Volvo Truck 2003-05

Lower Ball Joints

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Removal & Installation



  1. Remove the wheel.
  2.  
  3. Install cap nut 7062-1 on the ball joint pinion.
  4.  
  5. Tighten the nut against the control arm.
  6.  
  7. Then turn back one turn to form a gap between the cap nut and the control arm.
  8.  
  9. Position the extractor on the control arm. Detach the ball joint from the control arm.
  10.  
  11. Pull down the control arms using a tension strap.
  12.  
  13. Release the spring strut from the control arm.
  14.  
  15. Remove the bolt for the halfshaft. Use a prybar as a counterhold on the brake disc.
  16.  
  17. Remove the halfshaft from the hub. Knock the halfshaft out using a brass drift.
  18.  
  19. Push the spring strut to one side.
  20.  
  21. Remove the bolts for the ball joint.
  22.  
  23. Remove the rubber seal.
  24.  
  25. Install the inner sleeve so that both halves hook securely in the flange (see arrow) on the ball joint.
  26.  
  27. Turn the inner sleeve so that the slit is at right angles to the bolt holes.
  28.  
  29. Install the outer sleeve around the inner sleeve halves. Tighten the bolt.
  30.  
  31. Install an M12 nut on the ball joint bolt.
  32.  
  33. Screw on the nut so that the ball joint bolt is just protruding from the nut.
  34.  
  35. Using Tool 999 5781-3:
    1. The guide bolts have a wrench grip (see arrow) which is asymmetrically positioned.
    2.  
    3. Aluminum wheel spindle: Use the bolt (1) with the greater distance to the wrench grip.
    4.  
    5. Steel wheel spindle: Use the bolt (2) with the shortest distance from the wrench grip.
    6.  
    7. Screw in the guide bolts fully.
    8.  

  36.  
  37. Using Tool 999 5781:
    1. Install the support using 3 wheel studs.
    2.  
    3. Screw the guide bolts down until they are in contact with the support.
    4.  
    5. Position supplementary support 999 5781-4 on the hydraulic press.
    6.  
    7. Screw the connector 999 5781-5 into place on the hydraulic press.
    8.  
    9. Install the connector on the nut on the ball joint.
    10.  

  38.  
  39. Press off the ball joint.
  40.  
  41. Remove the tool and the ball joint.
  42.  


    Click image to see an enlarged view

    Fig. Securing the control arms

    Securing the control arms

    Click image to see an enlarged view

    Fig. Inner sleeve installation

    Inner sleeve installation

    Click image to see an enlarged view

    Fig. Outer sleeve installation

    Outer sleeve installation

    Click image to see an enlarged view

    Fig. Installing the support

    Installing the support

    Click image to see an enlarged view

    Fig. Removing the ball joint

    Removing the ball joint

To install:

  1. Clean the ball joint seat and the mating surfaces for the ball joint to the wheel spindle. Use a rotary wire brush.
  2.  
  3. Lubricate the seat using wheel bearing grease.
  4.  
  5. Loosely install the new ball joint using the guide bolts.
  6.  


NOTE
Leave the protective cap for the ball joint in position to prevent damaging the rubber seal.

  1. Press the ball joint up towards the seat using impact drift 999 5796. Check that the ball joint is centered in the seat.
  2.  
  3. Knock in the ball joint using a copper mallet.
  4.  
  5. Tighten the ball joint using new bolts. Tighten to 37 ft. lbs. (50 Nm).
  6.  
  7. Install the halfshaft in the hub.
  8.  
  9. Install a new bolt. Use a prybar as a counterhold. Tighten to 37 ft. lbs. (50 Nm).
  10.  
  11. Align the ball joints (1) in the control arm.
  12.  


CAUTION
Take care when releasing the tension strap.

  1. Release the control arms by releasing the tension strap.
  2.  
  3. Install a new nut.
  4.  


WARNING
The ball joint pinion must not rotate. Use a Torx wrench as a counterhold so that the rubber boot is not damaged.

  1. Tighten to 58 ft. lbs. (80 Nm).
  2.  
  3. Install the wheels.
  4.  

  1. Remove the wheel.
  2.  
  3. Install cap nut 7062-1 on the ball joint pinion.
  4.  
  5. Tighten the nut against the control arm.
  6.  
  7. Then turn back one turn to form a gap between the cap nut and the control arm.
  8.  
  9. Position the extractor on the control arm. Detach the ball joint from the control arm.
  10.  
  11. Pull down the control arms using a tension strap.
  12.  
  13. Release the spring strut from the control arm.
  14.  
  15. Remove the bolt for the halfshaft. Use a prybar as a counterhold on the brake disc.
  16.  
  17. Remove the halfshaft from the hub. Knock the halfshaft out using a brass drift.
  18.  
  19. Push the spring strut to one side.
  20.  
  21. Remove the bolts for the ball joint.

    Click image to see an enlarged view

    Fig. Securing the control arms-2003-04

    Securing the control arms-2003-04
  22.  
  23. Remove the rubber seal.
  24.  
  25. Install the inner sleeve so that both halves hook securely in the flange (see arrow) on the ball joint.
  26.  
  27. Turn the inner sleeve so that the slit is at right angles to the bolt holes.
  28.  
  29. Install the outer sleeve around the inner sleeve halves. Tighten the bolt.
  30.  
  31. Install an M12 nut on the ball joint bolt. Tighten to 59 ft. lbs. (80 Nm).
  32.  
  33. Screw on the nut so that the ball joint bolt is just protruding from the nut.

    Click image to see an enlarged view

    Fig. Inner sleeve installation-2003-04

    Inner sleeve installation-2003-04

    Click image to see an enlarged view

    Fig. Outer sleeve installation-2003-04

    Outer sleeve installation-2003-04

    Click image to see an enlarged view

    Fig. Installing the support-2003-04

    Installing the support-2003-04

    Click image to see an enlarged view

    Fig. Removing the ball joint-2003-04

    Removing the ball joint-2003-04
  34.  
  35. Using Tool 999 5781-3:
    1. The guide bolts have a wrench grip (see arrow) which is asymmetrically positioned.
    2.  
    3. Aluminum steering knuckle: Use the bolt (1) with the greater distance to the wrench grip.
    4.  
    5. Steel steering knuckle: Use the bolt (2) with the shortest distance from the wrench grip.
    6.  
    7. Screw in the guide bolts fully.
    8.  

  36.  
  37. Using Tool 999 5781:
    1. Install the support using 3 wheel studs.
    2.  
    3. Screw the guide bolts down until they are in contact with the support.
    4.  
    5. Position supplementary support 999 5781-4 on the hydraulic press.
    6.  
    7. Screw the connector 999 5781-5 into place on the hydraulic press.
    8.  
    9. Install the connector on the nut on the ball joint.
    10.  

  38.  
  39. Press off the ball joint.
  40.  
  41. Remove the tool and the ball joint.
  42.  

To install:

  1. Clean the ball joint seat and the mating surfaces for the ball joint to the steering knuckle. Use a rotary wire brush.
  2.  
  3. Lubricate the seat using wheel bearing grease.
  4.  
  5. Loosely install the new ball joint using the guide bolts.
    NOTE
    Leave the protective cap for the ball joint in position to prevent damaging the rubber seal.

  6.  
  7. Press the ball joint up towards the seat using impact drift 999 5796. Check that the ball joint is centered in the seat.
  8.  
  9. Knock in the ball joint using a copper mallet.
  10.  
  11. Tighten the ball joint using new bolts. Tighten to 37 ft. lbs. (50 Nm).
  12.  
  13. Install the halfshaft in the hub.
  14.  
  15. Install a new bolt. Use a prybar as a counterhold. Tighten to 37 ft. lbs. (50 Nm).
  16.  
  17. Align the ball joints (1) in the control arm.
    CAUTION
    Take care when releasing the tension strap.

  18.  
  19. Release the control arms by releasing the tension strap.
  20.  
  21. Install a new nut.
    WARNING
    The ball joint pinion must not rotate. Use a Torx wrench as a counterhold so that the rubber boot is not damaged.

  22.  
  23. Tighten to 59 ft. lbs. (80 Nm).
  24.  
  25. Install the wheels.
  26.  

  1. Remove the front wheels.
  2.  
  3. Remove the bolt for the drive shaft. Use a prybar in the brake disc as counterhold.
  4.  
  5. Remove the drive shaft from the hub by tapping out the drive shaft with a brass drift.
  6.  
  7. Fold aside the spring strut.
  8.  
  9. Loosen the ball joint pin from the link arm. Use tool 999 7062.

    Click image to see an enlarged view

    Fig. Loosen the ball joint pin from the link arm-2005-06

    Loosen the ball joint pin from the link arm-2005-06
  10.  
  11. Install the cap nut for the ball joint pinion. For earlier versions (deep thread pitch) use 999 7062 and for later versions (closer thread pitch) use 999 7231.
  12.  
  13. Tighten the nut against the link arm.
  14.  
  15. Then turn back one turn so that clearance is created between the cap nut and link arm.
  16.  
  17. Place the puller on the link arm and loosen the ball joint from the link arm.
    NOTE
    If the catch is placed by (2), the rubber gaiter on the ball joint may be damaged.

  18.  
  19. Press the control arm down using lever 999 7076. Position the hook at (1).

    Click image to see an enlarged view

    Fig. Press the control arm down using lever 999 7076-2005-06

    Press the control arm down using lever 999 7076-2005-06
  20.  
  21. Disconnect the spring strut from the link arm.
  22.  
  23. Remove the ball join bolts.

    Click image to see an enlarged view

    Fig. Ball joint bolts-2005-06

    Ball joint bolts-2005-06

    Click image to see an enlarged view

    Fig. Ball joint removal-2005-06

    Ball joint removal-2005-06
  24.  
  25. Install the nut on the ball joint. Use 999 7149 for earlier versions (deep thread pitch) and for later versions (closer thread pitch) use 999 7230.
  26.  
  27. Tap loose the ball joint.
    CAUTION
    Always use safety glasses. Clean both in the seat for the ball joint and the contact surfaces with a rotating steel brush. Grease the seat with wheel bearing grease.

  28.  

To install:


NOTE
The guide bolts 999 5781 have a wrench grip (see arrow) which is asymmetrically positioned.



Click image to see an enlarged view

Fig. The guide bolts 999 5781 have a wrench grip (see arrow) which is asymmetrically positioned-2005-06

The guide bolts 999 5781 have a wrench grip (see arrow) which is asymmetrically positioned-2005-06
NOTE
Use the bolt (2) with the shortest distance from the wrench grip.


NOTE
Leave the ball joint's protective cup on to avoid damaging the rubber gaiter.

  1. Install the new ball joint loosely using the guide bolts.

    Click image to see an enlarged view

    Fig. Install the new ball joint loosely using the guide bolts-2005-06

    Install the new ball joint loosely using the guide bolts-2005-06
  2.  
  3. Press up the ball joint against the seat with press tool 999 5796.
  4.  
  5. Check that the ball joint is centered in the seat.

    Click image to see an enlarged view

    Fig. Drive in the ball joint with a copper hammer-2005-06

    Drive in the ball joint with a copper hammer-2005-06
  6.  
  7. Drive in the ball joint with a copper hammer.
  8.  
  9. Remove the guide bolts.
  10.  
  11. Tighten down the ball joint with the new bolts. Tighten to 74 ft. lbs. (100 Nm).

    Click image to see an enlarged view

    Fig. Tighten down the ball joint with the new bolts-2005-06

    Tighten down the ball joint with the new bolts-2005-06
  12.  
  13. Remove the protective cup.
  14.  
  15. Install the halfshaft.
    WARNING
    If the catch is placed by (2), the rubber gaiter on the ball joint may be damaged.

  16.  
  17. Press down the link with lever 999 7076.
  18.  
  19. Place the catch by (1).
  20.  
  21. Install the spring strut in the link arm.
    NOTE
    The ball joint pin may not rotate. Use a bit Torx as counterhold in order to prevent damaging the rubber gaiter.

  22.  
  23. Use 999 5500 as adapter for the torque wrench.

    Click image to see an enlarged view

    Fig. Tightening the stud nut-2005-06

    Tightening the stud nut-2005-06
  24.  
  25. Install the nut. Tighten according to 37 ft. lbs. (50 Nm) plus 35°.
  26.  
  27. Install the wheels.
  28.  

 
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