Volvo Truck 2003-05

Shock Absorbers

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Testing & Inspection



  1. Check the rubber parts for damage or deterioration.
  2.  
  3. Check the spring for correct height, deformation, deterioration, or damage.
  4.  
  5. Check the shock absorber for abnormal resistance or unusual sounds.
  6.  
  7. Check for oil seepage around seals.
  8.  
  9. Replace as needed.
  10.  

Removal & Installation



  1. Raise the vehicle.
  2.  
  3. Remove the wheels.
  4.  
  5. Install tensioner 999 5659 as follows:
    1. Remove the parking brake cable mountings from the sub-frame.
    2.  
    3. Install the tensioner.

      Click image to see an enlarged view

      Fig. Tensioner installed

      Tensioner installed
    4.  
    5. The tool is secured to the sub-frame with mounting 999 7061. This means that the lift stability is not affected during work.
    6.  
    7. Install the thread bar on the tensioner 999 5659.
    8.  
    9. Lift up the tensioner with the threaded bar 999 5659.
    10.  
    11. Insert the threaded bar in the mounting 999 7061 from underneath.
    12.  
    13. Insert the locking washer with the handle in from the side in mounting 999 7061 under the threaded bolt.
    14.  
    15. Lock the bolt in the locking washer. Align the locking washer in the mounting.
    16.  

  6.  


NOTE
The locking washer has a locating pin which must be aligned with the bolt.

  1. Install the 2 bolts (5740-36) from kit 998 9761 in the control arm holes.
  2.  
  3. Install the rails 5740-1 modified according to (WG-276) on the control arms.
  4.  
  5. Ensure that the rollers lie against the rails on both sides of the control arms.
  6.  


NOTE
The tensioner must be positioned as far out as possible on the tensioner plates to provide the correct lifting force.

  1. Raise the control arms to their normal position using the tensioner. The normal position of the rear suspension is 453 mm from the fender edge to the center of the wheel.
  2.  

  1. With 5 seats:
    1. Remove:
    2.  

    1. The front floor hatch
    2.  
    3. The form-molded floor mat.
    4.  

  2.  
  3. Fold the soundproofing over the shock absorber mounting out of the way.
  4.  
  5. With 7 seats:

    Slide the seat cushion back on the rear row of seats.
     
    Lift up the carpet.
     
    Cut up the soundproofing as illustrated.
     

  6.  
  7. Fold up the soundproofing. Remove the cover on the splash guard.
  8.  
  9. Remove the shock absorber nut. Use socket 999 5500 and a Torx-wrench as a counterhold.
  10.  
  11. Remove:
    1. The bolt in the lower mounting for the shock absorber
    2.  
    3. The shock absorber.
    4.  

  12.  


    Click image to see an enlarged view

    Fig. Cut the sound proofing

    Cut the sound proofing

    Click image to see an enlarged view

    Fig. Removing the upper shock absorber mounting nut

    Removing the upper shock absorber mounting nut

    Click image to see an enlarged view

    Fig. Removing the lower shock absorber mounting bolt

    Removing the lower shock absorber mounting bolt

To install:



Insert the new shock absorber through the control arm to the upper mounting.
 
Install the new nut loosely.
 


NOTE
Ensure that the bushing seats correctly in the opening in the rear suspension.

  1. Fix the shock absorber in the lower mounting. Tighten the upper nut for the shock absorber. Tighten to 44 ft. lbs. (60 Nm). Tighten the lower bolt to 58 ft. lbs. (80 Nm).
  2.  
  3. Reinstall the carpet.
  4.  
  5. With 5 seats: Reinstall the front floor hatch.
  6.  
  7. With 7 seats: Slide the seat cushion forward.
  8.  
  9. Detach the tensioner, pull out the fork and lower the tensioner using the threaded bar.
  10.  
  11. Remove:
    1. Mounting 999 5659 from the sub-frame
    2.  
    3. The rails 5740-1 from the control arms.
    4.  

  12.  
  13. Install the parking brake cable mountings in the sub-frame.
  14.  
  15. Install the wheel.
  16.  


NOTE
If the car is equipped with Bi-Xenon lamps, the position sensor must be calibrated.

  1. Raise the vehicle.
  2.  
  3. Remove the wheels.
  4.  
  5. Install tensioner 999 5659 as follows:
    1. Remove the parking brake cable mountings from the sub-frame.
    2.  
    3. Install the tensioner.

      Click image to see an enlarged view

      Fig. Tensioner installed

      Tensioner installed
    4.  
    5. The tool is secured to the sub-frame with mounting 999 7061. This means that the lift stability is not affected during work.
    6.  
    7. Install the thread bar on the tensioner 999 5659.
    8.  
    9. Lift up the tensioner with the threaded bar 999 5659.
    10.  
    11. Insert the threaded bar in the mounting 999 7061 from underneath.
    12.  
    13. Insert the locking washer with the handle in from the side in mounting 999 7061 under the threaded bolt.
    14.  
    15. Lock the bolt in the locking washer. Align the locking washer in the mounting.
      NOTE
      The locking washer has a locating pin which must be aligned with the bolt.

    16.  
    17. Install the 2 bolts (5740-36) from kit 998 9761 in the control arm holes.
    18.  
    19. Install the rails 5740-1 modified according to (WG-276) on the control arms.
    20.  
    21. Ensure that the rollers lie against the rails on both sides of the control arms.
      NOTE
      The tensioner must be positioned as far out as possible on the tensioner plates to provide the correct lifting force.

    22.  
    23. Raise the control arms to their normal position using the tensioner. The normal position of the rear suspension is 18 inches (453mm) from the fender edge to the center of the wheel.
    24.  

  6.  
  7. With 5 seats:
    1. Remove:

      The front floor hatch
       
      The form-molded floor mat.
       

    2.  

  8.  
  9. Fold the soundproofing over the shock absorber mounting out of the way.
  10.  
  11. With 7 seats:
    1. Slide the seat cushion back on the rear row of seats.
    2.  
    3. Lift up the carpet.
    4.  
    5. Cut up the soundproofing as illustrated.

      Click image to see an enlarged view

      Fig. Cut the sound proofing

      Cut the sound proofing
    6.  

  12.  
  13. Fold up the soundproofing. Remove the cover on the splash guard.
  14.  
  15. Remove the shock absorber nut. Use socket 999 5500 and a Torx-wrench as a counterhold.
  16.  
  17. Remove:

    The bolt in the lower mounting for the shock absorber
     
    The shock absorber.

    Click image to see an enlarged view

    Fig. Removing the upper shock absorber mounting nut

    Removing the upper shock absorber mounting nut

    Click image to see an enlarged view

    Fig. Removing the lower shock absorber mounting bolt

    Removing the lower shock absorber mounting bolt
     

  18.  

To install:

  1. Insert the new shock absorber through the control arm to the upper mounting.
  2.  
  3. Install the new nut loosely.
    NOTE
    Ensure that the bushing seats correctly in the opening in the rear suspension.

  4.  
  5. Fix the shock absorber in the lower mounting. Tighten the upper nut for the shock absorber. Tighten to 44 ft. lbs. (60 Nm). Tighten the lower bolt to 59 ft. lbs. (80 Nm).
  6.  
  7. Reinstall the carpet.
  8.  
  9. With 5 seats: Reinstall the front floor hatch.
  10.  
  11. With 7 seats: Slide the seat cushion forward.
  12.  
  13. Detach the tensioner, pull out the fork and lower the tensioner using the threaded bar.
  14.  
  15. Remove:

    Mounting 999 5659 from the sub-frame
     
    The rails 5740-1 from the control arms.
     

  16.  
  17. Install the parking brake cable mountings in the sub-frame.
  18.  
  19. Install the wheel.
    NOTE
    If the car is equipped with Bi-Xenon lamps, the position sensor must be calibrated.

  20.  

 
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