Volvo Coupes/Sedans/Wagons 1970-1989 Repair Guide

Coil Spring

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REMOVAL & INSTALLATION



140 Series and 164 Models
  1. Remove the hub cap and loosen the lug nuts two or three turns.
  2.  
  3. Firmly apply the parking brake and place blocks in back of the rear wheels. Jack up the front of the car and place jackstands in back of the front jacking points. Remove the front wheels.
  4.  
  5. Remove the shock absorber.
  6.  
  7. Remove the cotter pin and ball nut; disconnect the steering rod from the steering knuckle. Loosen the clamp for the flexible brake hoses. Remove the stabilizer attachment from the lower control arm.
  8.  
  9. Place a jack under the lower control arm. Raise the jack to unload the lower control arm. Remove the cotter pins and loosen the nuts for the upper and lower ball joints; then rap with a hammer until they loosen from the spindle. Remove the nuts and lower the jack slightly.
  10.  
  11. Remove the steering knuckle with the front brake caliper and disc still connected to the brake lines. In order not to stretch the brake lines, place the brake unit on a milk crate or other suitable stand.
  12.  


CAUTION
Do not attempt to remove the spring until it is fully extended. As an added safety measure, a chain may be attached to the lower spring coil and secured to the frame.

  1. Slowly lower the jack and the lower control arm to the fullest extent. Remove the spring and rubber spacer.
  2.  

To install:
  1. Place a jack directly beneath the spring attachment point on the lower control arm. Place the spring with the rubber spacer in position, and lift up the lower control arm with the jack so that the steering knuckle and brake unit assembly may be installed.
  2.  
  3. Install and tighten the upper and lower ball joint nuts. Connect the stabilizer to its attachment on the lower control arm.
  4.  
  5. Install the shock absorber.
  6.  
  7. With the wheel pointing straight ahead, and the lower control arm unloaded, connect the steering rod to the steering knuckle and install the ball nut and cotter pin.
  8.  
  9. Clamp the brake hoses to the stabilizer bolt.
  10.  
  11. Install the wheel. Remove the jackstands and lower the car. Tighten the lug nuts to 85-90 ft. lbs. (115-122 Nm) and install the hub cap.
  12.  

1800 Series
  1. Remove the hub cap and loosen the lug nuts a turn or two.
  2.  
  3. Firmly apply the parking brake and place blocks in back of the rear wheels.
  4.  
  5. Jack up the front of the car and place jackstands beneath the front crossmember. Remove the wheel.
  6.  
  7. Remove the shock absorber.
  8.  
  9. Position a jack directly beneath the lower spring attachment on the lower control arm, and raise the jack until the upper control arm rubber buffer is lifted.
  10.  
  11. Disconnect the stabilizer from the lower control arm. Remove the cotter pin and ball nut from the lower ball joint.
  12.  


CAUTION
Do not attempt to remove the spring until it is fully extended. As an added safety measure, a chain may be attached to the lower spring coil and secured to the frame.

  1. Slowly lower the jack and the lower control arm. If the lower ball joint does not release when the jack is lowered, it must be pressed out with a press tool (Volvo No. 2281 or similar). When the lower control arm is lowered sufficiently, carefully remove the spring, rubber spacer and washer assembly.
  2.  

To install:
  1. When reinstalling, take care to place the rubber spacer and washer correctly on top of the spring, prior to installation. Position the jack under the lower arm and place the spring in its seat.
  2.  
  3. Slowly raise the jack and lower arm. As the spring comes into position, make sure it seats properly at the top and reconnect and tighten the lower ball joint. Install a new cotter pin when the nut is secure.
  4.  
  5. Reconnect the stabilizer to the lower control arm.
  6.  
  7. Install the shock absorber.
  8.  
  9. Install the wheel. Lower the car from its stands and tighten the wheel lugs to 75 ft. lbs. (102 Nm).
  10.  

200 and 700 Series With MacPherson Struts

See Figures 1 and 2


CAUTION
Use of the correct special tools or their equivalent is REQUIRED for this procedure. To remove the spring, a coil spring compressor must be used. Under no circumstances should you attempt to lower and disassemble the strut assembly without the proper spring compressor. Serious injury could result. Spring compressors can be rented from many repair and supply shops.

  1. Remove the hub cap and loosen the lug nuts two or three turns.
  2.  
  3. Firmly apply the parking brake and place blocks in back of the rear wheels.
  4.  
  5. Install the spring compressor on the spring directly beneath the upper mount. Make sure that at least 3 coils of the spring are between the tool attachment points. Tighten the tool and compress the spring.
  6.  
  7. Jack up the front of the car at the center of the front crossmember. When the wheels are 2-3 in. (50-75mm) off the ground, the car is high enough. Place jackstands beneath the front jacking points. Remove the floor jack from the crossmember, and reposition it beneath the lower control arm to provide support at the outer end. Remove the wheel.
  8.  
  9. Using a ball joint puller, disconnect the steering rod from the steering arm.
  10.  
  11. Disconnect the stabilizer bar at the upper link.
  12.  
  13. Remove the bolt holding the brake line bracket to the fender well.
  14.  
  15. Open the hood and remove the cover from the top of the strut assembly upper mount. Mark the position of the upper mounts relative to their holes.
  16.  
  17. While keeping the strut from turning, loosen and remove the nut for the upper strut mount.
  18.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the front suspension-200 series

  1. Before lowering the strut assembly, wire or tie the strut to some stationary component (or use a holding fixture such as Volvo No. 5045) to prevent the strut from traveling down too far and damaging the hydraulic brake lines. Lower the jack supporting the lower arm and allow the strut to tilt out at about a 60° angle. At this angle, the top of the strut assembly should just protrude past the wheel well, allowing removal of the strut components from the top. Take great care to control the descent of the strut and prevent damage to the fender.
  2.  
  3. Lift off the spring seat, rubber bumper, and the shock absorber protector. On 700 series, the upper spring mount must be removed from the shaft. Remove the coil spring and compressor assembly from the strut.
  4.  
  5. Slowly relieve the tension on the compressor and remove it from the spring. Place the compressor on the replacement spring (making sure at least 3 coils separate the attachment points as before) and compress.
  6.  

If the spring compressor does not have enough travel to fully release the spring tension, it will be necessary to use another sandwich type compressor to remove the original compressor once the spring is out of the car.

To install:
  1. Position the new spring and compressor on the strut assembly. On 700 Series, install the upper spring mount. Make sure the spring end is properly aligned with the lower mount.
  2.  

Make sure that the compressor bolts face downwards.

  1. Install the rubber bumper and the shock absorber protector. Position the spring seat on the spring, making sure it is aligned with the spring.
  2.  
  3. Carefully lift and guide the strut assembly into its upper attachment in the spring tower. Connect the stabilizer bar to the stabilizer link.
  4.  
  5. Guide the shock absorber spindle into the upper attachment and raise the jack beneath the lower control arm. Install the washer and nut on top of the shock absorber spindle. Position the upper mount according to marks made during removal. Tighten the upper mounting bolts. The smaller outer nuts should be tightened to 15-25 ft. lbs. (20-34 Nm). The large center nut should be tightened to 90-100 ft. lbs. (122-135 Nm).
  6.  
  7. Install the cover.
  8.  
  9. Attach the brake line bracket to its mount. Make sure that the brake lines sit properly in their mounts. Tighten the nut holding the stabilizer bar to the link. Connect the steering rod at the steering arm.
  10.  
  11. Release the coil spring compressor and install the wheel and tire assembly. Remove the jackstands and lower the car.
  12.  
  13. Push on the bumper to bounce the suspension a few times to settle the components.
  14.  
  15. Road test the vehicle.
  16.  



Click image to see an enlarged view

Fig. Fig. 2: Cutaway view of the front suspension-700 series

 
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