean the ball joint seat and the mating surfaces of the ball joint to the wheel spindle. Use a rotary wire brush.
  2.  
  3. Lubricate the seat using wheel bearing grease.
  4.  

To install:

  1. Loosely install the new ball joint using the guide bolts.
  2.  


WARNING
Leave the protective cap for the ball joint in position to prevent damaging the rubber seal.

  1. Press the ball joint up towards the seat using the impact drift (1) (P/N 999 5796). Check that the ball joint is centered in the seat.
  2.  
  3. Knock in the ball joint using a copper mallet.
  4.  
  5. Tighten the ball joint using new bolts. Tighten to 37 ft. lbs.(50 Nm)
  6.  
  7. Remove the protective cap (1).
  8.  
  9. Install the halfshaft in the hub. Install a new bolt.
  10.  
  11. Align the ball joints (1) in the control arm.
  12.  


CAUTION
Take care when releasing the tension strap.

  1. Slowly release the control arms (1) by releasing the tension strap (2).
  2.  
  3. Install a new nut.
  4.  


NOTE
The ball joint pinion must not rotate. Use a Torx wrench as a counterhold so that the rubber boot is not damaged. Tighten to 59 ft. lbs. (80 Nm).

  1. Install the wheels. Tighten to 103 ft. lbs. (140 Nm).
  2.  

  1. Raise the car.
  2.  
  3. Slacken off the ball joint nut as much as possible.
  4.  


NOTE
Clean the ball joint thread using a wire brush. Use rust penetrator. If the ball joint releases in the cone, position a transmission jack under the control arm. Carefully lift (not more than so the front spring is in the resting position) until the cone jams. Remove the nut.

  1. Remove the stud in the front edge
  2.  
  3. Remove the two bolts at the rear edge. Move the wheel to one side. Pull out the control arm from the cross member.
  4.  


NOTE
Ensure that the halfshaft is not pulled out of the transmission.

  1. Slacken off the nut positioned on the ball joint as much as possible. Press the rubber down.
  2.  


WARNING
Secure the tool to prevent damage.

  1. Press out the ball joint.
  2.  
  3. Remove the nut and draw out the control arm.
  4.  

To install:


CAUTION
Replace the ball joint rubber ring if it is worn or damaged.



Click image to see an enlarged view

Fig. Inspect the rubber rings-S40, V40

Inspect the rubber rings-S40, V40
  1. Clean the area around the ball joint.
  2.  
  3. Remove the old rubber ring.
  4.  
  5. Lubricate the new ring and install it.
  6.  
  7. Ensure that the locking springs are correctly installed.
  8.  
  9. Install the control arm with the ball joint on the wheel spindle.
  10.  
  11. Install the control arm in the cross member. Install the bolt and nut.
  12.  
  13. Install the two bolts in the rear bushing.
  14.  
  15. Tighten all bolts and nuts by hand.
  16.  
  17. Post-tighten the two rear bolts. Tighten to 68 ft. lbs. (90 Nm).
  18.  
  19. Press the ball joint all the way down. Tighten to 51 ft. lbs. (67 Nm).
  20.  
  21. Remove the support and rock the car a few times so that the bushings come into the correct position.
  22.  
  23. Tighten the nut. Tighten to 68 ft. lbs. (90 Nm) + 60 deg.
  24.  
  25. Check the front mounting and wheel alignment.
  26.  


    Click image to see an enlarged view

    Fig. Lower control arm final tightening-S40, V40

    Lower control arm final tightening-S40, V40

  1. Remove the wheel
  2.  
  3. Remove the halfshaft bolt. Use a counterhold.
  4.  
  5. Detach the halfshaft end at the hub Tap in the shaft end approximately 10-15 mm. Use a rubber or copper mallet.
  6.  
  7. Blow clean around the ball joint with compressed air.
  8.  
  9. Generously spray the ball joint and the bolt and nut retaining the ball joint using rust penetrator.
  10.  


NOTE
Do not insert a screwdriver or punch between the ears on the wheel spindle.

  1. If the bolt has rusted solid, slacken off the nut a few turns. Knock the bolt so that it loosens.
  2.  
  3. Remove the bolt and the nut.
  4.  
  5. Spray the ball joint with rust penetrator again.
  6.  


NOTE
The inner diameter of the socket must be larger than the outer diameter of the cover. This is to prevent damage to the cover.

  1. Tap the ball joint off the wheel spindle. Use a socket as a spacer.
  2.  
  3. Spray the ball joint with rust penetrator again.
  4.  
  5. Move the ball joint up and down by hand (or a jimmy bar can be used) until the ball joint detaches from the wheel spindle.
  6.  
  7. Withdraw the halfshaft from the hub.
  8.  
  9. Twist the spring strut to one side. Hang the halfshaft so that the control arm is not in contact with the halfshafts.
  10.  
  11. Remove the two bolts from the engine pad on the right side.
  12.  
  13. Remove the bolt (1) from the rear engine pad
  14.  
  15. Remove the bolt (3) from the front engine pad
  16.  
  17. Remove the bolt and nut (2) from the torque rod.
  18.  

On the left side:

  1. Position a jack on the torque rod mounting in the transmission.
  2.  


    Click image to see an enlarged view

    Fig. Support the torque rod with a jack-S40, V40

    Support the torque rod with a jack-S40, V40


NOTE
Use a wooden block as a shim.

  1. Remove the four bolts from the control arm
  2.  
  3. Remove the control arm.
  4.  

On the right side:

  1. Position a jack against the oil pan.
  2.  


NOTE
Use a wooden block as a shim.

  1. Lift the engine to access the control arm bolts.
  2.  
  3. Remove the four bolts (1) from the control arm
  4.  
  5. Remove the control arm.
  6.  

To install:

On the left side:

  1. Install the control arm on the sub-frame. Use new bolts. Tighten to 49 ft. lbs. (65 Nm). Angle-tighten 90 deg.
  2.  
  3. Lower and remove the jack.
  4.  

On the right side:

  1. Install the control arm on the sub-frame. Use new bolts. Tighten to 49 ft. lbs. (65 Nm). Angle-tighten 90 deg.
  2.  
  3. Lower and remove the mobile jack.
  4.  
  5. Install the two bolts (1) at the engine pad on the right side. Tighten to 27 ft. lbs. (35 Nm). Angle-tighten 90 deg.
  6.  


NOTE
Use new bolts.

  1. Install the bolts (1, 3). Tighten to 37 ft. lbs. (50 Nm).
  2.  
  3. Install the bolt and nut (2) for the torque rod. Tighten to 30 ft. lbs. (40 Nm). Angle-tighten 40 deg.
  4.  


NOTE
Use a new bolt and nut.

  1. Clean the hub and the halfshaft splines.
  2.  
  3. Fold out and twist the spring strut and locate the halfshaft in the hub. Use an adjustable wrench to hold the control arm down.
  4.  
  5. Install a new halfshaft bolt. Tighten to 27 ft. lbs. (35 Nm). Angle-tighten 90 deg. Counterhold the brake disc.
  6.  


NOTE
Lubricate the threads and flange on the bolt.

  1. Check that the groove on the ball joint spindle lines up with the bolt hole in the wheel spindle.
  2.  


NOTE
Press the ball joint upwards so that the conical top is visible above the bolted joint on the wheel spindle. Use a new locknut in the wheel spindle bolt. Tighten to 38 ft. lbs. (50 Nm).

  1. Install the wheel.
  2.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Front wheel
     
    Stabilizer bar link
     
    Lower ball joint from the lower control arm
     
    Lower ball joint from the strut
     

  4.  

To install:

  1. Install or connect the following:

    Lower ball joint. Tighten the strut bolts to 22 ft. lbs. (30 Nm) plus 90 degrees.
     
    Lower control arm. Tighten the nut to 44 ft. lbs. (60 Nm).
     
    Stabilizer bar link
     
    Front wheel
     

  2.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Front wheel
     
    Steering knuckle pinch bolt
     
    Lower control arm bolts
     
    Lower ball joint
     

  4.  

To install:

  1. Remove or disconnect the following:

    Lower ball joint. Tighten the pinch bolt to 37 ft. lbs. (50 Nm).
     
    Lower control arm bolts. Tighten the bolts to 13 ft. lbs. (18 Nm) plus 120 degrees.
     
    Front wheel
     

  2.  



Click image to see an enlarged view

Fig. Front suspension assembly-960, S90 and V90 models

Front suspension assembly-960, S90 and V90 models
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Front wheel
     
    Steering knuckle pinch bolt
     
    Lower control arm bolts
     
    Lower ball joint
     

  4.  

To install:

  1. Remove or disconnect the following:

    Lower ball joint. Tighten the pinch bolt to 37 ft. lbs. (50 Nm).
     
    Lower control arm bolts. Tighten the bolts to 13 ft. lbs. (18 Nm) plus 120°.
     
    Front wheel
     

  2.  

  1. Remove the stub axle
  2.  
  3. Place the stub axle in a soft jawed vise
  4.  
  5. Remove the two bolts holding the ball joint in the stub axle.
  6.  
  7. Tap out the ball joint alternately. Use a drift.

    Click image to see an enlarged view

    Fig. Ball joint removal-V70XC

    Ball joint removal-V70XC
  8.  

To install:

  1. Clean the stub axle mating surfaces of the ball joint.
  2.  
  3. Center the ball joint against the stub axle. Use the bolt (but do not tighten the bolt yet)
    NOTE
    Use new bolts.

  4.  
  5. Tap the ball joint fully into the stub axle. Tap alternately with a drift.
  6.  
  7. Tighten the bolts. Tighten to 37 ft. lbs. (50 Nm).
  8.  
  9. Install the stub axle
  10.  

  1. Remove the front wheels.
  2.  
  3. Remove the nut from the control arm. Use a Torx® wrench as a counterhold.
    WARNING
    Ensure that the tension strap is correctly secured in the control arms.

  4.  
  5. Pull down the control arms (1) using a tension strap (2).
  6.  
  7. Release the spring strut from the control arm.
  8.  
  9. Remove the bolt from the halfshaft. Use a screwdriver as a counterhold on the brake disc.
  10.  
  11. Remove the halfshaft from the hub. Knock the halfshaft out using a brass drift.
  12.  
  13. Push the spring strut to one side.
  14.  
  15. Remove the bolts from the ball joint.
  16.  
  17. Remove the rubber seal (1).

    Click image to see an enlarged view

    Fig. Removing rubber seal-S60, S70, S80, V70

    Removing rubber seal-S60, S70, S80, V70
  18.  

Installing the inner sleeve (P/N 999 5781-1)

Click image to see an enlarged view

Fig. Guide bolts installed-S60, S70, S80, V70

Guide bolts installed-S60, S70, S80, V70

  1. Install the inner sleeve so that both halves hook securely in the flange (see arrow) on the ball joint.
  2.  
  3. Turn the inner sleeve so that the slit is at right angles to the bolt holes.
  4.  

Installing the outer sleeve (P/N 999 5781-2)

Click image to see an enlarged view

Fig. Guide bolt identification-S60, S70, S80, V70

Guide bolt identification-S60, S70, S80, V70

Click image to see an enlarged view

Fig. Installing outer sleeve-S60, S70, S80, V70

Installing outer sleeve-S60, S70, S80, V70

Click image to see an enlarged view

Fig. Installing inner sleeve-S60, S70, S80, V70

Installing inner sleeve-S60, S70, S80, V70

  1. Install the outer sleeve around the inner sleeve halves. Tighten the bolt (1).
  2.  
  3. Install an M12 nut on the ball joint bolt (2).
  4.  
  5. Screw on the nut so that the ball joint bolt is just protruding from the nut.
  6.  

Installing the guide bolts (P/N 999 5781-3)

Click image to see an enlarged view

Fig. Ball joint removal tool installed-S60, S70, S80, V70

Ball joint removal tool installed-S60, S70, S80, V70

Click image to see an enlarged view

Fig. Support tool installed-S60, S70, S80, V70

Support tool installed-S60, S70, S80, V70


NOTE
The guide bolts have a wrench grip (see arrow) which is asymmetrically positioned. 1. Aluminum wheel spindle: Use the bolt (1) with the greater distance from the wrench grip 2. Steel wheel spindle: Use the bolt (2) with the shortest distance from the wrench grip.

  1. Screw in the guide bolts (1) fully.
  2.  
  3. Install the support (P/N 999 5781) using 3 wheel studs.
  4.  
  5. Screw the guide bolts (1) down until they are in contact with the support.
  6.  
  7. Position the supplementary support (2) (P/N 999 5781-4) on the hydraulic press (1).
  8.  
  9. Screw the connector (3) (P/N 999 5781-5) into place on the hydraulic press.
  10.  
  11. Install the connector on the nut on the ball joint.
  12.  
  13. Press off the ball joint.
  14.  
  15. Remove the tool and the ball joint.
    WARNING
    Use protective goggles.

  16.  
  17. Clean the ball joint seat and the mating surfaces of the ball joint to the wheel spindle. Use a rotary wire brush.
  18.  
  19. Lubricate the seat using wheel bearing grease.
  20.  

To install:

  1. Loosely install the new ball joint using the guide bolts.
    WARNING
    Leave the protective cap for the ball joint in position to prevent damaging the rubber seal.

  2.  
  3. Press the ball joint up towards the seat using the impact drift (1) (P/N 999 5796). Check that the ball joint is centered in the seat.
  4.  
  5. Knock in the ball joint using a copper mallet.
  6.  
  7. Tighten the ball joint using new bolts. Tighten to 37 ft. lbs. (50 Nm)
  8.  
  9. Remove the protective cap (1).
  10.  
  11. Install the halfshaft in the hub. Install a new bolt.
  12.  
  13. Align the ball joints (1) in the control arm.
    CAUTION
    Take care when releasing the tension strap.

  14.  
  15. Slowly release the control arms (1) by releasing the tension strap (2).
  16.  
  17. Install a new nut.
    NOTE
    The ball joint pinion must not rotate. Use a Torx® wrench as a counterhold so that the rubber boot is not damaged. Tighten to 59 ft. lbs. (80 Nm).

  18.  
  19. Install the wheels. Tighten to 103 ft. lbs. (140 Nm).
  20.  

  1. Raise the car.
  2.  
  3. Slacken off the ball joint nut as much as possible.
    NOTE
    Clean the ball joint thread using a wire brush. Use rust penetrator. If the ball joint releases in the cone, position a transmission jack under the control arm. Carefully lift (not more than so the front spring is in the resting position) until the cone jams. Remove the nut.

  4.  
  5. Remove the stud in the front edge
  6.  
  7. Remove the two bolts at the rear edge. Move the wheel to one side. Pull out the control arm from the cross member.
    NOTE
    Ensure that the halfshaft is not pulled out of the transmission.

  8.  
  9. Slacken off the nut positioned on the ball joint as much as possible. Press the rubber down.
    WARNING
    Secure the tool to prevent damage.

  10.  
  11. Press out the ball joint.
  12.  
  13. Remove the nut and draw out the control arm.
  14.  

To install:


CAUTION
Replace the ball joint rubber ring if it is worn or damaged.



Click image to see an enlarged view

Fig. Inspect the rubber rings-S40, V40

Inspect the rubber rings-S40, V40
  1. Clean the area around the ball joint.
  2.  
  3. Remove the old rubber ring.
  4.  
  5. Lubricate the new ring and install it.
  6.  
  7. Ensure that the locking springs are correctly installed.
  8.  
  9. Install the control arm with the ball joint on the wheel spindle.
  10.  
  11. Install the control arm in the cross member. Install the bolt and nut.
  12.  
  13. Install the two bolts in the rear bushing.
  14.  
  15. Tighten all bolts and nuts by hand.
  16.  
  17. Post-tighten the two rear bolts. Tighten to 68 ft. lbs. (90 Nm).
  18.  
  19. Press the ball joint all the way down. Tighten to 51 ft. lbs. (67 Nm).
  20.  
  21. Remove the support and rock the car a few times so that the bushings come into the correct position.
  22.  
  23. Tighten the nut. Tighten to 68 ft. lbs. (90 Nm) plus  60 deg.

    Click image to see an enlarged view

    Fig. Lower control arm final tightening-S40, V40

    Lower control arm final tightening-S40, V40
  24.  
  25. Check the front mounting and wheel alignment.
  26.  

  1. Remove the wheel
  2.  
  3. Remove the halfshaft bolt. Use a counterhold.
  4.  
  5. Detach the halfshaft end at the hub Tap in the shaft end approximately 10-15mm. Use a rubber or copper mallet.
  6.  
  7. Blow clean around the ball joint with compressed air.
  8.  
  9. Generously spray the ball joint and the bolt and nut retaining the ball joint using rust penetrator.
    NOTE
    Do not insert a screwdriver or punch between the ears on the wheel spindle.

  10.  
  11. If the bolt has rusted solid, slacken off the nut a few turns. Knock the bolt so that it loosens.
  12.  
  13. Remove the bolt and the nut.
  14.  
  15. Spray the ball joint with rust penetrator again.
    NOTE
    The inner diameter of the socket must be larger than the outer diameter of the cover. This is to prevent damage to the cover.

  16.  
  17. Tap the ball joint off the wheel spindle. Use a socket as a spacer.
  18.  
  19. Spray the ball joint with rust penetrator again.
  20.  
  21. Move the ball joint up and down by hand (or a jimmy bar can be used) until the ball joint detaches from the wheel spindle.
  22.  
  23. Installation is the reverse order of removal. Replace the ball joint wheel spindle nut with a new one and tighten to 52 ft. lbs. (70 Nm).
  24.  

 
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