Volvo Truck 2003-05

Flexplate (Driveplate)

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Removal & Installation



8-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the transaxle. Refer to Automatic Transaxle Assembly removal and installation.
  4.  
  5. Lock the flexplate using an M10 bolt.
  6.  
  7. Remove the flexplate.

    Click image to see an enlarged view

    Fig. Locking flexplate with M10 bolt-8-Cylinder Engines

    Locking flexplate with M10 bolt-8-Cylinder Engines
  8.  

To install:


CAUTION
Ensure that the mating surfaces on the crankshaft and carrier plate are completely clean. The carrier plate must lie against the crankshaft flange before the bolts are installed. There is a risk that excess locking fluid on the bolts will come between the mating surfaces.

  1. Brush off all the old locking fluid from 2 of the old bolts using a wire brush. Mark the cleaned bolts using a marker pen.
  2.  
  3. Install the carrier plate, tighten it in towards the crankshaft with the two cleaned and marked bolts.
    NOTE
    Check that the locating pin on the crankshaft is positioned opposite the hole in the carrier plate.

  4.  
  5. Install 6 new bolts and tighten in a cross pattern to 59 ft. lbs. (80 Nm).
  6.  
  7. Remove the 2 old marked bolts.
  8.  
  9. Install the remaining new bolts. Tighten to 59 ft. lbs. (80 Nm).
  10.  
  11. Remove the M10 locking bolt from the flexplate.
  12.  
  13. Install the transaxle.
  14.  

5- & 6-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the transaxle. Refer to Automatic Transaxle Assembly removal and installation.
  4.  
  5. Remove the engine speed (RPM) sensor with the bracket.
  6.  
  7. Block the flexplate using gear sector 999 5112.
  8.  
  9. Remove or disconnect the following:

    Flexplate bolts
     
    Flexplate
     
    Gear sector 999 5112

    Click image to see an enlarged view

    Fig. Blocking the flexplate with gear sector tool 999 5112-5 & 6-cylinder engines

    Blocking the flexplate with gear sector tool 999 5112-5 & 6-cylinder engines
     

  10.  

To install:

  1. Check the crankshaft seal for leakage. Replace seal if necessary. Refer to Rear Main Seal removal and installation.
    NOTE
    Ensure that the mating surfaces on the crankshaft and flexplate are completely clean.

  2.  
  3. Install tool 999 5678, which consists of 3 studs with nuts.
    NOTE
    Check that the locating pin on the crankshaft is positioned opposite the hole in the flexplate. Locate gear sector 999 5112 against the flexplate.



    Click image to see an enlarged view

    Fig. Using tools 999 5678 and 999 5112 to install flexplate-5 & 6-cylinder engines

    Using tools 999 5678 and 999 5112 to install flexplate-5 & 6-cylinder engines
  4.  
  5. Pull the flexplate towards the crankshaft using the 3 nuts on special tool 999 5678.
    CAUTION
    The flexplate must lie against the crankshaft flange before the bolts are installed. There is a risk that excess locking fluid on the bolts will come between the mating surfaces.

  6.  
  7. Install 7 new bolts after applying locking fluid. Tighten crosswise to 33 ft. lbs. (45 Nm).
  8.  
  9. Remove the 3 nuts and studs of special tool 999 5678.
  10.  
  11. Install the remaining 3 new bolts with locking fluid applied. Tighten to 33 ft. lbs. (45 Nm).
  12.  
  13. Angle-tighten all 10 bolts in a crosswise pattern 50°
  14.  
  15. Install the engine speed (RPM) sensor with the bracket and tighten to 88 inch lbs. (10 Nm).
  16.  
  17. Install the transaxle.
  18.  

 
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