Suspension/Steering - Ball Joint Replacement
NO: 61-09DATE: 7-24-2006
MODEL: XC90
M. YEAR: 2003-
SUBJECT: Ball Joint Replacement, New Method & Tools
REFERENCE: VIDA; Special Tool Bulletins listed below
DESCRIPTION:
This TNN describes the method to replace the ball joints using the new ball joint tools 9997255 and 9997256. Tool 9997256 is used to compress the front MacPherson strut when replacing the ball joint and/or control arm. Compression of the strut makes it possible to replace these components while removing only a minimum number of front end connections.
Note!
When servicing any front-end components, it is always a good service practice to check the overall condition of the front suspension. Before replacing any front-end component, verify whether the vehicle exhibits symptoms of needing wheel alignment, such as pulling, tire wear, or an off-center steering wheel. See VIDA for information on checking and repairing play in the front suspension: Information > Repair > Cleaning, Inspection, and Adjustment > 6 Suspension and Steering > 60 General > Wheel Alignment > Wheel alignment, checking / adjusting.
SPECIAL TOOLS:
MATERIAL:
Caution!
Use special tool 9997256 with hand tools only! Do not use power-driven or impact tools in combination with this special tool to compress or release the front strut.
Removal
1
Raise the vehicle.
Remove the front wheel.
Position the spring compressor 999 7256, first on the strut tower in the engine compartment, and then against the underside of the MacPherson strut seat.
Note!
Position the upper seat of the tool so that the marking points out toward the fender. See illustration. Also be sure to avoid contact between the tool and the hood strut.
Tighten the tool until it makes light contact.
Then tighten so that the spring is compressed to about 60 mm (2-3/8").
Caution!
Use hand tools only!
2
Remove:
- the ball joint nut (clean the threads protruding beyond the nut before removing it).
- the 2 ball joint bolts.
3
Fitting the press tool
When fitting press tool 999 7255, fit the tool's screw cap onto the ball joint. Make sure there is 1-1.5 mm (.04-.06 in.) clearance (A) between the nut and the control arm.
Note!
Be absolutely certain to use the correct nut as two different thread pitches are used.
4
Fit tool 999 7255 as illustrated.
Note!
Turn the seat on the bolt so that the side with the lower height (A) faces forward in the direction of the vehicle.
Tighten the tool's bolt so that the ball joint releases from the control arm.
Remove the tool.
5
Removing the MacPherson strut from the control arm
Unhook the control arm from the ball joint. Use lever 999 7076.
6
Move the MacPherson strut back slightly to expose the ball joint. Hold the MacPherson strut in place with tensioner band 999 5682, or equivalent.
7
Removing the ball joint from the wheel spindle
Install:
- nut 999 7149 (coarse thread pitch) for early edition, or nut 999 7230 (fine thread pitch) for late edition, on the ball joint.
- sledge hammer 999 2709 on the nut.
Tap the ball joint loose.
8
Cleaning the ball joint mounting surfaces Warning! Always use protective goggles.
Use a rotating steel brush to clean the ball joint seat and the contact surfaces. Lubricate the seat with wheel bearing grease, part no. 1161689.
Installation
9
Fitting the guide screws
Guide screws 999 5781 have a wrench grip (see arrow) that is asymmetrically positioned. Install the guide screw so that the stud (2) with the shorter distance from the wrench grip is facing downward.
10
Installing the ball joint
Note!
Take extreme care so as not to damage the ball joint boot.
Temporarily remove the protective cup from the ball joint. Loosely install the new ball joint using the guide screws 999 5781.
11
Note!
Take extreme care so as not to damage the ball joint boot.
Use press tool 999 5796 to press the ball joint up toward the seat.
Check that the ball joint is centered in the seat.
Tap the ball joint into place with a brass or other suitable soft-faced hammer.
Remove the 2 guide screws.
12
Refit the ball joint's protective cup (1).
Tighten the ball joint with the 2 new bolts.
Tighten to 50 Nm (37 lb. ft.).
13
Installing the ball joint in the control arm
Note!
Position the hook of the lever 999 7076 on the control arm so that it does not come into contact with the ball joint's boot when it is fitted to the control arm.
Remove the tensioner band from the MacPherson strut.
Press down the control arm using the lever 999 7076.
Remove the protective cup from the ball joint and fit the ball joint pin in the control arm.
14
Fitting the nut to the ball joint
Note!
The ball joint pin must not rotate. Use torx wrench TX40 as a holding tool so that the rubber boot is not damaged.
Use socket 999 5467 as an adapter for the torque wrench or a ring wrench adapter designed for the torque wrench.
Fit the 1 nut and tighten to 100 Nm (74 lb. ft.).
Apply rustproofing agent to the threads outside the nut.
15
Finishing work
Remove the spring compressor.
Caution!
Use hand tools only when removing the spring compressor.
Install the wheel, see Vida:
- Removal, replacement and installation
- Springs and Wheels
- Wheels, tires, hubs
- Wheel
Warranty Claim Information