Volvo Coupes/Sedans/Wagons 1970-1989 Repair Guide

Axle Housing-Complete Unit

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REMOVAL & INSTALLATION




WARNING
This operation requires removal of a substantial amount of weight from the rear of the car. The vehicle may become front heavy; make sure that floorstands or lifting arms are properly positioned to support the vehicle with the rear axle removed. The use of an axle cradle or two floor jacks is required. Because of the size and weight of the axle assemble, it cannot be safely controlled and supported on a single jack.

1800 Series and 140/160 Series
  1. Elevate the car and support it firmly with stands. Do not place the stands in the area of the axle or rear suspension. Locate the stands at the jack points on the body or on the frame. With the car elevated and securely supported, remove the rear wheels.
  2.  
  3. Using the jacks or cradle, elevate the rear axle slightly--just enough to take the tension off its upper mounts. Loosen and remove the upper attaching bolts for the shock absorbers.
  4.  
  5. Disconnect the handbrake cables from the levers and brackets on the backing plates.
  6.  
  7. Disconnect the driveshaft from the flange on the pinion.
  8.  
  9. Remove the brake pipe connector from the rear axle housing. Plug the open lines.
  10.  
  11. Loosen the front attaching bolts for the support arms about one turn. Unscrew the rear bolts for the torque rods.
  12.  
  13. Remove the track rod (Panhard rod) from its mount on the rear axle case and remove the lower attaching bolts for the springs.
  14.  
  15. Lower the jacks or cradle until the support arms release from the springs. Loosen the bolts holding the rear axle to the support arms.
  16.  
  17. Lower the jacks or cradle and remove the axle assembly by pulling it forwards.
  18.  
  19. When reinstalling, position the unit on its jacks or cradle in place under the car. Loosely reconnect the bolts for the support arms and torque rods.
  20.  
  21. Elevate the axle assembly until the track rod mount on the axle is at the same height as the attachment on the body. Install the track rod and secure its bolts.
  22.  
  23. Install the attaching bolts for the springs. Tighten the nuts for the support arms and torque rods.
  24.  
  25. Remove the plugs and reinstall the brake lines and retainers to the axle housing. Carefully connect the lines.
  26.  
  27. Attach the driveshaft to the pinion flange.
  28.  
  29. Install the upper bolts for the shock absorbers. Reinstall the handbrake cables into the brackets and levers.
  30.  
  31. Double check all nut and bolt attachments. If all are secure and tightened, the jacks or cradle may be slowly lowered and removed from the area.
  32.  
  33. Bleed the brake system and adjust the handbrake.
  34.  
  35. Reinstall the rear wheels and lower the vehicle to the ground.
  36.  
  37. Tighten the wheel lugs to 70-100 ft. lbs. (95-135 Nm)
  38.  

240/260 Series

See Figure 1

  1. Elevate the car and support it firmly with stands. Do not place the stands in the area of the axle or rear suspension. Locate the stands at the jack points on the body or on the frame. With the car elevated and securely supported, remove the rear wheels.
  2.  
  3. Remove the rear axle vent hose and the brake line brackets. Do not loosen any brake lines; they will be left intact.
  4.  
  5. Remove the brake calipers and secure them to the upper spring mount with a piece of stiff wire.
  6.  
  7. Remove the brake discs and parking brake shoes.
  8.  
  9. Remove the thrust washer bolts through the holes in the axle shaft flange. Using a puller (slide hammer), remove the axle shaft, bearing and oil seal assembly. If a slide hammer is not available, the brake disc may be bolted onto the axle backwards (remember to mount the nuts tapered side out) and used to pull the axle free.
  10.  
  11. Position the jacks or cradle below the rear axle so that the axle is supported but not elevated.
  12.  
  13. If the exhaust system runs under the axle housing, disconnect the first joint forward of the axle, disconnect any hangers or brackets behind the axle and remove the rear section of the exhaust system.
  14.  
  15. Disconnect the two reaction rods which run from the top of the axle housing to the bodywork.
  16.  
  17. Disconnect the panhard rod from the rear axle.
  18.  
  19. Loosen and remove the bolts attaching the driveshaft to the pinion flange.
  20.  
  21. Separate the handbrake cables from the rear axle.
  22.  
  23. Remove the bolts which hold the lower mount of the shock absorber. Then remove the adjacent bolt which holds the anti-roll bar (sway bar).
  24.  
  25. Loosen, but do not remove, the trailing arm bolts at the front of the trailing arm. Lower the jacks or cradle and allow the axle assemble to pivot downwards on the trailing arms. When clear of the car and well supported on the jacks or cradle, remove the trailing arm mounts at the axle housing. Remove the axle assembly from under the car.
  26.  



Click image to see an enlarged view

Fig. Fig. 1: Remove the axle by detaching the above components-240 and 260 series models

To install:
  1. When reinstalling, position the axle unit under the vehicle and attach the trailing arm mounts. Tighten the bolts only enough to hold and still allow motion.
  2.  
  3. Elevate the rear axle and align the springs to their upper mounts. Install the anti-roll bar bolts and the bolts for the lower shock absorber mounts
  4.  
  5. Attach the torque rods to their mounts and attach the Panhard rod to its mount. Tighten these bolts only enough to hold and still allow motion.
  6.  
  7. Replace the handbrake cable brackets.
  8.  
  9. Install the driveshaft to the pinion flange and secure the bolts.
  10.  
  11. If the rear exhaust section was removed, reinstall it.
  12.  
  13. Reinstall the axles in their housings and secure the thrust washer bolts.
  14.  
  15. Install the parking brake shoes, the brake discs and the brake calipers. Tighten the caliper mounting bolts to 42 ft. lbs. (57 Nm).
  16.  
  17. Replace the wheels and lower the vehicle to the ground. Tighten the wheel lugs to 83 ft. lbs. (112 Nm).
  18.  
  19. With the weight of the vehicle on the wheels, tighten the bolts at the torque rod-to-axle mount, the panhard rod-to-axle mount and the front mounts of the trailing arms.
  20.  

740/760 Series Without Multi-link Suspension
  1. Elevate the car and support it firmly with stands. Do not place the stands in the area of the axle or rear suspension. Locate the stands at the jack points on the body or on the frame. With the car elevated and securely supported, remove the rear wheels.
  2.  
  3. Remove the brake calipers and secure them to the upper spring mount with a piece of stiff wire.
  4.  
  5. Remove the brake discs and parking brake shoes. Disconnect the cables from the parking brake levers and remove the bolts for the pressure plate.
  6.  
  7. Remove the parking brake cable and the mounting brackets on the rear axle.
  8.  
  9. Position the jacks or cradle below the rear axle so that the axle is supported but not elevated.
  10.  
  11. Remove the thrust washer bolts through the holes in the axle shaft flange. Using a puller (slide hammer), remove the axle shaft, bearing and oil seal assembly. If a slide hammer is not available, the brake disc may be bolted onto the axle backwards (remember to mount the nuts tapered side out) and used to pull the axle free.
  12.  
  13. Disconnect the lower torque rod from the rear axle housing.
  14.  
  15. Raise the jacks or cradle slightly. If the exhaust system runs under the axle housing, disconnect the first joint forward of the axle, disconnect any hangers or brackets behind the axle and remove the rear section of the exhaust system.
  16.  
  17. Disconnect the Panhard rod from the rear axle.
  18.  
  19. Remove the connector for the speedometer transmitter and, if equipped, the connectors for the ETC system.
  20.  
  21. Loosen and remove the bolts attaching the driveshaft to the pinion flange.
  22.  
  23. Remove the upper torque rod from the rear axle.
  24.  
  25. Remove the bolts which hold the lower mount of the shock absorber.
  26.  
  27. Double check that the axle is firmly supported by the jacks or cradle. Remove the front brackets for the support arms. Pry the support arms loose from the front mounts and remove the rear axle assembly from under the car.
  28.  
  29. Once the axle assembly is clear of the car, remove the anti-roll bar (sway bar). Mark the support arms for the left and right sides and remove the arms from the axle housing. When reinstalling, make sure the left and right markings are observed. Fit the bushings within the clamps and fit the clamps.
  30.  
  31. Tighten the clamps in a crisscross pattern to 33 ft. lbs. (45 Nm) and reinstall the anti-roll bar if so equipped.
  32.  
  33. Position the axle on its jacks or cradle and elevate it so the support arms align with both their front mounts and the spring seats.
  34.  
  35. Install the front brackets for the support arms and tighten the two bolts to 35 ft. lbs. (47 Nm). Tighten the nut to 62 ft. lbs. (84 Nm).
  36.  
  37. Install the lower shock absorber bolts and tighten to 62 ft. lbs. (84 Nm).
  38.  
  39. Reinstall the driveshaft to the pinion flange. Connect the wiring for the ETC sensor and/or the speedometer sensor.
  40.  
  41. Attach the Panhard rod to the axle and tighten it to 62 ft. lbs. (84 Nm).
  42.  
  43. Reinstall the exhaust system as necessary. It will be helpful to elevate the axle to gain clearance.
  44.  
  45. Reinstall the upper torque rod but do not tighten it now.
  46.  
  47. Loosely fit the lower torque rod to its frame. If you loosen the frame to position the bolts, the frame must be tightened before the rod bolts are tightened.
  48.  
  49. Reinstall the parking brake cable to the brake levers. Check the boots at the backing plates.
  50.  
  51. Replace the axles.
  52.  
  53. Reinstall the parking brake shoes, the brake discs and the brake calipers. Tighten the caliper mounting bolts to 42 ft. lbs.
  54.  
  55. Install the rear wheels, remove the jacks or cradle and lower the car to the ground.
  56.  
  57. With the weight of the car on the ground, tighten both torque rods (upper and lower) to 100 ft. lbs. (135 Nm). If this is not done with the axle loaded, the bushings will turn when the axle moves up or down.
  58.  
  59. Adjust the parking brake cable. Check the oil level in the axle housing and top up as necessary.
  60.  

760/780 With Multi-link Suspension

See Figures 2 and 3

Because of the nature of the Multi-link suspension, component position and bolt tightening values (torque) are critical to ride quality and rear wheel alignment. When installing components, exact location must be achieved--close doesn't count. Tightening specifications must be followed exactly or component function will be impaired.

  1. Elevate the car and support it firmly with stands. Do not place the stands in the area of the axle or rear suspension. Locate the stands at the jack points on the body or on the frame. With the car elevated and securely supported, remove the rear wheels.
  2.  
  3. On one side only, remove the bolt holding the support arm to the wheel bearing housing. Drive out the support arm.
  4.  



Click image to see an enlarged view

Fig. Fig. 2: Remove the axle by detaching the above components-740 and 760 series models with Multi-link suspension



Click image to see an enlarged view

Fig. Fig. 3: Exploded view of the Multi-link final drive components

  1. Remove the nut and bolt holding the lower link arm to the wheel bearing housing.
  2.  
  3. Remove the bolts holding the track rod (Panhard rod) to the wheel bearing housing. Use a puller and a long bolt to move the rod away from the housing.
  4.  
  5. Remove the eight bolts joining the upper and lower sections of the rear axle housing.
  6.  
  7. Swing the lower part of the wheel bearing housing outwards and swing down the lower part of the axle housing. It will still have the two arms attached to it and will be attached to the car by the arms on the opposite side.
  8.  
  9. Matchmark the flanges at the rear of the driveshaft. Remove the four bolts and lower the driveshaft.
  10.  
  11. Place a jack or cradle under the center of the final drive (differential) unit. Elevate the jack and support the unit.
  12.  
  13. Remove the three bolts holding the final drive to the upper housing.
  14.  
  15. Lower the final drive slightly. Remove the wiring to the impulse sender.
  16.  
  17. Remove the bolts holding the axles to the final drive. Carefully lower the final drive unit and remove it from under the car.
  18.  
  19. When reinstalling, raise the final drive unit almost to its final position under the car and connect the impulse sender cable. Tighten the bolt to 7 ft. lbs. (9.5 Nm).
  20.  
  21. Raise the unit to its final position and install the three bolts to the upper housing. Tighten the bolts to 117 ft. lbs. (159 Nm). When the bolts are secure, the jack or cradle may be removed.
  22.  
  23. Attach the halfshafts to the final drive. Tighten the bolts to 22 ft. lbs. (30 Nm) PLUS 90°of rotation.
  24.  
  25. Remount the driveshaft to the pinion flange, tightening the bolts to 36 ft. lbs. (49 Nm). Remember to observe the matchmarks made earlier and position the driveshaft properly.
  26.  
  27. Raise the lower section of the axle housing. Loosely install the eight bolts which retain it to the upper housing. Before tightening the eight mounting bolts, install two long 12mm bolts (or two 12mm drifts) in the centering holes and align the panel. This is essential to insure correct wheel alignment when finished.
  28.  
  29. Tighten the eight bolts to 52 ft. lbs. (71 Nm) PLUS an additional 30° of rotation.
  30.  
  31. Position and install the lower link arm on the wheelbearing housing. Before tightening the nut and bolt, pull the housing in towards the center of the car. When all the play is out of the mount, tighten the link bolt to 36 ft. lbs. (49 Nm) PLUS 90° of rotation.
  32.  
  33. Reconnect the support arm and tighten its bolt to 44 ft. lbs. (60 Nm) PLUS 90° of rotation.
  34.  
  35. Install the track rod and tighten to 62 ft. lbs. (84 Nm).
  36.  
  37. Install the wheels and lower the car from its stands. Tighten the wheels to 62 ft. lbs. (84 Nm). Check the oil level in the final drive and top up as necessary.
  38.  

 
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