Ring and Pinion or Bearing Replacement
Tool No. 999 2529, Floor Stand And 999 2522, Fixture:
DISASSEMBLY
1. Mount rear axle in fixture 2522. Use floor stand 2520 or bench stand 5154.
2. Remove:
- drive (axle) shaft pressure plates
- drive (axle) shafts (use brake disc to withdraw)
3. Remove inspection cover Turn final drive to drain remaining oil.
Tool No. 9992394, Expansion Tool, Differential Removal/Installation:
4. Remove [1][2]differential housing.
Check clamp markings and remove clamps. Attach expander 2394 and holder 2601. Expand tool until it engages holes. Turn screw (max. 2.5 turns) until [1][2]differential can be lifted out. Remove tool.
5. Remove drive flange Undo nut. Withdraw drive flange using puller 2261.
6. Remove pinion and seal. Tap out pinion with plastic mallet. Hold pinion with hand. Use implement such as screwdriver to remove seal.
Remove oil thrower plate and bearing.
7. Remove pinion bearing outer races Use brass drift.
Discard shim (if fitted) under rear bearing race.
Tool No. 999 5214, Support Ring Rear Pinion Bearing Removal:
8. Press off rear pinion bearing Place ring 5214 on a pair of vee-blocks. Use half-rings 5215 on type 1030 drive and 5216 on type 1031.
Retain shim (if fitted).
Tool No. 999 2483, Puller, Differential Housing Bearing:
9. Remove differential bearings Withdraw bearings using puller 2483. Retain shims.
10. Remove crown wheel.
NOTE: Bolts must not be reused.
11. Remove drive (axle) shaft seals
12. Clean and inspect components
Replace complete bearing if rollers or races exhibit scoring or other damage. Inspect teeth for scoring, gouging, etc. Inspect sealing face on drive flange.
ASSEMBLY
IMPORTANT: Oil all surfaces before assembly.
13. Install pinion bearing outer races
Use press tool 2686 for type 1030 rear axle.
Use press tool 2845 for type 1031 rear axle.
Ensure that bearing races are fully seated.
Tool No. 999 2395, Mounting Sleeve, Pinion Bearing Inner Race:
14. Install rear pinion bearing and shims (if required). Proceed as follows:
- if rear axle has already been reconditioned and shims have been installed under outer race:
- On type 1030 rear axle, use shims of thickness 0.72 mm (0.0283 inch).
- On type 1031 rear axle, use shims of thickness 1.0 mm (0 0394 inch).
- Press on bearing using sleeve 2395 or 2842 as appropriate.
15. Install pinion.
Type without compression sleeve:
- Install 0.75 mm (0.0295 inch) shim and almost one turn of soldering wire approx. 1.5 mm (0.0591 inch) in thickness.
Type with compression sleeve:
- Do not install sleeve at this point, but proceed to step 21.
Both types:
- Insert pinion and press on front bearing. Use wrench 2404 and nut.
- Tighten nut to obtain bearing preload of 2.5-3.5 Nm (1.8-2.6 ft. lbs.) for new, oiled bearing or 1.5-2.5 Nm (1.1-1.8 ft. lbs.) for run-in, oiled bearing.
- Turn pinion until rollers have been centered and torque is steady. Use torque meter 9177. Turn at about one revolution riser second.
16. Pinion height setting
The pinion must be set at a certain distance (A) from the center line of the crown wheel.
This distance should be 57.15 ±0.03 mm (2.25 ±0.0012 inch) (plus the deviation tolerance marked on the pinion as described below).
EXAMPLE: If the pinion is marked 30, A = 57.15 + 0.30 = 57.45 mm ±0.03 mm.
Since the face is ground by at cast 0.30 mm (0.0118 inch) in all cases, the tolerance deviation will always be smaller. In addition, since the deviation is always specified as a positive value, the plus sign is omitted.
NOTE: The normal degree of grinding (0.30 mm/0.0118 inch)) is no longer marked on pinions manufactured from January 1990 on. Only pinions which deviate from this value are marked.
EXAMPLE: Where A = 57.15 + 0.40 = 57.55 ±0.03 mm, the pinion is marked "40".
A special tool incorporating a pinion gauge is used to facilitate measurement. The length of the gauge is chosen so that only the difference between the gauge and measuring tool placed in the differential bearing seats need be measured.
In the case of a pinion marked "30" or not provided with a marking, the face of the gauge must be 0.30 ±0.03 mm (0.0118 ±0.0012 inch) below the measuring surface of the tool.
The pinion setting is adjusted by installing a shim (B) between the pinion end and rear bearing.
Tool No. 9992393, Dial Gauge, Pinion Adjustment:
Inspection And Adjustment Of Pinion Setting
17. Check pinion setting
Place measuring tool 2393 in differential bearing seat and on pinion. Ensure that tool is fully seated in bearing seat.
Ensure that gauge is in firm contact with pinion end.
Arrows indicate tool measuring surfaces.
18. Measurement
Place holder 2284 and a dial gauge on rear axle housing. Measure difference in height between gauge and smaller diameter of measuring tool. Gauge should be below face of smaller diameter by the same amount as marking on pinion + 0.03 mm (0.0012 inch).
NOTE: The normal degree of grinding of 0.30 mm/0.0118 inch) is no longer marked on pinions manufactured from January 1990 on. Only pinions which deviate from this value are marked.
Tool No. 999 5214, Support Ring Rear Pinion Bearing Removal:
19. Adjust pinion setting. (Required only if deviation is outside tolerance range)
Remove rear pinion bearing. Place ring 5214 on a pair of vee-blocks. Use half-rings 5215 (1030) or 5216 (1031) as appropriate.
Measure shim thickness. If deviation is positive, add until tolerance range is reached. If deviation is negative, reduce until tolerance range is reached.
Adjust until tolerance is as close as possible to ideal value.
Install rear pinion bearing.
EXAMPLE:
If deviation is +0.10, add 0.05-0.12.
Select 0.08 mm shim.
If deviation is -0.10, subtract 0.08-0.15.
Above figures are based on a shim thickness of 0.72 mm (0.0283 inch) or 1.0 mm (0.0394 inch) as appropriate, plus a suitable number of thin shims.
20. Adjustment of pinion bearing preload.(Applies to pinions without compression sleeve).
Measure total thickness of shim and soldering wire.
If piston setting deviation is positive, add same amount as when adjusting setting. If pinion setting is negative, subtract same amount as when adjusting setting.
Shim Thickness and Part No.
- 0.08 (0.0031 inch): 191 834-1
- 0.13 (0.0051 inch): 191 835-8
- 0.25 (0.0098 inch): 191 837-4
- 0.75 (0.0295 inch): 191 836-6
21. Install pinion. Insert pinion and install compression sleeve or shims as described above.
Press on front bearing. Use wrench 2404.
22. Install seal
Grease seal lip (see arrow) with Volvo bearing grease, P/N 1161241-3.
Install oil thrower (if removed).
Place seal on tool 5538 (against side marked 1031).
1 = Seal.
Press on seal using tool 5156 (M20 thread) or 5504 (M24 thread).
23. Install drive flange.
NOTE: Do not use nut runner.
Pinion without compression sleeve:
Install drive flange, oiled on the seal surface. Use press tool
5156 (M20 thread) or 5504 (M24 thread). Remove tool. Install
new nut using counterhold 5149. Tighten nut to 200-250 Nm
(148-184 ft lb). Set bearing preload using torque wrench
9177, turning at about 1 turn/second.
Pinion with compression sleeve:
Install drive flange, oiled on the seal surface. Use press tool 5156 (M20 thread) or 5504 (M24 thread). Remove tool. Install new nut using counterhold 5149. Tighten nut in stages. Rotate pinion until rollers are centred and torque is steady. Use torque wrench 9177, turning at about 1 turn per second. Cease tightening when correct bearing preload has been reached. Replace compression sleeve if preload is exceeded. Bearing preload is 2,5-3,5 Nm (1.8-2.6 ft lb) for new, oiled bearing and 1,5-2,5 Nm (1.1-1.6 ft lb) for oiled, run-in bearing.
23. Install drive flange.
Pinion without compression sleeve:
Install drive f range. Use press tool 5156. Remove tool. Install new nut. Use counterhold 5149. Tighten nut to 200-250 Nm (148-184 ft. lbs.). Check bearing preload. Use torque meter 9177, turning at approx. one revolution per second.
Pinion with compression sleeve:
Install drive flange. Use press tool 5156. Remove tool. Install new nut. Use counterhold 5149. Tighten nut in stages. Turn pinion until rollers have been centered and torque is steady. Use torque meter 9177. Conclude when correct bearing preload has been reached. Turn at approx. one revolution per second.
Replace compression sleeve if preload is exceeded.
Bearing preload for new, oiled bearing is 2.5-3.5 Nm (1.8-2.6 ft. lbs.).
Preload for run-in bearing is 1.5-2.5 Nm (1.1-1.8 ft. lbs.).
24. Check pinion setting. Permissible deviation from nominal value is ±0.03 mm (0.0012 inch).
Use holder 2284 and measuring tool 2393.
25. Install crown wheel.
Ensure that mating surfaces are clean and free of grease.
On cars with limited slip [1][2]differential:
Use thread locking fluid on crown wheel face.
Two opposite holes in [1][2]differential housing are smaller in size; these are intended as guide holes.
Tighten bolts alternately to 35 Nm (26 ft. lbs.) + angle tighten through 60 degrees.
Use protractor 5098.
NOTE: Always use new, oiled bolts.
26. Adjustment of backlash/differential bearing preload
The distance between the crown wheel (ring gear) and pinion, i.e. the backlash, must be within certain limits to ensure quiet running and long life. Adjustment is carried out by moving the [1][2]differential housing sideways.
The differential bearing preload is adjusted by installing shims to increase the clearance between the bearings.
27. Determination of [1][2]differential housing position.
Mount assembly rings 2595 on [1][2]differential housing.
Lubricate ring seating surfaces. Mount rings on bearing seats of housing with black ring on crown wheel side.
28. Install [1][2]differential housing in final drive.
Raise apart assembly rings until [1][2]differential housing is seated firmly without preload.
No gap is permissible between rings and [1][2]differential housing or final drive housing.
29. Adjust backlash
Mount dial gauge in position with plunger resting on a crown wheel tooth approx. 3 mm from big end of tooth.
Hold pinion and move crown wheel forwards and backwards against plunger. Backlash should vary between 0.10-0.16 mm (0.0039-0.0063 inch), but should be as close as possible to 0.13 mm (0.0051 inch). Max. variation between three different positions should be ±0.03 mm (0.0012 inch).
Adjust clearance by using pins to turn both assembly rings in same direction. Lock rings when backlash is correct, and remove [1][2]differential housing and assembly rings.
Tool No. 999 2600, Measuring Fixture:
30. Measure thickness of shims.
NOTE: Ensure that correct bearings and shims are located on either side of [1][2]differential housing, otherwise backlash will be incorrect.
Crown Wheel Side:
Place bearing (3) in fixture 2600 with outer race facing upward, and mount plate, spring and nut.
Apply nut with flat side downwards. Turn plate (and bearing) forwards and backwards a few times to ensure that rollers assume correct position.
Mount assembly ring (1) on fixture. Mount holder 2284 on dial gauge (2).
Place dial gauge plunger on assembly ring and zero gauge.
Next, place plunger against bearing and read gauge.
Use micrometer to measure shims with combined thickness equal to indicated value plus 0.07 mm (0.0028 inch) for new bearing and 0.04 mm (0.0016 inch) for used bearing. This will give correct differential bearing preload.
Place shims and measured bearing aside.
Repeat Procedure On Other Side
Shim thickness and Part No.:
- 0.08 mm (0.0031 inch): 81374-1
- 0.13 mm (0.0051 inch): 81375-8
- 0.25 mm (0.0098 inch): 120622-6
- 0.72 mm (0.0283 inch): 81377-4
Tool No. 999 4112, Drift For Differential Housing Bearing Installation:
31. Install differential bearings
Place shims and locking plate (A) in position. (Not applicable to cars with limited slip [1][2]differential)
Use drift 4112 and press on bearing.
NOTE: Ensure that locking plate is not jammed between bearing and housing.
Use drift 4112 as support when installing second bearing.
Tool No. 9992394, Expansion Tool, Differential Removal/Installation:
32. Install [1][2]differential housing. Mount expander 2394 and holder 2601. Expand tool until it engages and turn a further 2.5 turns. Place differential and bearings in housing.
Remove tool.
33. Use new bolts and install clamps. (Note previous marking.)
Tighten to 35 Nm (26 ft. lbs.) + angle tighten through 60 degrees.
34. Check backlash. Clearance should be 0.10-0.16 mm (0.003-0.0063 inch). Measure at three points 3 mm (0.1181 inch) from outer edge.
35. Mount inspection cover.
The correct gasket must be used for the inspection cover, (see image for application chart)
Tighten to 20-30 Nm (15-22 ft. lbs.).
Fill final drive with oil.
36. Install drive (axle) shaft seals.
Pack space between seal lips with grease. Use drift 5009 and handle 1801.
37. Install drive (axle) shafts together with parking brake retaining springs
Tighten drive (axle) shaft pressure plates to 40 Nm (30 ft. lbs.).