Volvo Cars 1999-05

Transfer Case Removal & Installation

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

    Right front wheel
     
    Right axle halfshaft
     
    Transfer case vibration damper and bracket
     
    Rear driveshaft
     
    Transfer case
     

  4.  

To install:

  1. Install or connect the following:

    Transfer case and tighten the bolts to 37 ft. lbs. (50 Nm)
     
    Rear driveshaft
     
    Transfer case vibration damper and bracket
     
    Right axle halfshaft
     
    Right front wheel
     

  2.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Right front wheel
     
    Right axle halfshaft
     
    Transfer case vibration damper and bracket
     
    Rear driveshaft
     
    Transfer case
     

  4.  

To install:

  1. Install or connect the following:

    Transfer case and tighten the bolts to 37 ft. lbs. (50 Nm)
     
    Rear driveshaft
     
    Transfer case vibration damper and bracket
     
    Right axle halfshaft
     
    Right front wheel
     

  2.  

  1. Remove or disconnect the following:

    Right halfshaft
     
    Charge air hose under engine
     
    Heated oxygen sensor (HO 2 S) wiring
     
    Lower torque rod
     
    Driveshaft CV-joint
     
    Transfer case bracket attached to engine block
     
    Transfer case heat shield
     
    Transfer case
     

  2.  

To install:

  1. Install or connect the following:

    Transfer case and tighten bolts to 37 ft. lbs. (50 Nm)
     
    Heat shield and tighten bolts to 18 ft. lbs. (24 Nm)
     
    Transfer case bracket. Tighten bolts into transfer case to 37 ft. lbs. (50 Nm) and bolts into engine block to 18 ft. lbs. (24 Nm).
     
    Driveshaft CV-joint
     
    Lower torque rod
     
    HO 2 S wiring
     
    Charge air hose
     
    Right halfshaft
     

  2.  


NOTE
Ensure the parking brake is not applied and the gear selector is in position P.

  1. Remove or disconnect the following:

    Engine splash guard
     
    Right front wheel
     
    Bolt for the halfshaft and wheel hub
     
    Link for the anti-roll bar in the spring strut
     
    Nut for the ball joint/link arm. Counterhold the ball joint pinion with a Torx® wrench so the boot does not twist.
     

  2.  
  3. Position a jack under the right-hand side of the sub-frame. Remove the bolts from the support bracket for the right-hand side of the sub-frame.
  4.  
  5. Slacken off, but do not remove, the remaining bolts for the sub-frame.
  6.  
  7. Unhook the control arm from the ball joint.
  8.  
  9. Press out the wheel spindle.
  10.  
  11. Detach the halfshaft from the hub, remove the bolts from the bearing cap for the half-shaft. Pull the half-shaft straight out.
  12.  
  13. Remove or disconnect the following:

    Front cross-member
     
    Exhaust pipe
     
    Catalytic converter
     
    Driveshaft
     
    Transfer case
     

  14.  

To install:

  1. Install or connect the following:

    Transfer case, and tighten bolts to 37 ft. lbs. (50 Nm)
     
    Driveshaft
     
    Catalytic converter
     
    Exhaust pipe
     
    Front cross-member and tighten bolts to 18 ft. lbs. (24 Nm)
     
    Halfshaft and bearing cap.
     
    Ball joint and control arm
     
    Anti-roll bar link
     
    Engine splash guard
     
    Wheel
     

  2.  
  3. Fill the bevel to the correct level.
  4.  

 
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