Recall - (Canadian Vehicles) Rear Control Arm Fractures
855 AWD1997
Section
6
Group
65
No.
0002
Year
03
Month
07
Service Campaign 118 (Canada) Rear control arm, AWD
Background
Volvo Cars of Canada Ltd. has found that on some of the affected cars there is a possibility that, under certain conditions, the rear suspension control arms may develop cracks. Volvo has determined that galvanic corrosion processes may accelerate the deterioration of the rear control arms. In co-ordination with Transport Canada, Volvo has determined that these conditions, if left unchecked, could lead to a rear control arm fracture, which can affect the directional stability of the vehicle.
The following information should be used to complete Service Campaign 118, replacing rear control arms, AWD.
Materials
Special tools
Control arm, lateral link
Rear control arm AWD, replace
Removing the upper shock absorber mountings 1
Fold the rear backrests forward on both sides.
Fold up the front floor hatch.
Remove:
- the side floor panels
- the screws for the front floor hatch.
Pull the hatch backward so that it releases from the mountings at the front edge.
Remove the hatch.
Removing the cover 2
Remove the cover from the upper shock absorber mounting on both sides.
Removing the nut 3
Remove the nut from the upper shock absorber mounting on both sides.
Special tools:
- 999 5498, socket for standard shock absorbers
- 999 5499, spanner for standard shock absorbers
- 999 5500, socket for Nivomat shock absorbers
- 999 5501, spanner for Nivomat shock absorbers.
Preparations 4
Raise the car.
Remove both the rear wheels.
Install tensioner J41470-850 or 999 5659.
Note!
Ensure that the rear lifting arms do not block the support arm mountings/rear jacking points for the rear suspension.
Using tensioner J41470-850 5
Install J41470-850 on the rear axle member.
Install the long screw for the tensioner into J41470-850.
Screw tensioner into place using the long screw.
Note!
Ensure that the rear axle mating surfaces are clean where the tool will be used.
Checking 6
Note!
The rollers must be in contact with the control arms on both sides.
Raise the control arms to their normal position using tensioner J41470-850.
Using tensioner 999 5659 7
Special tools:
- 999 5659
- 999 5660
The tensioner is used when working with he suspension where it is vital that the screwed joints for the rubber bushings are tightened in the normal position (in the same position as when the car is on the ground).
The tensioner takes the loads off the suspension components when removing/installing them. The tool is attached to the rear axle using mounting 999 5660. This means that the stability of the hoist is not affected during work.
Install:
- the long screw for the tensioner on the mounting
- mounting 999 5660 on the rear axle member.
Note!
Ensure that the mating surfaces of the tool on the rear axle member are clean.
Screw tensioner 999 5659 into place in the long screw.
Checking 8
Ensure that the rollers are against the control arms on both sides. See the illustration.
9
Raise the control arms to their normal position using the tensioner.
Normal position 10
The normal position of the rear suspension is when the distance from wheel arch edge (1) to wheel centre is 381 mm.
Removing the jacking points and the control arm mounting 11
Note!
Carry out all steps in this method on both sides.
Detach the rear jacking point.
Remove the 3 screws from the lateral link. This is to detach the control arm mounting.
Press the jacking point backward so that the control arm passes it.
Caution!
Do not damage the brake pipe.
Slacken off the screws for the lateral link mountings in the control arm.
Release the control arms from tensioner J41470-850.
Removing the spring and shock absorber 12
Remove the nut for mounting the anti-roll bar link.
Remove the nuts for the lower shock absorber mounting.
Remove the shock absorber.
Slacken off the nut for the inner trailing arm mounting two turns.
Remove the nut for the outer trailing arm mounting.
Knock out the screw.
Note!
The screw is locked by splines and cannot be turned.
Pull the trailing arm downward.
Remove:
- the spring
- the spring seat
- the bump stop.
13.
Remove the screws for the inner control arm mounting. Transfer the lateral link with the new bushings (1) to the new control arm. Use new screws.
Note!
The control arms and lateral link must not be tightened until the rear axle is in its normal position.
Install the control arm on the inner control arm mounting using new screws from the kit.
Note!
Press in the screw only so far that the splines are not in the bushing.
Install the spring with the spring seat (2) and the bump stop.
Install the shock absorber. Use new nuts. Tighten to 24 Nm.
Installing the jacking point 14
Position the tensioner rollers under the control arms.
Press up the control arms using the tensioner to install the screw for the outer mounting on the control arm. Use new screws and nuts.
Note!
Do not press in the screw so far that the splines are in the bushing.
Note!
Ensure that the anti-roll bar link is correctly positioned.
Note!
Use new screws.
Adjust the tensioner so that the mounting for the lateral link can be installed. Use new screws. Do not tighten the screws yet
Install the jacking points. Do not tighten the screw yet.
Press the control arms up to the normal position.
15
The normal position of the rear suspension is when the distance from the edge of the wheel arch (1) to the centre of the wheel (2) is 381 mm.
Knock in the screws for the inner and outer control arm mountings so that the splines enter the bushings.
16
Tighten:
- Outer and inner control arm mountings. Tighten to 80 Nm.
- The lateral link mountings in the control arm. Tighten to 80 Nm.
- The screws for the lateral link mounting. Tighten to 65 Nm + angle-tighten 60°
- Jacking point.
Tighten to 105 Nm + angle-tighten 90°.
Remove the tensioner.
Installing the wheel 17
Ensure that the brake disc and wheel mating surfaces are clean. Lubricate the centre guide for the rim on the hub. Use installation paste 1161397.
Lightly install the screws.
Tighten crosswise. Tighten to 110 Nm. Use torque socket 951 1526 if using an impact wrench.
The studs must be tightened crosswise and to the correct torque to prevent stresses in the brake disc.
Note!
Torque sockets are intended for tightening wheel studs using normal, pneumatic impact wrenches which achieve a torque of 250-350 Nm.
Upper shock absorber mounting 18
Lower the car completely.
Install the washer and nut on the upper shock absorber mounting.
Tightening torques for the nuts:
- for standard shock absorbers tighten to 40 Nm
- for nivomat shock absorbers with M12 nuts tighten to 40 Nm
- for nivomat shock absorbers with M10 nuts tighten to 20 Nm. Angle tighten 90°.
Special tools:
- 999 5498, socket for standard shock absorbers
- 999 5499, spanner for standard shock absorbers
- 999 5500, socket for Nivomat shock absorbers
- 999 5501, spanner for Nivomat shock absorbers
- 951 2050, bevel protractor.
19
Install the cover on the upper shock absorber mounting.
Reassemble the cargo compartment 20
Align the floor hatch mountings at the front edge.
Install the screws at the rear edge.
Align the hatch with the rear floor hatch. Tighten the screws.
Fold up the backrest.
Checking 21
Check the wheel alignment. Adjust if necessary.