Volvo Truck 2003-05

Final Drive

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Removal & Installation



  1. Remove the halfshafts on both sides.
  2.  
  3. Remove the rear section of the exhaust system and the spare wheel.
  4.  
  5. Support the rear edge of the three-way catalytic converter so as not to put strain on the exhaust manifold.
  6.  
  7. Remove the propeller shaft from the final drive. Remove the member for the center bearing.
  8.  
  9. Tie up the shaft.
  10.  
  11. Use the rear cross member as support.
  12.  
  13. Remove one bolt and slacken off the other. Turn out the member.
  14.  
  15. Remove the connector from the Differential Electronic Module.
  16.  
  17. Detach the cable harness from the final drive housing and the mounting in the rear axle member.
  18.  
  19. Fold the cable harness to one side to prevent damage when removing the final drive.
  20.  
  21. Remove:

    The cover for the rear axle member
     
    The bolt for the front mounting for the final drive housing.
     

  22.  
  23. Slacken off the 2 rear bolts for the rear axle member/final drive housing. Leave the bolts in place by a few threads.
  24.  
  25. Bring mobile jack 998 5972 into light contact with the front section of the rear axle member.
  26.  
  27. Remove the bolts from the front mounting in the body for the rear axle member, on both sides.
  28.  
  29. Carefully lower the frame. Remove the jack.
  30.  
  31. Support the final drive housing and remove the 2 loose bolts.
  32.  
  33. Lift out the final drive housing from the rear axle member. Position the final drive housing on a workbench.
  34.  

To install:



Click image to see an enlarged view

Fig. Removing the final drive

Removing the final drive
  1. Install the final drive housing in the rear axle member. Loosely secure the final drive housing to the rear bushings in the frame using bolts.
  2.  
  3. Bring mobile jack 998 5972 into light contact with the front section of the rear axle member.
  4.  
  5. Install the bolts in the front mounting for the rear axle member in the body on both sides.
  6.  
  7. Install the 2 M12 bolts for the bracket/body. Tighten.
  8.  
  9. Install the 1 M12 bolt for the bracket/rear axle member/body.
  10.  
  11. Remove the mobile jack.
  12.  
  13. Install:

    1 M12 front bolt for the final drive housing. Tighten
     
    The cover for the rear axle member using 4 M12 bolts. Tighten
     
    The 2 rear M12 bolts for the sub-frame/final drive housing. Tighten.
     

  14.  
  15. Connect the connector to the control module for the differential electronic module (DEM). Install the cable harness in the mounting in the rear axle member.
  16.  
  17. Install the propeller shaft on the final drive.
  18.  
  19. Install the member for the center bearing.
  20.  
  21. Install the halfshafts on both sides. Check that the gasket for the flanged joint between the front and rear exhaust pipe is not damaged. Replace if necessary.
  22.  
  23. Install the rear cross member. Use 2 x M8 bolts. Tighten.
  24.  
  25. Fill the Active on Demand Coupling with oil. Check the oil level. The front level plug is for the Active on Demand Coupling.
  26.  
  27. Fill the final drive with oil. Check the oil level. The rear level plug is for the final drive.
  28.  
  29. Tighten both level plugs.
  30.  

  1. Remove the halfshafts on both sides. Refer to Halfshaft removal and installation.
  2.  
  3. Remove the rear section of the exhaust system and the spare wheel.
  4.  
  5. Support the rear edge of the three-way catalytic converter so as not to put strain on the exhaust manifold.
  6.  
  7. Remove the propeller shaft from the final drive. Remove the member for the center bearing.
  8.  
  9. Tie up the shaft.
  10.  
  11. Use the rear cross member as support.
  12.  
  13. Remove one bolt and slacken off the other. Turn out the member.
  14.  
  15. Remove the connector from the Differential Electronic Module.
  16.  
  17. Detach the cable harness from the final drive housing and the mounting in the rear axle member.
  18.  
  19. Fold the cable harness to one side to prevent damage when removing the final drive.
  20.  
  21. Remove:

    The cover for the rear axle member
     
    The bolt for the front mounting for the final drive housing.
     

  22.  
  23. Slacken off the 2 rear bolts for the rear axle member/final drive housing. Leave the bolts in place by a few threads.
  24.  
  25. Bring mobile jack 998 5972 into light contact with the front section of the rear axle member.
  26.  
  27. Remove the bolts from the front mounting in the body for the rear axle member, on both sides.
  28.  
  29. Carefully lower the frame. Remove the jack.
  30.  
  31. Support the final drive housing and remove the 2 loose bolts.
  32.  
  33. Lift out the final drive housing from the rear axle member. Position the final drive housing on a workbench.
  34.  

To install:

Click image to see an enlarged view

Fig. Removing the final drive

Removing the final drive

  1. Install the final drive housing in the rear axle member. Loosely secure the final drive housing to the rear bushings in the frame using bolts.
  2.  
  3. Bring mobile jack 998 5972 into light contact with the front section of the rear axle member.
  4.  
  5. Install the bolts in the front mounting for the rear axle member in the body on both sides.
  6.  
  7. Install the 2 M12 bolts for the bracket/body. Tighten to 59 ft. lbs. (80 Nm).
  8.  
  9. Install the 1 M12 bolt for the bracket/rear axle member/body. Tighten to 59 ft. lbs. (80 Nm).
  10.  
  11. Remove the mobile jack.
  12.  
  13. Install:

    1 M12 front bolt for the final drive housing. Tighten to 59 ft. lbs. (80 Nm).
     
    The cover for the rear axle member using 4 M12 bolts. Tighten to 59 ft. lbs. (80 Nm).
     
    The 2 rear M12 bolts for the sub-frame/final drive housing. Tighten to 59 ft. lbs. (80 Nm).
     

  14.  
  15. Connect the connector to the control module for the Differential Electronic Module (DEM). Install the cable harness in the mounting in the rear axle member.
  16.  
  17. Install the propeller shaft on the final drive.
  18.  
  19. Install the member for the center bearing.
  20.  
  21. Install the halfshafts on both sides. Check that the gasket for the flanged joint between the front and rear exhaust pipe is not damaged. Replace if necessary.
  22.  
  23. Install the rear cross member. Use 2 x M8 bolts. Tighten to 18 ft. lbs. (24 Nm)..
  24.  
  25. Fill the Active on Demand Coupling (AOC) with oil. Check the oil level. The front level plug is for the AOC.
  26.  
  27. Fill the final drive with oil. Check the oil level. The rear level plug is for the final drive.
  28.  

 
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