TSB : All Wheel Drive Control Arm - Replacement (GROUP 61, NO. 805)

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WARNING: This page is about the 850 T-5, 4D Sedan, which is a different variant/trim than selected. Publication date: 1996-07-01 Reference number: GROUP 61, NO. 805 ALL WHEEL DRIVE CONTROL ARM - REPLACEMENT ALL WHEEL DRIVE CONTROL ARM - REPLACEMENT TECHNICAL SERVICE BULLETIN Reference Number(s): GROUP 61, NO. 805, Date of Issue:  July, 1996 REPLACING 850 AWD CONTROL ARM Model(s): 1997 Volvo 850 Section: 6 - Suspension & Steering Group: 61 Bulletin No.: 805 Date: July, 1996 REFERENCE TP 4314201, Section 4 (43, 46) AWD (All Wheel Drive); 850 1997-. SERVICE INFORMATION Because the mountings in the sub-frame control arm on the AWD are different from those on other 850 models, a new method for replacing the control arm has been developed. This service bulletin describes the method for replacing the control arm for the 850 AWD. See Fig 1 . CONTROL ARM COMPONENTS - See Fig 1 . Spring strut Control arm Anti-roll bar Sub-frame Link Upper bearing Ball joint REPLACING 850 AWD CONTROL ARM LEFT SIDE SPECIAL TOOLS Special tools: 951 2050-7, 999 5006-5, 999 5033-9, 999 5460-4, 999 5517-1, 999 5562-7. REMOVING CONTROL ARM Install: See Fig 2 . Supports 999 5033-9 on fenders. Lifting beam 999 5006 5 on support. Position lifting beam as close to hood hinge as possible. Lifting hook 999 5460-4. Tighten lifting hook approximately 5 mm (3/16") to unload engine pads. Raise the car. Remove: See Fig 3 . Wheel. Front engine pad screw. Torque rod screw and nut. Brake pipe bracket screw. See Fig 4 . Two engine pad screws. See Fig 4 . Control arm/ball joint screw and nut. Unhook control arm from ball joint. See Fig 5 . Install: - Protective sleeve 999 5562-7 on the ball joint pin. See Fig 5 . Remove: - Link from anti-roll bar. Install: Transmission jack into contact with sub-frame. See Fig 6 . Remove: See Fig 6 . Two rear screws from the bracket. The two sub-frame screws. Install: Two screws 999 5517-1. Lower the sub-frame using the screws 999 5517-1. See Fig 7 . NOTE: Check that the steering column is not in contact with the edge of the metal panel. MOVE TRANSMISSION JACK TO THE TRANSMISSION Lift the transmission/engine to access the control arm screws. Remove: See Fig 8 . The four control arm screws. The control arm. The splash guard from the control arm. INSTALLING THE CONTROL ARM Install: See Fig 8 . The mud flap on the new control arm. The control arm. The four control arm screws (use new screws). Tighten to 65 N.m (48 ft-lb). Angle-tighten 90°. Remove the transmission jack. Install: See Fig 7 . The sub-frame. Move transmission jack under sub-frame. Remove the two screws 999 5517-1. NOTE: Use new screws (2 x M14). Grease screw threads. Install the sub-frame and support bracket screws. See Fig 6 . Tighten sub-frame screws to 105 N.m (77 ft-lb). Angle-tighten 120°. Use a protractor 951 2050-7. Tighten sub-frame bracket screws to 50 N.m (37 ft-lb). Remove the transmission jack. Two engine pad screws. Tighten to 50 N.m (37 ft-lb). See Fig 4 . Brake hose bracket. See Fig 4 . Front engine mounting screw. See Fig 3 . Tighten to 50 N.m (37 ft-lb). Screw and nut on torque rod. Use a new nut. Tighten to 35 N.m (26 ft-lb). Angle-tighten 90 °. Control arm/ball joint and stub axle screws and nuts. See Fig 9 . Tighten to 50 N.m (37 ft-lb). Anti-roll bar and link nut. Tighten to 50 N.m (37 ft-lb). Wheel. Lower the Car. Remove: See Fig 2 . Lifting hook 999 5460-4. Lifting beam 999 5006-5 from support. Supports 999 5033-9 from fenders. AB. CONTROL ARM, RIGHT SIDE, REPLACEMENT SPECIAL TOOLS Special tools: 951 2050-7, 999 5562-7. REMOVING CONTROL ARM Remove: Wheel. Two engine pad screws. See Fig 10 . Control arm/ball joint screw and nut. See Fig 9 . Unhook control arm from ball joint. Install: Protective sleeve 999 5562-7 on the ball joint pin. Remove: Link from anti-roll bar. Install: Transmission jack 998 5972-0 and jack into contact with sub-frame. See Fig 11 . Remove: See Fig 11 . Two rear screws from the bracket. The two sub-frame screws. NOTE: Use new screws. Oil/lubricate the screws. Screw in the new screws 10 mm (3/8"). MOVE TRANSMISSION JACK TO OIL PAN NOTE: Use a wooden block as a shim. See Fig 12 . Lift the engine to access the screws. Remove: See Fig 12 . The four control arm screws. The control arm. The splash guard from the control arm. INSTALLING THE CONTROL ARM Install: See Fig 12 . The mud flap on the new control arm. The control arm. The four control arm screws (use new screws). Tighten to 65 N.m (48 ft-lb). Angle-tighten 90°. Remove the transmission jack. MOVE TRANSMISSION JACK Move the transmission jack back into contact with sub-frame. Install: Sub-frame and support bracket screws. See Fig 11 . Tighten sub-frame screws to 105 N.m (ft-lb). Angle-tighten 120°. NOTE: Use new screws. Use a protractor 951 2050-7. Tighten sub-frame bracket screws to 50 N.m (37 ft-lb). Remove: Transmission jack. Install: Control arm ball joint and stub axle screws and nuts. See Fig 9 . Tighten to 50 N.m (37 ft-lb). Anti-roll bar and link nut. Tighten to 50 N.m (37 ft-lb). The two engine pad screws. See Fig 10 . Tighten to 35 N.m (26 ft-lb). Angle tighten 90°. NOTE: Use new screws. WARRANTY STATEMENT Claims may be submitted under the New Car Limited Warranty when a manufacturing defect is present using claim type: 01. OPERATION NO.: 61208-2 LABOR DESCRIPTION: Control arm, remove/replace 1 side. TIME ALLOWANCE: 0.6 hr. OPERATION NO.: 61216-2 LABOR DESCRIPTION: Control arm, remove/replace 2 sides. TIME ALLOWANCE: 1.1 hr. Fig 1: Sub-Frame Control Arm Mountings - Location Fig 2: Control Arm - Removing Fig 3: Front Engine Pad Screw Fig 4: Brake Pipe Bracket Screw & Two Engine Pad Screws Fig 5: Ball Joint Pin Protective Sleeve - Location Fig 6: Bracket Rear Screws & Sub-frame Screws - Location Fig 7: Screws, P/N 999 5517-1 - Location Fig 8: Control Arm Screws, Control Arm & Control Arm Splashguard Fig 9: Control Arm/Ball Joint & Stub Axle Screws & Nuts - Location Fig 10: Engine Pad Screws - Location Fig 11: Bracket Rear Screws & Sub-frame Screws - Location Fig 12: Wooden Block Location - Utilize As A Shim