Volvo Truck 2003-05

Halfshafts

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain transaxle oil.
  4.  
  5. Remove or disconnect the following:

    Front wheel
     
    Spindle nut on halfaxle
     

  6.  
  7. Remove stub of halfshaft from hub.
    NOTE
    If necessary, use a screwdriver in brake disc vents as a counterhold and tap the end of the halfshaft with a plastic hammer or brass drift until halfshaft moves into the hub approximately 3 / 4 -1 inch (20-25mm).

  8.  
  9. Remove lower ball joint from the knuckle. Refer to Lower Ball Joint removal and installation.
  10.  
  11. Remove halfshaft from the hub.
  12.  
  13. If removing the left side halfshaft:
    1. Use prybar 999 5462 B, or suitable prybar, to pry the inner joint out of the transaxle.
    2.  

  14.  
  15. If removing the right side halfshaft:
    1. 5- & 8-Cylinder transaxles: Remove the bearing cap for the halfshaft, hold down the spring strut, and pull out the halfshaft.
    2.  
    3. 6-Cylinder tansaxles: Use prybar 999 5462 B, or suitable prybar, to pry the inner joint out of the transaxle.
    4.  

  16.  
  17. Remove halfshaft.
  18.  

To install:


NOTE
Use new circlips, split pins, and self-locking nuts for assembly.

  1. Apply gear oil on the halfshaft splines.
  2.  
  3. When installing the halfshaft, set the opening side of the circlip so it faces downward.
  4.  
  5. Install the inner joint so that the circlip is felt to seat in the retaining groove.
  6.  
  7. Lubricate the halfshaft splines for the wheel hub with a small amount of oil.
  8.  
  9. Hold down the control arm as when removing. Align the halfshaft in the hub.
  10.  
  11. Align the ball joint in the control arm.
  12.  
  13. Install a new lock nut on the ball joint. Tighten to 59 ft. lbs. (80 Nm).
    NOTE
    Counterhold the end of the ball joint while tightening so that the boot does not twist. Use a Torx wrench.

  14.  
  15. Install a new bolt for the halfshaft/wheel hub. Tighten to 26 ft. lbs. (35 Nm), plus 120°.
  16.  
  17. Install front wheel and tighten lug nuts to 102 ft. lbs. (138 Nm).
  18.  
  19. Check and/or adjust the wheel alignment.
  20.  

CV-Joints



Overhaul
Outer CV-Joint
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the halfshaft from the vehicle.
  4.  
  5. Remove the grease boot clamps and push the boot away from the joint.
  6.  
  7. Expand the inner race circlip and pull the CV-joint off of the axle shaft.
  8.  
  9. Disassemble the inner race, cage and balls for cleaning and inspection.
  10.  

To install:

  1. Assemble the inner race, cage and balls into the outer joint housing.
  2.  
  3. Expand the circlip and push the joint on to the axle shaft.
  4.  
  5. Fill the outer race and the grease boot with CV-joint grease and tighten the boot clamps.
  6.  
  7. Install the axle halfshaft.
  8.  

Inner CV-Joint

The inner CV-joint is serviced with the axle shaft as an assembly. The inner CV-joint boot can be serviced by removing the outer CV-joint.

 
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