Volvo Truck 2003-05

Removal & Installation

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CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the fuel tank.
  6.  
  7. Block the parking brake pedal in the neutral position.
  8.  
  9. Remove or disconnect the following on both sides:

    Rear wheels
     
    Rear brake calipers
     
    Rear brake discs
     
    Rear tension spring and expander
     

  10.  
  11. Lift the brake shoe slightly. Grip the expander. Pull the expander outwards.
  12.  
  13. Unhook the expander from the metal bracket.

    Click image to see an enlarged view

    Fig. Removing expansion spring from rear brake

    Removing expansion spring from rear brake
  14.  
  15. Remove or disconnect the following on both sides:

    The guide sleeve for the cable sleeve. Apply a screwdriver between the guide sleeve lug and wheel arch. Pry apart slightly to remove the sleeve.
     
    The parking brake cable from the tie rod and the sub-frame
     

  16.  
  17. Remove 2 bolts from the cable clips and 2 bolts from the front mounting for the heat deflector plate.
  18.  
  19. Fold out the cables from the heat deflector plate. Hang the cables up at the front of the car.
  20.  
  21. Remove the exhaust system from the three-way catalytic converter and backwards.
    NOTE
    Hang up the three-way catalytic converter to prevent damaging the flex boot.

  22.  
  23. Remove the rear driveshaft:
    1. Mark up the position of the joint on the flange on the final drive and at the center bearing.
    2.  
    3. Remove bolts from the joints. Use counterhold 999 7057.
    4.  
    5. Remove the rear section of the driveshaft.
    6.  

  24.  
  25. Lower the rear suspension:
    1. Place the mobile jack: 999 5972 with plate: 999 5972 under the rear suspension.
    2.  
    3. Raise to light contact.
    4.  

  26.  
  27. Remove or disconnect the following on both sides:

    The 2 bolts for the mounting bracket
     
    The mounting screw for the sub frame bushing
     
    The brake pipe on both sides from the plastic clips on the bracket
     

  28.  
  29. Lower the rear suspension carefully.
  30.  
  31. Place a lifting table under the fuel tank.
  32.  
  33. Remove or disconnect the following:

    The upper quick-release connector plastic pipe on the carbon filter container
     
    The 4 bolts for the fuel tank securing strap
     
    Remove the clamp for the fuel filler pipe
     
    Remove the clamp for the bleed pipe
     

  34.  
  35. Lower the lifting table to access the plastic pipes on top of the tank.
  36.  
  37. Remove the plastic pipe.
  38.  
  39. Remove the ABS cable harness from the clips on both sides of the fuel tank.
  40.  
  41. Remove the fuel tank.

    Click image to see an enlarged view

    Fig. Removing fuel tank straps and heat shield

    Removing fuel tank straps and heat shield
  42.  

To install:

  1. Place the fuel tank on the lifting table.
  2.  
  3. Raise the lifting table to install the plastic hoses on the right-hand level sensor and in the grooves in the tank.
  4.  
  5. Secure the hoses in place using silver tape.
  6.  
  7. Install the ABS cable harnesses in the clips on both sides of the tank.
  8.  
  9. Align the fuel filler pipe and the bleed pipe.
  10.  
  11. Insert the cable harnesses for the level sensor and the fuel tank pressure sensor through the inspection holes in the floor.
  12.  
  13. Raise the fuel tank to the installation position.
    NOTE
    Ensure that the fuel filler pipe and bleed pipe slide into position while raising the fuel tank.

  14.  
  15. Install the 4 bolts for the fuel tank securing strap. Tighten to 18 ft. lbs. (24 Nm).
  16.  
  17. Remove the lifting table.
  18.  
  19. Install or connect the following:

    The clamp for the fuel filler pipe
     
    The clamp for the bleed pipe
     
    The upper plastic pipe in the quick-release connector for the carbon filter container
     

  20.  
  21. Install the rear suspension:
    1. Place the mobile jack: 999 5972 and plate: 999 5972 under the rear suspension.
    2.  
    3. Carefully raise the rear suspension.
      NOTE
      Ensure that no cable harness or brake lines are trapped while raising the rear suspension.

    4.  

  22.  
  23. Install or connect the following on both sides:

    The 2 bolts for the mounting bracket. Tighten to 59 ft. lbs. (80 Nm)
     
    The bolt for the sub frame mounting. Tighten to 59 ft. lbs. (80 Nm)
     
    The brake line in the plastic clip and bracket
     

  24.  
  25. Install the brakes.
  26.  
  27. Install the parking brake cable along the heat shields.
  28.  
  29. Install the bolts in the center and front mountings for the heat shield.
  30.  
  31. Install or connect the following:

    The parking brake cables on the wheel units
     
    The parking brake cable mountings in the sub-frame. Tighten bolts to 19 ft. lbs. (25 Nm).
     
    The mounting for the parking brake cable on the tie rods.
     

  32.  
  33. Press the guide sleeves for the parking brake cables into place on the wheel units.
    NOTE
    Lubricate the O-rings on the guide sleeves. Use lubricant 1161580 or silicon grease.

  34.  
  35. Install or connect the following:

    The expander on the cable. Press the mounting together to lock the cable in the expander
     
    The expander between the brake shoes
     
    The return spring.
     

  36.  
  37. Install the brake disc and the locating pin. Tighten to 88 inch lbs. (10 Nm).
  38.  
  39. Install the brake caliper. Use new bolts. Tighten to 44 ft. lbs. (60 Nm).
    NOTE
    Activate parking brake adjuster.

  40.  
  41. Install the rear drive shaft.
    1. Position the propeller shaft as marked previously.
    2.  
    3. Install new bolts for the joints. Use counterhold 999 7057. Tighten all bolts to 22 ft. lbs. (30 Nm).
    4.  

  42.  
  43. Install the exhaust system. Use a new flange gasket. Tighten the bolts to 18 ft. lbs. (25 Nm).
  44.  
  45. Install the cover over the level sensor.
  46.  
  47. Connect the wiring and the connectors.
  48.  
  49. Install rear wheels and tighten lug nuts to 102 ft. lbs. (138 Nm).
  50.  

 
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