Service Manual Truckshhrvresource.com/VolvoDocs/60-79/PV776-TSP143273.pdf · The J–44544...

Service ManualTrucks

Group 720–500

Volvo Optimized Air Suspensionfrom 5/99

VN

PV776-TSP143273

Foreword

The descriptions and service procedures contained in this manual are based on de-signs and methods studies carried out up to July 2000.

The products are under continuous development. Vehicles and components producedafter the above date may therefore have different specifications and repair methods.When this is believed to have a significant bearing on this manual, supplementary ser-vice bulletins will be issued to cover the changes.

The new edition of this manual will update the changes.

In service procedures where the title incorporates an operation number, this is a refer-ence to an S.R.T. (Standard Repair Time).

Service procedures which do not include an operation number in the title are for gen-eral information and no reference is made to an S.R.T.

The following levels of observations, cautions and warnings are used in this ServiceDocumentation:

Note: Indicates a procedure, practice, or condition that must be followed in order tohave the vehicle or component function in the manner intended.

Caution: Indicates an unsafe practice where damage to the product could occur.

Warning: Indicates an unsafe practice where personal injury or severe damage to theproduct could occur.

Danger: Indicates an unsafe practice where serious personal injury or death could oc-cur.

Volvo Trucks North America, Inc.Greensboro, NC USA

Order number: PV776-TSP143273

© 2000 Volvo Trucks North America, Inc., Greensboro, NC USA

All rights reserved. No part of this publication may be reproduced, stored inretrieval system, or transmitted in any forms by any means, electronic, me-chanical, photocopying, recording or otherwise, without the prior writtenpermission of Volvo Trucks North America, Inc..

ContentsGeneral .................................................................................................... 3

Basic Description ................................................................................... 3

Specifications ......................................................................................... 5Torque Chart .......................................................................................... 5Ride Height and Pinion Angle Specifications ........................................ 6Volvo Optimized Air Suspension Applications ....................................... 7

Tools ........................................................................................................ 9Special Tools ......................................................................................... 9Special Equipment ............................................................................... 11

Design and Function ........................................................................... 13Volvo Optimized Air Suspension ......................................................... 13

Troubleshooting ................................................................................... 23Volvo Optimized Air Suspension Troubleshooting ............................... 23

Service Procedures ............................................................................. 25Air Suspension, Adjustment (Ride Height and Drive Line Calculation) 25Rear Spring U-bolt Torque, Adjustment .............................................. 32Load Leveling Valve, Adjustment ........................................................ 34Load Leveling Valve, Replacement ..................................................... 36Leveling Rod, Replacement ................................................................ 37Crossbeam (Pedestal), Replacement ................................................ 38Z-Spring, Replacement ........................................................................ 39Radius Leaf Spring, Replacement ...................................................... 42Torque Rod, Replacement ................................................................... 44Torque Rod Frame Rail Bracket, Replacement ................................... 45Rear Spring Hanger, Replacement ..................................................... 46Wear Plate (Pad), Replacement .......................................................... 48Rear Shock Absorber Bracket, Replacement (Upper) ........................ 49Rear Shock Absorber, Replacement ................................................... 50Top Plate, Replacement ...................................................................... 51Bottom Plate/Rear Shock Absorber Bracket, Replacement (Lower) .. 53Axle Seat, Replacement ...................................................................... 54Rear Air Spring, Replacement ............................................................ 57Pneumatic Switch, Replacement ......................................................... 58HUCK-FIT® Fastener, Removal ........................................................... 59

Feedback

Operation Numbers

1

Group 72 Volvo Optimized Air Suspension General

GeneralBasic Description

W7001036

This information covers specifications, service proce-dures, ride height adjustments, calculations, andpinion angles for the Volvo Optimized Air Suspensionproduced since May 1999. Information in this manualis essential to maintain proper serviceability andproper ride height set by the manufacturer for theVolvo Optimized Air Suspension.

CAUTION

The Volvo Optimized Air Suspension ride height is setat the factory. Changing the ride height will affect thedriveshaft angles and may cause driveline vibrationand/or shorten component life.Ride height adjustments must be performed in ac-cordance with all documented service procedures.

3

Group 72 Volvo Optimized Air Suspension General

4

Group 72 Volvo Optimized Air Suspension Specifications

SpecificationsTorque Chart

M20 STD 38K 6X4

500 ± 75 Nm (369 ± 55 ft-lb)U-Bolts for Suspension

M22 STD 40K 6X4, 4X2

575 ± 50 Nm (424 ± 37 ft-lb)

Radius Spring to Spring Hanger Bracket M16 275 ± 45 NM (203 ± 33 ft-lb)

Air Spring Crossbeam (Pedestal) to Leaf M12 105 ± 20 Nm (77 ± 15 ft-lb)

Air Spring to Crossbeam (Pedestal) M12 50 ± 10 Nm (37 ± 7.5 ft-lb)

Torque Rod to Frame-Mounted Bracket M16 320 ± 50 Nm (236 ± 37 ft-lb)

Torque Rod to Axle Housing M16 320 ± 50 Nm (236 ± 37 ft-lb)

Shock Absorber Bracket to Frame M14 275 ± 45 Nm (203 ± 33 ft-lb)

Shock Absorber to Bracket (Upper and Lower) M16 275 ± 45 Nm (203 ± 33 ft-lb)

Bracket for Load Leveling Valve to Frame M14 275 ± 45 Nm (203 ± 33 ft-lb)

Load Leveling Valve to Bracket M8 30 ± 5 Nm (22 ± 4 ft-lb)

Load Leveling Valve Control Arm to Lever onValve and Air Bag Pedestal

M6 10 ± 1.5 Nm (7 ± 1 ft-lb)

Spring Hanger Bracket to Frame M14 275 ± 45 Nm (203 ± 33 ft-lb)

5


Ride Height and Pinion Angle Specifications

6X4 VOAS

Frame Height mm (in.) Ride Height mm(in.)

Pinion Angle (�) Pinion Angle (�)

(first drive axle) (second drive axle)

Meritor RT40-145

266 (10.47) axle space 1320 225 ± 5 (8.86 ± 0.2) 2.5 ± 1� 13.2 ± 1�

RRH200 axle space 1520 217 ± 5 (8.54 ± 0.2) 1.7 ± 1� 12.0 ± 1�

300 (11.81) axle space 1320 208 ± 5 (8.19 ± 0.2) 2.5 ± 1� 13.2 ± 1�

RRH200 axle space 1520 200 ± 5 (7.87 ± 0.2) 1.7 ± 1� 12.0 ± 1�

266 (10.47) axle space 1320 181 ± 5 (7.13 ± 0.2) 2.5 ± 1� 13.2 ± 1�

RRH160 axle space 1520 173 ± 5 (6.81 ± 0.2) 1.7 ± 1� 12.0 ± 1�

Dana 404

266 (10.47) axle space 1320 208 ± 5 (8.19 ± 0.2) 1.8 ± 1� 12.2 ± 1�

RRH200 axle space 1520 206 ± 5 (8.11 ± 0.2) 1.6 ± 1� 10.8 ± 1�

300 (11.81) axle space 1320 191 ± 5 (7.52 ± 0.2) 1.8 ± 1� 12.2 ± 1�

RRH200 axle space 1520 189 ± 5 (7.44 ± 0.2) 1.6 ± 1� 10.8 ± 1�

266 (10.47) axle space 1320 164 ± 5 (6.46 ± 0.2) 1.8 ± 1� 12.2± 1�

RRH160 axle space 1520 157 ± 5 (6.18 ± 0.2) 1.6 ± 1� 10.8 ± 1�

4X2 VOAS with any Axle

266 (10.47) 225 ± 5 (8.86 ± 0.2) 3.5 ± 1�

RRH200

300 (11.81) 208 ± 5 (8.19 ± 0.2) 3.5 ± 1�

RRH200

Table 1. Ride Height and Corresponding Pinion Angle

As measured from the axle center to the frame rail bottom. *In the event that both the ride height and pinion anglescan not be adjusted at the same time for 6X4s, the ride height should be adjusted to the minimum cancellation errorangle for the intermediate prop shaft, then lowered by 10 mm.

Note: Working angles are measured at the forward axlejoint or rear axle joint; See “Calculation Form” page 31.

6


Volvo Optimized Air Suspension Applications

Available AxlesSuspension

Configuration

MaximumGAWR

Metric Ton (lb)

MaximumGCW

Metric Ton (lb)

Axle Spacingmm (in.)

Required Numberof ParkingChambers Models Metric Ton (lb)

4x2 9 (20,000) N/A TWOEatonMeritor

10(23,000)

17 (38,000) 1320 (52) TWO (1st Axle)

18 (40,000) 1320 (52) FOUR6x4

18 (40,000)

50 (110,000)(1)

1524 (60) FOUR

EatonMeritor

18(40,000)

(1) GCW (Gross Combination Weight) rating can be reduced by vehicle operating applications, engine horse-power/torque, axle type/model, axle ratio, and/or vehicle tire size.

7

Group 72 Volvo Optimized Air Suspension Tools

ToolsSpecial ToolsThis air line release tool, part no. J–42189 may be usedto safely disconnect air lines from switches. This tool isavailable from Kent-Moore (telephone: 800–328–6657)

W0001198

The J–44773 is an air line release tool, available fromKent-Moore (telephone: 800–328–6657)

W0001874

The J–44544 adjustment socket is used to adjust theride height on trucks with Volvo Optimized Air Suspen-sion built after May 1999. It is available from Kent Moore(telephone: 800–328–6657).

W0001815

9


The J–44684 is a ride height gauge, used to check ormeasure ride height. It is available from Kent-Moore(telephone: 800–328–6657).

W0001960

10


Special EquipmentThe following tools can be used to ensure proper inclina-tions and/or angles on the Volvo Optimized AirSuspension:

The Anglemaster is a digital inclinometer, available fromDana-Spicer (telephone: 419–535–4300).

W7000250

The J–38460–A is a digital protractor, available fromKent-Moore (telephone: 800–328–6657).

W7000708

The J–38460–25 is a bracket, this tool is used along withthe Kent-Moore digital protractor or the Dana-Spicer digi-tal inclinometer for checking pinion angles. It is availablefrom Kent-Moore (telephone: 800–328–6657).

W7000726

11

Group 72 Volvo Optimized Air Suspension Design and Function

Design and FunctionVolvo Optimized Air Suspension

W7001036

The design of the Air-Ride Suspension has been refinedby Volvo Trucks North America. The result of this refine-ment process is the Volvo Optimized Air Suspension.This new Suspension is a rear air suspension with im-proved ride characteristics and increased durability.

CAUTION

The Volvo Optimized Air Suspension is set at the fac-tory. Changing the ride height will affect the driveshaftangles and may cause driveline vibration and/orshorten component life.Ride height adjustments must be performed in ac-cordance with all documented service procedures.

13


Air Suspension, Adjustment (RideHeight and Drive Line Calcula-tion)Ride height has a direct relationship with driveline pinionangles. It is critical to maintain all ride height specifica-tions as recommended by Volvo Trucks North America,Inc. (VTNA).

Interaxle cancellation (equal forward and rear interaxleU-joint angles) is the key to reduced driveline vibrationsand increased component life. “Air Suspension, Adjust-ment (Ride Height and Drive Line Calculation)” page 25,describes how to achieve interaxle cancellation by main-taining the proper ride height and pinion angles.

14


Spring HangerThe Spring Hanger is a ductile iron casting and includesan internal alignment guide to help center the Z-springwithin the bracket during initial assembly.

W7001044

Wear PlateThe wear plate (pad) is constructed of the same Ultra-High Molecular Weight Polyethylene as earlier wearplates. This material provides an extremely smooth sur-face for the spring to contact and virtually eliminates thenoise associated with the metal-to-metal contact of othersuspension designs. The Volvo Optimized Air Suspen-sion wear plate mounts with a single fastener into apocket between the vertical legs of the spring hanger.

Note: Wear plates (pads) must be replaced in pairs (leftand right) to avoid excessive stress on the suspension.

W7000739

Z-SpringThe Z-spring has been improved to provide a largerclamping surface, an improved alignment with matingcomponents, and increased clearance to the lower shockmounting bracket.

Note: The Z-Spring on the second drive axle on the 6 x4 may be longer than the first drive axle.

W7001045

15


Radius Leaf SpringThe radius leaf spring is crucial to the vehicle’s align-ment. The radius leaf spring has an improved bushingfor increased component durability. The Volvo OptimizedAir Suspension spring uses a locating pin that preciselylocates the radius leaf spring for an improved fit with themating Z-spring and axle seat. Precisely locating the ra-dius leaf spring helps to improve the vehicles overallaxle alignment.

Note: The first and second drive axles on the 6 x 4 havedifferent radius leaf springs. W7001046

CrossbeamThe crossbeam (pedestal plate) has been redesigned toimprove strength while reducing weight. The Volvo Opti-mized Air Suspension crossbeam uses only fourmounting bolts (two on each end) for easy installation ofthe Z-spring.

W7000704

Crossbeam

Axle SeatThe axle seat defines the axle pinion inclination. It hasbeen refined to eliminate the extra spacers necessary inearlier designs. By eliminating the spacers, the VolvoOptimized Air Suspension axle seat forms a strong andsecure joint between the radius leaf spring and the axle.

Note: For proper positioning of axle seat, see “AxleSeat, Replacement” page 54.

W7001200

Axle seat

16


Bottom Plate/Rear Shock Absorber Bracket, LowerThe bottom axle plate/lower shock absorber bracket isfound underneath the axle housing, and is held in placeby the U-bolts. It helps maintain axle alignment with thesprings in the suspension and prevents movement of theaxle. It can also be helpful in keeping U-bolts properlyaligned and secured.

Note: There is a left-and right-hand bracket.

W7001049

Bottom plate/rear shock absorber bracket (Righthand bracket shown above)

Top PlateThe top plate (upper clip) is located at the top of the Z-spring and is clamped down by the U-bolts. It helpsmaintain alignment of the U-bolts to secure and align theZ-spring, radius leaf spring, and axle seats. The topplate also helps maintain a secure surface for U-boltswhen the nuts are tightened.

W7001050

Top plate

Air SpringThe air spring in the Volvo Optimized Air Suspensionsystem is a rolling-lobe, sleeve type with a compositepiston. The air spring uses a single stud to attach to thecrossbeam.

CAUTION

Do not mix the air springs of the Volvo Optimized AirSuspension with air springs of earlier suspensions.System failure may result.

W7000225

17


Leveling RodThe Volvo Optimized Air Suspension uses a leveling rodthat is factory adjusted and set to accurately control thedimensions of the air springs, prevent inappropriate ad-justments, and avoid unnecessary servicing.

W7001195

Load Leveling ValveThe load leveling valve was designed to simplify thechassis air suspension system. The quick-dump valve isnow combined into the height control valve. This elimi-nates one valve and the related plumbing.

The valve is located on the left side of the frame rail, ad-jacent to the fifth wheel.

The Volvo Optimized Air Suspension height valve incor-porates an integrated dump feature that eliminates theneed for a separate valve and allows the rear to be low-ered when driving out from under an uncoupled trailer.

W7001051

Shock Absorber Bracket, UpperThe upper shock absorber bracket has been redesignedto eliminate the need for left-hand and right-handversions.

W7001053

18


Torque RodThe torque rod is located on top of the axle housing. It ispositioned between the frame rail mounted bracket andthe axle housing mounted bracket. It helps maintainlateral alignment of the rear axle or axles for the suspen-sion.

Note: Different models of torque rods should not beinterchanged.

W7000722

19


Pneumatic Switch PanelThe air suspension level switch is used to lower the truckwhen uncoupling the trailers. It then enables you to re-turn to the raised position (“ride”) for a better ride.

W7000714

TerminalSwitch SwitchFunction

A B C D

InteraxleDLO

To ClusterTelltale Lamp

+12V Supply Ground +12V Illumi-nationControl

Fifth WheelSlide


Not Used Ground +12V Illumi-nationControl

SuspensionDump


Not Used Ground +12V Illumi-nationControl

W3000574

W3000573

InterwheelDLO

N/A Not Used Ground +12V Illumi-nationControl

20


Dump Switch OperationTo “dump” air from the system (to lower the suspension),push the switch to the position labeled “uncouple.”

To fill the system (to return to the normal ride height),push the switch to the position labeled “ride.”

Note: Lower the suspension when disconnecting andconnecting the trailer.

W7001198

Volvo Optimized Air Suspension

A Dump System

B Air Suspension System

C Air Supply

1 Supply for Dash Systems

2 Air Suspension Dump

3 BulkHead pass through

4 Air Spring

5 6 X 4 only

6 Air Suspesnion Leveling Valve

7 Frame Rail

21

Group 72 Volvo Optimized Air Suspension Troubleshooting

Troubleshooting

Volvo Optimized Air Suspension TroubleshootingProblem Cause

U-joint angle incorrect

Improper phasing of drivelines

Axle inclination incorrect

Worn wear plate

Worn radius arm bushing

Improper ride height

Broken or defective spring

Thrust alignment incorrect

Improper wheel run-out or balance

Broken or loose U-bolts

Excessible wheel bearing end play

Mismatched wheels and tires

Vibration

Improper axle seat installation

Broken or defective shock absorber

Defective leveling valve

Overloaded vehicle

Pressure regulator set too low

Wrong air spring

Improper ride height


Bottoming Out

Low air pressure

Thrust alignment incorrect

Worn or defective torque rod bushing

Worn radius arm bushing

Broken or loose U-bolts


Total wheel alignment of axles incorrect

Tracking

Lateral alignment of axles incorrect

Improper axle seat installation


Ride height not set properly

Axle inclination incorrect

Overloaded vehicle

Ride Height Incorrect

Defective air spring

Defective manifold


Air leak or loose line

Defective pressure regulator

Low Air Pressure

Defective dump switch

23

Group 72 Volvo Optimized Air Suspension Troubleshooting

Volvo Optimized Air Suspension Ride Height and Driveline AngleCheck Flow Diagram

W7000749

1 See “Air Suspension, Adjustment (Ride Height and Drive Line Calculation)” page 252 See “Interaxle U-joint Angle Cancellation Check (Calculation)” page 273 See “Load Leveling Valve, Adjustment” page 344 See “Forward Axle Pinion Angle to Frame Check” page 295 See “Rear Spring U-bolt Torque, Adjustment” page 32

24

Group 72 Volvo Optimized Air Suspension Service Procedures

Service Procedures7281-05-02-01Air Suspension, Adjustment(Ride Height and Drive LineCalculation)

CAUTION

The Volvo Air Suspension is set at the factory. Chang-ing the ride height will affect the driveshaft angles andmay cause driveline vibration and/or shorten compo-nent life. Ride height adjustments must beperformed in accordance with all documented ser-vice procedures.

Note: After work has been performed on the air suspen-sion, wheel realignment may be required.

For proper specifications for checking the wheel align-ment, refer to:

ServiceBulletin

601–006Wheel Alignment Steer and Drive AxlesVN/VHD

IMPACT Function Group 601Information Type: Bulletin“Alignment Specifications and Proce-dures"

Other special equipment: J–38460–A,J–38460–25

Air Suspension Ride HeightCheck

Before working on a vehicle, set the parking brakes,place the transmission in neutral and block thewheels. Failure to do so can result in unexpectedvehicle movement and can cause serious personal in-jury or death.

1

W7000765

1 Load leveling valve

2 Ride height

3 Axle center line

4 Crossbeam

Before you can accurately calculatethe ride height, prepare the vehicle us-ing these steps:

• Measurements must be per-formed on an unloaded vehicle.

• Park the vehicle on a level sur-face.

• The steer and rear drive axle tiresmust be at normal operating pres-sure.

• Free and center all suspensionjoints by slowly moving the vehicleback and forth twice without usingthe brake. When coming to acomplete stop, make sure thebrakes (parking and service) arereleased.

• Front wheels must be pointedstraight ahead.

25


2Chock the front wheels on the vehicle.

3Dump (release) the suspension air(see “Dump Switch Operation” page21).

Stay clear when suspension air is released. Chassismay drop quickly and can cause serious injury ordeath to anyone under the vehicle.

Start the engine and fill the suspen-sion with air. Turn off the engine.

4

W7001054

The ride height is the distance fromthe axle centerline to the bottom of theframe rail. The ride height must bewithin specifications See “Ride Heightand Pinion Angle Specifications” page6.

To accurately measure ride height:

a. Measure from the ground to thebottom of the frame rail (1).

b. Locate the axle centerline (thecenter hole on the end of the hubworks best) using a steel rule oran appropriate tool (2). Measurefrom the ground to the axle cen-terline (3).

c. Calculate the difference between(1) and (3). The difference is theride height (4).

d. Ride height should fall withinspecifications (see above).

5Record the measurement for calcula-tion (refer to “Calculation Form” page31). If the measurement is not withinthe specified range, it must be cor-rected before proceeding. If the rideheight is not adjusted to specification,check for the following:

• Excessively worn wear plates(pads).

Note: Wear plates (pads) must bereplaced in pairs (left and right onsame axle); see “Wear Plate(Pad), Replacement” page 48.

• Damaged spring hanger.

• Damaged air spring, Z-spring,and/or radius leaf spring.

• Damaged leveling rod.

• Faulty load leveling valve.

Replace the components as neces-sary, then adjust the suspension rideheight (see “Load Leveling Valve, Ad-justment” page 34).

6Re-measure the ride height followinginstructions shown in step 4. Repeatas necessary until the measurement iswithin specifications.

7Proceed to “Interaxle U-joint AngleCancellation Check (Calculation)”page 27.

26


Interaxle U-joint Angle Cancella-tion Check (Calculation)1The steps from “Air Suspension RideHeight Check” page 25must be per-formed before continuing with thisprocedure.

Note: All angle measurements are rel-ative to level ground.

2

W7001194

A Angle A FWD Axle pinion

B Angle B Interaxle shaft Angle

C Angle C Rear Axle pinion

D Angle D FWD Axle Joint Working Angle

E Angle E Rear Axle Joint Working Angle

1 Ride Height

2 Angle P Relative to frame

3 Frame Rail

W7000252

Measure the forward axle angle (A)using a protractor or recommendedtool. Record the measurement for cal-culation (refer to “Calculation Form”page 31).

Note: Wipe surface clean of dirt anddebris before taking measurement.

J-38460-A

27


3

W7001202

1 Digital Protractor J-38460

2 Bracket J-38460–25

Measure the interaxle shaft angle (B)using the recommended tools. Recordthe measurement for calculation (referto “Calculation Form” page 31).


4Calculate : B – A = DThe interaxle angle minus the forwardaxle angle will give the value (D) (referto “Calculation Form” page 31).

5

W7001194






1 Ride Height


3 Frame Rail

W7000253

Measure the rear axle angle (C) usingthe recommended tools. Record themeasurement for calculation (refer to“Calculation Form” page 31).


6Calculate: C – B = EThe rear axle angle minus the interaxleangle will give the value (E). Recordthe measurement for calculation (referto “Calculation Form” page 31).

28


7Calculate: D – E = FRecord the measurement for calcula-tion (refer to “Calculation Form” page31).

Compare the value of angle (F) withthe following guidelines:

If (F) is less than –4, lower theride height.

If (F) is between –4 and –1, noadjustment is necessary.

If (F) is greater than –1, raise theride height.

For procedures on lowering or raisingride height, refer to “Load LevelingValve, Adjustment” page 34.

8Proceed to “Forward Axle Pinion Angleto Frame Check” page 29.

Forward Axle Pinion Angle toFrame Check


1

W7001201

1 Digital protractor

Place a protractor or recommendedtool on top of the frame. “Zero-out”protractor or recommended tool.

J-38460-A

29


2

W7001194






1 Ride Height


3 Frame Rail

W7000252

Measure the forward axle angle (P),using the “zeroed out” protractor orrecommended tool.

3The angle (P) measurement must bewithin the specified range, as shown inthe following table:

Forward Axle Angle Relative toFrame (P)

Axle Model Specification (indegrees)

Tandem, 6x4 2.5 +0/-1

Single, 4x2 3.5 ± 1

If angle (P) is outside the specifica-tions, it must be corrected. Check forthe following:

• Excessively worn wear plates(pads).

Note: Wear plates (pads) must bereplaced in pairs (left and right onsame axle); see “Wear Plate(Pad), Replacement” page 48.

• Damaged spring hanger.

• Damaged air spring, Z-spring,and/or radius leaf spring.

• Damaged leveling rod.

• Broken/loose U-bolts.

• Faulty load leveling valve.

Replace the components as neces-sary, then adjust the suspension rideheight (see “Load Leveling Valve, Ad-justment” page 34).

4Repeat all steps in “Air SuspensionRide Height Check” page 25,“Interaxle U-joint Angle CancellationCheck (Calculation)” page 27, and“Forward Axle Pinion Angle to FrameCheck” page 29.

Note: If, after the second attempt, theaxle pinion angles are still not withinspecification, perform the “Rear SpringU-bolt Torque, Adjustment” page 32,as a last attempt to correct the axlepinion angles.

30


Calculation FormUse this form to record the measurements for calculating ride height and checking pinion angles (all angle measuresare in degrees).

MEASUREMENTS

ANGLEINITIAL FINAL

1) MEASURE THE RIDE HEIGHT:

Ride Height must be within specification. See "Ride Height Pinion Angle Specifications" page 6.

If ride height is not within specification, it must be corrected before continuing.

2) MEASURE FORWARD AXLE ANGLEA

(Relative to the ground)

3) MEASURE THE INTERAXLE SHAFTB


4) CALCULATE: B - A = D

The difference between B and A is value "D"

5) MEASURE THE REAR AXLE ANGLE C


6) CALCULATE: C - B =E

The difference between C and B is value "E"

7) CALCULATE: D - E = ± F

ACTION: LOWER RIDE HEIGHT No Adjustment RAISE RIDE HEIGHT

IF ANGLE "F" IS: less than -1.5 between -1.5 and 1.5 greater than 1.5

Note: The Air Suspension ride height cannot fall outside the specified tolerance. If the adjustment for angle (F)requires that the air suspension ride height be adjusted outside the specified range, see "Volvo Optimized Air Suspen-sion Troubleshooting" page 23.

SPECIFICATIONS

Tandem, 6x4 2.5 +0/-1MEASURE FORWARD AXLE

ANGLE (RELATIVE TO FRAME)Single, 4x2 3.5 ± 1

P

Note: If angle (P) is not within tolerance, see "Volvo Optimized Air Suspension Troubleshooting" page 23.

31


7229-05-02-01Rear Spring U-bolt Torque, Ad-justment


Loosening and re-tightening the suspension U-bolts in aparticular sequence can influence the axle pinion angle.U-bolts on both the left and right side of the same axlemust be loosened and re-tightened before performingthis procedure.

Method 1 (Preferred)1

W7000752

Failure to properly support the nose of the axle mayresult in the axle rolling forward, causing serious in-jury or death.

Support the nose of the axle with anadequate jack.

Note: Always replace both U-bolts at aparticular axle position. The longer ofthe two U-bolts is positioned to therear side of the axle housing.

2Loosen the U-bolts enough to allowthe bottom plate/rear shock absorberbracket to be slightly free from theaxle housing. Lower the jack slightly,approximately 10 – 15 mm (0.38 –0.50 in.).

Note: Any time you work on the sus-pension, make sure you loosen bothsides of the suspension on an axle atthe same time. It is difficult to realignall parts with opposite side of the axlerestricting motion.

3Tighten the U-bolt nuts so that there isno movement in the bottom plate/rearshock absorber bracket.

Note: Whenever the U-bolts areloosened and/or the suspension com-ponents attached to the axle are beingworked on, make sure that the locatingfeatures on each component are prop-erly engaged so that the componentsare positioned together properly.

Note: Make sure that the pin in the ra-dius leaf spring has not been pushedout of position. If the pin is correctlyset, make sure that the pin is placed inits proper position relative to the axleseat and Z-spring before clamping itwith the U-bolts.

4

W7000750

Tighten U-bolts using a cross patternshown above. Tighten as follows:

M20: 500 ± 75 Nm (370 ± 55 ft-lb)

M22: 575 ± 50 Nm (425 ± 37 ft-lb)

Note: Use the “crossover method”(see pattern above) to evenly tightenthe U-bolt nuts. Tighten nuts to atorque of approximately 100 Nm (75 ft-lb) increments until fully tightened.

M20:500 ± 75 Nm(370 ± 55 ft-lb)M22:575 ± 50 Nm(425 ± 37 ft-lb)

32


5Road-test the vehicle to seat compo-nents, then re-tighten the U-bolt nuts.

6Re-perform the procedure: “Air Sus-pension, Adjustment (Ride Height andDrive Line Calculation)” page 25. Ifaxle pinion angles are still outside thespecifications, proceed with Method 2.

Method 2


1

W7000752



Note: Always replace both U-bolts at aparticular axle position. The longer ofthe two U-bolts is positioned to therear side of the axle housing.

2Loosen the U-bolts enough to allowthe bottom plate/rear shock absorberbracket to be slightly free from theaxle housing. Lower the jack slightly,approximately 10 –15 mm (0.38 – 0.50in.).

Note: Any time you work on the sus-pension, make sure you loosen bothsides of the suspension on an axle atthe same time. It is difficult to realignall parts with opposite side of the axlerestricting motion.

3Tighten the U-bolt nuts so that there isno movement in the bottom plate/lowershock absorber bracket.

4

W7000750


M20: 500 ± 75 Nm (370 ± 55 ft–lb)

M22: 575 ± 50 Nm or (425 ± 37ft-lb)

Note: Tightening one U-bolt before theother can influence the axle pinion an-gle.Tightening the nuts on the U-bolt onthe rear side of the axle housing (leftand right) first can decrease the axlepinion angle.Tightening the nuts on the U-bolt onthe front side of the axle housing (leftand right) first can increase the axlepinion angle.

M20:500 ± 75 Nm(370 ± 55 ft-lb)M22:575 ± 50 Nm(425 ± 37 ft-lb)

5Road-test the vehicle to seat compo-nents, then re-tighten the U-bolt nuts.

33


6Re-perform the procedure: “Air Sus-pension, Adjustment (Ride Height andDrive Line Calculation)” page 25.

7641-05-02-01Load Leveling Valve, Adjust-ment


1Park the vehicle on a level surface,place the transmission in neutral andchock the front wheels.

2

W7001203

A Alternate tool position for checking RideHeight.

1 Adjustment Socket J-44544

2 Ride Height Gauge J-44684

Use caution when moving the load leveling valve armdown. This will release the suspension air and thechassis may drop quickly, possibly causing serious in-jury or death to anyone under the vehicle.

To raise or lower the suspension rideheight, use a ratchet and extension,along with Kent Moore tool numberJ–44544. Place tool inside the hole inthe frame rail. The hole is located onthe left side, behind the 1st drive axle.

34


3

Use caution when moving the load leveling valve armdown. This will release the suspension air and thechassis may drop quickly, possibly causing serious in-jury or death to anyone under the vehicle.

Position the ride height gauge suchthat it is clamped, either to the top orbottom flange of the frame rail. Makesure the rod for the ride height gaugerests on top of the axle housing.

4

W7001204

A Alternate tool location for checking RideHeight.

1 Axle Housing

2 Ride Height Gauge

The scale on the ride height gauge isused to read the ride height from thetop flange on the frame rail.

J-44684

5

W7001056

A Raise

B Neutral

C Lower

The suspension ride height is changedby turning the load leveling valvebracket clockwise (to raise) or counterclockwise (to lower).

Stay clear when suspension air is released. Chassismay drop quickly, possibly causing serious injury toanyone under the vehicle.

6Dump (release) the suspension air(see “Dump Switch Operation” page21).

7Start the engine to build up air pres-sure to check the ride height (see “AirSuspension Ride Height Check” page25). The ride height must be withinspecifications. See “Ride Height andPinion Angle Specifications” page 6.

8Perform the “Interaxle U-joint AngleCancellation Check (Calculation)”page 27), and the “Forward Axle Pin-ion Angle to Frame Check” page 29.

35


7641-03-02-01Load Leveling Valve, Replace-ment


CAUTION

Do not try to alter the load leveling valve. Do not takeit apart. Do not lengthen or shorten the handle on thevalve. Altering the load leveling valve may result insystem failure.

Removal

1Chock the front wheels on vehicle andrelease the parking brakes.

2


Dump (release) the suspension air(see “Dump Switch Operation” page21).

3Remove rod from the load levelingvalve handle.

4

W7001058

Remove bolts that hold the valvemounting bracket in place in the frame.

Note: These may be Huck®-style fas-teners, which require additional effortfor removal. See “HUCK-FIT® Fas-tener, Removal” page 59.

5Note the air line positions and orienta-tion to the fittings in the valve.Disconnect the air lines, and removethe valve.

6Swap fittings (or position new fittings)to the replacement valve.

7Swap bracket from faulty valve to re-placement valve. Tighten screws asfollows:

M8: 30 ± 5 Nm (22 ± 4 ft-lb).

M8:30 ± 5 Nm(22 ± 4 ft-lb)

36


Installation

8Lay the valve in the frame and installthe air lines.

9Install the bolts through the valvebracket and the frame. Tighten boltsas follows:

M14: 200 ± 33 Nm (148 ± 24 ft-lb).

M14:200 ± 33 Nm(148 ± 24 ft-lb)

10Connect the leveling rod to the arm.Tighten the rod nut as follows:

M6: 10 ± 1.5 Nm (7 ± 1 ft-lb).

M6:10 ± 1.5 Nm(7 ± 1 ft-lb)

11When completed, start the engine tobuild up air pressure, then check theride height (see “Air Suspension RideHeight Check” page 25).

The ride height must be within the fol-lowing specifications: See “RideHeight and Pinion Angle Specifica-tions” page 6.

7647-03-02-01Leveling Rod, Replacement


Removal

1



2Unbolt leveling rod from load levelingvalve arm and crossbeam (pedestal).Remove from vehicle.

Installation

3Pre-set the length of the replacementleveling rod to approximately 500 mm(20.0 in.). Except for RRH-160.

Note: Do not crimp or tighten theclamp at the lower end of the levelingrod at this time.

4Install leveling rod. Note position ofwasher. Tighten both nuts as follows:

M6: 10 ± 1.5 Nm (7 ± 1 ft-lb).

Note: Mount in same hole in thecrossbeam (pedestal) as the originalleveling rod. Do not crimp or tightenclamp at lower end of the leveling rodat this time.

M6:10 ± 1.5 Nm(7 ± 1 ft-lb)

37


5When completed, start the engine tobuild up air pressure to check the rideheight (see “Air Suspension RideHeight Check” page 25).

The ride height must be within the fol-lowing specifications: See “RideHeight and Pinion Angle Specifica-tions” page 6.

6Crimp or tighten clamp at the lowerend of the leveling rod.

7262-03-02-03Crossbeam (Pedestal), Re-placement


Removal

1

Never work under or around a vehicle unless it is sup-ported on jack stands of adequate rating. Failure touse adequate jack stands can result in the vehiclefalling, which can cause serious injury or death toanyone under the vehicle.


Raise the rear suspension and supportthe frame with jack stands, maintainingthe approximate ride height. Dump (re-lease) the suspension air to relieve airpressure from the air springs.

2Remove the nuts that hold the airbags to the crossbeam (pedestalplate). Push the air springs out of thecrossbeam and forward.

3

W7000707

Remove the nuts and bolts that holdthe crossbeam to the Z-springs andremove the crossbeam.

38


Installation

4Install the crossbeam to the Z-springwith the nuts and bolts. Tighten thebolts as follows:

M12: 105 ± 20 Nm (77 ± 15 ft-lb).

M12:105 ± 20 Nm(77 ± 15 ft-lb)

5Install the air springs back onto thecrossbeam and tighten the nuts as fol-lows:

M12: 50 ± 10 Nm (37 ± 7.5 ft-lb).

CAUTION

Over-tightening will damage the air spring.

M1250 ± 10 Nm(37 ± 7.5 ft-lb)

6When completed, jack up the rear ofthe truck, remove the jack stands andlower the vehicle. Start the engine tobuild air pressure to raise the air sus-pension.

7224-03-02-02Z-Spring, Replacement


Removal

1Note: Always replace both U-bolts at aparticular axle position. The longer ofthe two U-bolts is positioned to therear side of the axle housing.Park the vehicle on a level surfacewith the transmission in neutral and,chock the front wheels.

39


2

W7001139


Jack up the axle being worked on, andsupport it with jack-stands of adequaterating.

Note: Never install jack directly underthe crossbeam. The crossbeam is notdesigned to support vehicle weight.

Note: The nose of the axle shouldalso be supported to prevent the axlefrom rolling forward during service.

3Remove wheels and tires on axle be-ing worked on.

4

W7000752

Support the nose of the axle with ajack of adequate rating.

Failure to properly support the nose of the axle mayresult in the axle rolling forward causing personal in-jury or death.

Jack up vehicle and place jack standsunder axles(s) being worked on. Whilelowering vehicle onto jack stands, sup-port the nose of the axle with a bottlejack.

40


5

W7001061

Remove the U-bolt nuts, then removethe bottom plate rear shock absorberbracket, U-bolts, and top clip plates.

6Remove the roller and pin from thespring hanger.

7Remove the bolts and nuts from theair spring crossbeam.

8Remove Z-spring.

Note: You may need to raise or lowerthe axle slightly to take tension off theZ-spring for removal.

Installation

9Install Z-spring into position and installthe roller and pin into the springhanger.

10Install the top (clip) plates, U-bolts,and bottom plate rear shock absorberbracket. Tighten the U-bolt nuts, butdo not torque at this time.

Note: To align the Z-spring with the ra-dius leaf spring it may be necessary toslightly raise or lower the axle. It mayalso be necessary to loosen the U-bolts on the opposite side of the axlefor alignment.

11Install the bolts and nuts to the airspring crossbeam. Tighten as follows:

M14: 105 ± 20 Nm (75 ± 15 ft-lb)

M14:105 ± 20 Nm(75 ± 15 ft-lb)

12Install the shock absorber. Tighten asfollows:

M10: 60 ± 10 Nm (45 ± 7ft-lb)

M10:60 ± 10 Nm(45 ± 7ft-lb)

41


13

W7000750


M20: 500 ± 75 Nm (370 ± 55 ft-lb)

M22: 575 ± 50 Nm (425 ± 37 ft-lb)

Note: Make sure the pin in the radiusleaf spring has not been pushed out ofposition. If the pin is correctly set,make sure the pin is placed in itsproper position, relative to the axleseat and Z-spring, before clamping itwith the U-bolts.

Note: Before tightening the U-boltnuts, position the suspension at ap-proximately the normal ride height andmake sure the bolts holding the crossbeam (pedestal plate) to the Z-springare loosened. This will help provideproper wheel alignment.

Note: Always “snug–up” all the U-boltnuts before tightening. Use a handheldclicker-style torque wrench.

M20:500 ± 75 Nm(370 ± 55 ft-lb)M22:575 ± 50 Nm(425 ± 37 ft-lb)

14Install the wheels and tires.

15Remove any jack stands and checkwheel alignment.For proper specifications for checkingthe wheel alignment, refer to:

ServiceBulletin

601–006Wheel AlignmentSteer and Drive AxlesVN/VHD

IMPACT Function Group 601Information Type: Bul-letin“Alignment Specifica-tions and Procedures"

7224-03-02-02Radius Leaf Spring, Replace-ment


Note: Always replace both U-bolts at a particular axleposition.

Removal

1


Park the vehicle on a level surfacewith the transmission in neutral andchock the front wheels.

2Jack up the axle being worked on, andsupport it with jack-stands of adequaterating.

42


3

W7000752


The nose of the axle should be sup-ported to prevent the axle from rollingforward during service.

4Remove the U-bolt nuts, then removethe bottom plate rear shock absorberbracket.

5

W7000725

Use a floor jack under the Z-spring toraise it enough to separate the Z-spring from the radius leaf spring.

6

W7001062

Remove the bolts from the radius leafspring, then remove the radius leafspring.

Installation

7Install radius leaf spring into place andtighten the bolts as follows:

M14: 275 ± 45 Nm (204 ± 34 ft-lb)

Note: Whenever the U-bolts areloosened and/or the suspension com-ponents attached to the axle are beingworked on, make sure that the locatingfeatures on each component is prop-erly engaged so that the componentsare positioned together properly.

M14:275 ± 45 Nm(204 ± 34 ft-lb)

8Lower vehicle, be certain that Z-springand radius leaf spring are properlyaligned while lowering.

9Install top (clip) plates, U-bolts, andbottom plate rear shock absorberbracket. “Snug up” the U-bolt nuts, butdo not tighten at this time.

Note: To align the Z-spring with the ra-dius leaf spring it may be necessary toslightly raise or lower the axle. It mayalso be necessary to loosen the U-bolts on the opposite side of the axlefor alignment.

43


10

W7000750


M20: 500 ± 75 Nm or (369 ± 55ft-lb)

M22: 575 ± 50 Nm or (424 ± 37ft-lb)

Note: Make sure that the pin in the ra-dius leaf spring has not been pushedout of position. If the pin is set cor-rectly, make sure the pin is placed inits proper position relative to the axleseat and Z-spring before clamping itwith the U-bolts.

Note: Before tightening the U-boltnuts, position the suspension at ap-proximately the normal ride height andmake sure the bolts holding the cross-beam (pedestal plate) to the Z-springare loosened. This will help provideproper alignment for the Z-springs.

Note: Always “snug–up” all the U-boltnuts before tightening. Use a handheldclicker-style torque wrench.

M20:500 ± 75 Nm(370 ± 55 ft-lb)M22:575 ± 50 Nm(425 ± 37 ft-lb)

11Remove any jack stands and checkwheel alignment.

6521-03-02-04Torque Rod, Replacement


Removal

1Remove any wires or air line clippingsfrom the torque rod.

2

W7000716

Remove the two (2) bolts holding thetorque rod to the frame rail sidebracket.

3Remove the two (2) bolts holding thetorque rod to the axle housing bracketand remove the torque rod.

Note: These may be Huck-style fas-teners, which require additional effortfor removal. See “HUCK-FIT® Fas-tener, Removal” page 59.

44


Installation

4Note: Use only approved fasteners.Install two (2) bolts through the torquerod at the axle housing bracket.

5Install two (2) bolts holding the torquerod to the frame rail side bracket.

6Tighten bolts to the torque rod.Tighten rod bracket as follows:

M16: 271 ± 27 Nm (200 ± 20 ft-lb).

M16:271 ± 27 Nm(200 ± 20 ft-lb)

7Re-attach any wires or air line clip-pings to the torque rod.

6529-03-02-02Torque Rod Frame RailBracket, Replacement


Removal

1

W7000716

Remove the bolts through the torquerod at the frame rail side bracket.

2Remove the fasteners to the torquerod frame rail bracket at the frame rail,and remove the bracket.

Note: These may be Huck-style fas-teners, which require additional effortfor removal.

Installation

3Install bolts to the torque rod frame railbracket at frame rail.

Note: Use only approved fasteners.

4Install bolts through the torque rod atthe frame rail side bracket.

5Tighten the bolts to tighten rod.Tighten rod bracket as follows:

M16: 271 ± 27 Nm (200 ± 20 ft-lb).

M16:271 ± 27 Nm(200 ± 20 ft-lb)

45


6Re-attach any wires or air line clip-pings to the torque rod frame railbracket.

7114-03-02-04Rear Spring Hanger, Replace-ment


Removal

1

W7001062

Park the vehicle on a level surfacewith the transmission in neutral andchock the front wheels.

2

W7001139


Jack up the vehicle, and support itwith jack stands of adequate rating.

Note: These may be Huck® style fas-teners, which require additional effortfor removal. See “HUCK-FIT® Fas-tener, Removal” page 59.

Note: The ABS modulator valve mayneed to be removed in some applica-tions.

3Remove the spring hanger.

Note: The Z-spring may need to beraised or lowered to relieve tensionfrom the spring hanger for removal.

4Remove the wear plate (pad) from thespring hanger and place it in the newspring hanger.

Note: If either wear plate needs re-placement, they should be replaced inpairs.

5Raise the rear of the truck to relievepressure off the spring hanger bolts.

46


6

W7001062

Remove spring hanger bolts in frontand behind the bracket.

7Remove hanger.

8Remove the split pin and retaining pinholding the wear plate (pad) into thespring hanger (frame) bracket. Re-move the wear plate.

Note: We recommend replacing wearplates (pads). They should be re-placed in pairs (left and right) on thesame axle. See “Wear Plate (Pad),Replacement” page 48.

Installation

9Install the spring hanger and the bolts.Tighten the bolts as follows:

M16: 320 ± 50 Nm (236 ± 37 ft-lb).

M16:320 ± 50 Nm(236 ± 37 ft-lb)

10Install the radius leaf spring bolts andtighten the bolts as follows:

M16: 275 ± 45Nm or (204 ± 34 ft-lb).

M16:275 ± 45Nm(204 ± 34 ft-lb)

11Install the roller and pin.

12Raise the vehicle and remove the jackstands.

Note: Ride height adjustment may berequired after service.

47


7114-03-02-03Wear Plate (Pad), Replacement


Removal

1

W7001062

Remove the retaining pin and isolator(spring roller) from spring hanger(frame) bracket (located under “hookend” of Z-spring).

Note: It is strongly recommended thatthe wear plates (pads) be replaced inpairs (left and right side) on the sameaxle.

2Chock front wheels on vehicle.

3



4

W7000725


Jack the vehicle from under the rear ofthe Z-spring at the crossbeam(pedestal plate) mounting until there issufficient gap between the wear plateand Z-spring to remove the wear plate.

Note: Jacking both the left and rightsides simultaneously will help obtain asufficient gap. Also, lifting (and prop-erly supporting) the rear of the chassismay increase the size of the gap.

5Remove the split pin and the retainingpin holding the wear plate into thespring hanger (frame) bracket.

6Pry out the old wear plate.

Installation

7Install the replacement wear plate intothe spring hanger (frame) bracket.

Note: The thick end of the wear plateis always positioned to the rear of thevehicle.

8Jack from the rear of the Z-spring.

48


9Install the retaining pin and a replace-ment split pin into the spring hanger(frame) bracket to hold the installedwear plate.

10Start engine to build air pressure toraise the air suspension.

11Install the isolator (spring roller), re-taining pin, and a replacement split pinin the spring hanger (frame) bracket,under the Z-spring.

12Ride height and axle pinion angle mayrequire adjustment. See “Air Suspen-sion, Adjustment (Ride Height andDrive Line Calculation)” page 25.

7614-03-02-02Rear Shock Absorber Bracket,Replacement (Upper)


Removal

1

W7001064

Remove upper shock mounting bolt.Move shock and position out of thework area.

2Remove frame fasteners holding shockbracket to frame. Remove bracket.

Note: These may be Huck®-style fas-teners, requiring additional effort forremoval. See “HUCK-FIT® Fastener,Removal” page 59.

3Remove upper shock bracket.

49


Installation

4Install the shock bracket. Tighten fas-teners as follows:

271 ± 27 Nm (200 ± 20 ft-lb).

Note: Use only approved fasteners.

271 ± 27 Nm(200 ± 20 ft-lb)

5Install shock, bushings, and uppershock mounting bolt. Tighten bolt asfollows:

47 ± 7 Nm (35 ± 5 ft-lb).

Note: When replacing shocks, useonly Volvo-approved components(shocks and bushings).

47 ± 7 Nm(35 ± 5 ft-lb)

7612-03-02-01Rear Shock Absorber, Replace-ment


Removal

1

W7001064

Remove lower shock mounting bolt.

2Remove upper shock mounting boltand remove shock.

Installation

3Install shock and bushings. Tightenbolts as follows:

47 ± 7 Nm (35 ± 5 ft-lb).

Note: When replacing shocks, useonly Volvo-approved components(shocks and bushings).

47 ± 7 Nm(35 ± 5 ft-lb)

50


7222-03-02-06Top Plate, ReplacementRemoval

1


Chock front wheels on vehicle.

2

W7000752



Note: Failure to properly support thenose of the axle may result in the axlerolling forward, which can cause seri-ous injury or death to anyone underthe vehicle.

3Remove nuts from the U-bolts, thenremove the U-bolts. Leave lower shockbracket attached to shock absorber,but position bracket clear of the workarea.

4

W7001061

Remove the top plate.

51


Installation

5Install the top plate.

Note: Make sure the alignment pin onthe top plate is engaged into thepocket on the top surface of the Z-spring.

For models using an earlier-style topplate (without an alignment pin), followsteps “a-e” to locate where the topplate should be placed after the radiusleaf spring and Z-spring are resting to-gether on the axle:

a. Hold/block the correct lowerplate to the axle housing under-side and insert a U-bolt over thetop plate hanging down throughthe holes in the lower plate.

b. Using a small square, makesure that the U-bolt threadssticking through the hole are per-pendicular to the “surface” bottom.

c. The top plate should be posi-tioned so that it is square with theU-bolt, and so that the bolt andcurve line up.

d. Use chalk or marker pen tomark the Z-spring to identify thelocation for the plate that lines upthe clip groove with the U-bolt.

e. Tighten the U-bolts before tight-ening with a torque wrench (see“Rear Spring U-bolt Torque, Ad-justment” page 32).

6Install the U-bolts.


7

W7000750


M20: 500 ± 75 Nm (370 ± 55 ft-lb).

M22: 575 ± 50 Nm or (425 ± 37ft-lb).


Note: To ensure proper tightening, re-fer to “Rear Spring U-bolt Torque,Adjustment” page 32.

M20:500 ± 75 Nm(370 ± 55 ft-lb)M22:575 ± 50 Nm(425 ± 37 ft-lb)

8Note: Ride height and pinion anglemay require adjustment. See “AirSuspension, Adjustment (Ride Heightand Drive Line Calculation)” page 25.

52


7614-03-02-05Bottom Plate/Rear Shock Ab-sorber Bracket, Replacement(Lower)Removal

1



2

W7000752




3Disconnect the shock from the bottomplate/lower shock absorber bracket.

4Remove nuts from the U-bolts, thenremove the bottom plate/lower shockabsorber bracket.

5

W7001061

53


Installation

6Install the bottom plate/lower shockabsorber bracket and reconnect thelower shock absorber and U-bolt nuts.


7

W7000750


M20: 500 ± 75 Nm (370 ± 55 ft–lb).

M22: 575 ± 50 Nm or (425 ± 37ft-lb).


Note: To ensure proper tightening, re-fer to “Rear Spring U-bolt Torque,Adjustment” page 32

M20:500 ± 75 Nm(370 ± 55 ft-lb)M22:575 ± 50 Nm(425 ± 37 ft-lb)

8Note: Ride height and pinion anglemay require adjustment. See “AirSuspension, Adjustment (Ride Heightand Drive Line Calculation)” page 25.

7222-03-02-05Axle Seat, ReplacementRemoval

1



2

W7000752




3Remove nuts from the U-bolts, thenremove the U-bolts. Leave lower shockbracket attached to shock absorber,but position bracket clear of the workarea.

54


4

W7000725

Using a lift, raise the Z-spring from theaxle seat, then remove axle seat.

Installation

5

W7001199

A Meritor

B Eaton/Dana

1 1st drive axle

2 2nd drive axle

When installing the new axle seat, If itis a Meritor axle, make sure the “M”markings at the tip of each axle seatare facing each other. For theEaton/Dana axle seat, the “D” mark-ings should be turned toward eachother.


55


6

W7001061

Install the axle seat.

7

W7000750


M20: 500 ± 75 Nm (370 ± 55 ft–lb).

M22: 575 ± 50 Nm or (425 ± 37ft-lb).


Note: To ensure proper tightening, re-fer to “Rear Spring U-bolt Torque,Adjustment” page 32

Note: Ride height and pinion anglemay require adjustment. See “AirSuspension, Adjustment (Ride Heightand Drive Line Calculation)” page 25.

M20:500 ± 75 Nm(370 ± 55 ft-lb)M22:575 ± 50 Nm(425 ± 37 ft-lb)

56


7261-03-02-03Rear Air Spring, Replacement


Removal

1Support the frame (maintaining the ap-proximate mormal ride height.) Deflateair springs.

2

Pneumatic components store compressed air and canseparate violently during disassembly or removal. Be-fore servicing any part of the pneumatic (air) system,completely release the air pressure. Failure to do socan result in serious personal injury or death.

Remove air lines from air springs

3

W7000719

Note: Remove the upper mounting nutand bottom nut.

4Remove the air spring from chassis.

5Remove the fitting from air spring.

Installation

6Install fitting in the air spring

7Install air spring back onto the frameand crossbeam (pedestal plate).

8Tighten upper mounting nut as follows:

M14: 200 ± 33 Nm (148 ± 24 ft-lb).

M14:200 ± 33 Nm(148 ± 24 ft-lb)

9Tighten lower nut as follows:

M12: 50 ± 10 Nm (37 ± 7.5 ft-lb).

CAUTION

Over-tightening will damage air spring.

M12:50 ± 10 Nm(37 ± 7.5 ft-lb)

10Install air lines into the air springs.

11Start engine to build pressure to inflatethe air suspension. Remove supportsfrom frame

12Check ride height (see “Air Suspen-sion, Adjustment (Ride Height andDrive Line Calculation)” page 25).

57


3646-03-02-32Pneumatic Switch, Replace-ment


Note: Make sure the vehicle ignition is OFF before be-ginning this procedure.

Removal

1

W3000649

Remove the ashtray from ashtrayhousing. Remove the (two) 2 screwsfrom the ashtray housing, then removethe housing.

2Once the ashtray housing is removed,the air switch panel can be removedfrom the dash. Pull the air switchpanel away from the dash and to theleft, to clear the tip inserts.

3

W3000656

Never disconnect an air system component unless allsystem pressure has been depleted. Failure to de-plete system pressure before disconnecting hoses orcomponents may result in them separating violentlyand causing serious bodily injury.

Disconnect the two terminal connec-tors from the cigar lighter and theelectrical LED connections on theswitch being replaced.

4Drain air pressure from vehicle sys-tem. Mark each air line to keep correctarrangement.

5

W0001937

1 J-42189

Disconnect air lines at switch being re-placed by pushing in on the ring andair line using the air line release tool(J-42189), then pulling the air line out.

J-42189

58


6

W3000658

To remove switch, insert a no. 1 flat tipscrewdriver into back of switch at topand bottom to release locking tabs.Push switch out of the panel.

Installation

7Install new air switch into the panel,pushing the switch into the panel untilit locks. Push back on the switch tomake certain it is locked in the panel.

8Connect air lines to the switch, makingsure they are installed in the correctposition. Be sure to insert airline toline indicated.

9Connect electrical LED connections onswitch, and both cigar lighter connec-tions.

10Align and install switch panel in dash.

11Install ashtray housing with the two (2)mounting screws. Tighten screws asfollows:

0.4 ± 0.1 Nm (3.5 ± 1 in-lb).

0.4 ± 0.1 Nm(3.5 ± 1 in-lb)

12Place ashtray in housing.

7113-01-02-01HUCK-FIT® Fastener, Removal


1An air impact wrench can generally beused to remove HUCK-FIT ® fasten-ers. Always try to remove the collarwith an air impact wrench first. Shouldyou encounter difficulty, increase airpressure to the maximum for yourequipment to obtain best results. If theair impact wrench fails to remove afastener, the collar must be split or cut.

2

W7001135

Fig. 1: Where to cut using torch

1 Cut through collar and pin at this location.

2 Swaged area.

A hydraulic collar splitter is availablefrom HUCK-FIT®. If the splitter is avail-able to you, it should be used. If it isnot, cut the collar with a torch asshown in Fig. 1.

Note: Use this method of removal onlyif the fastener cannot be removed withan air impact wrench or hydraulic split-ter.

59


3

W7001037

Fig. 2: Flange bolts and HUCK-FIT® bolts

HUCK-FIT® bolts and Flange bolts arenot to be mixed within a hole pattern,unless a specific exception is docu-mented.

4

W7001038

Fig. 3: Scored HUCK-FIT® collar

If the collar is scored, the tool anvil isworn and should be replaced.

60

Feedback

One of our objectives is that workshop personnel should have access to correct andappropriate service manuals where it concerns fault tracing, repairs and maintenanceof Volvo trucks.In order to maintain the high standards of our literature, your opinions and experiencewhen using this manual would be greatly appreciated.If you have any comments or suggestions, make a copy of this page, write down yourcomments and send them to us, either via telefax or mailing directly to the addresslisted below.

To

Volvo Trucks North America, Inc.

Dept. 516 Service Publications

7825 National Service Road

P.O. Box 26115

Greensboro, NC 27402-6115

USA

Fax (336) 393-3170

From

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Concerns Service Manual: ...............................................................................................................................

Operation Numbers

3646-03-02-32 Pneumatic Switch, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 586521-03-02-04 Torque Rod, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446529-03-02-02 Torque Rod Frame Rail Bracket, Replacement . . . . . . . . . . . . . . . . . . 457113-01-02-01 HUCK-FIT® Fastener, Removal . . . . . . . . . . . . . . . . . . . . . . . . . 597114-03-02-03 Wear Plate (Pad), Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 487114-03-02-04 Rear Spring Hanger, Replacement . . . . . . . . . . . . . . . . . . . . . . . . 467222-03-02-05 Axle Seat, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 547222-03-02-06 Top Plate, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517224-03-02-02 Radius Leaf Spring, Replacement . . . . . . . . . . . . . . . . . . . . . . . . 427224-03-02-02 Z-Spring, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397229-05-02-01 Rear Spring U-bolt Torque, Adjustment . . . . . . . . . . . . . . . . . . . . . . 327261-03-02-03 Rear Air Spring, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 577262-03-02-03 Crossbeam (Pedestal), Replacement . . . . . . . . . . . . . . . . . . . . . . . 387281-05-02-01 Air Suspension, Adjustment (Ride Height and Drive Line Calculation) . . . . . . . 257612-03-02-01 Rear Shock Absorber, Replacement . . . . . . . . . . . . . . . . . . . . . . . 507614-03-02-02 Rear Shock Absorber Bracket, Replacement (Upper) . . . . . . . . . . . . . . . 497614-03-02-05 Bottom Plate/Rear Shock Absorber Bracket, Replacement (Lower) . . . . . . . . . 537641-03-02-01 Load Leveling Valve, Replacement . . . . . . . . . . . . . . . . . . . . . . . . 367641-05-02-01 Load Leveling Valve, Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 347647-03-02-01 Leveling Rod, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Volvo Trucks North America, Inc.P.O. Box 26115, Greensboro, NC 27402-6115

Volvo Trucks Canada, Ltd.6490 Vipond Drive, Mississauga, Ontario L5T 1W8

http://www.volvotrucks.volvo.com

PV776-TSP143273 (1000) 7.00 © Volvo Trucks North America, Inc., 2000

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