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Home >> Volvo >> 2002 >> V70 2.4T AWD L5-2.4L Turbo VIN 58 B5244T3 >> Repair and Diagnosis >> Steering and Suspension >> Suspension >> Cross-Member >> Rear Cross-Member >> Service and Repair

Rear Cross-Member: Service and Repair


Replacing Sub-frame Rear
Special tools
999 5659

Removing the sub-frame

Preparations
Raise the car.

Note: Lift the sill edges so that the rear axle is free.





Remove
- the wheels
- the mounting screws for the brake caliper
- the ABS sensor
- The mountings for the ABS line. Hang up the line and the brake caliper. Use a piece of wire
- the screw for the bracket for the brake pipe on the sub-frame
- the locating pin for the brake disc
- the brake disc.





- the return spring at the expander
- the expander. Lift the brake shoe slightly.
Unhook the expander (1) from the mounting for the mechanical cable.





- the guide sleeve for the cable sleeve. Apply a screwdriver between the guide sleeve lug and wheel arch. Bend slightly to remove the sleeve





- the parking brake cable from the track rod and sub-frame
- the exhaust system according.
- the springs and shock absorbers according to Replacing the rear spring, refer to Coil Spring, Service and Repair.





- EVAP canister screw.

Note: The EVAP canister hangs in the bodywork when the subframe is lowered.





Remove
- the plastic nut for the fender liner. Bend the fender liner out of the way.
Drill out the heat deflector plate rivet on the sub-frame left rear bushing.

Remove the sub-frame
Position a lifting table under the sub-frame.





Remove
- the four sub-frame mountings
- the sub-frame brackets screws
- the brake hose mounting stays from mountings on the brackets
- the brake pipes from the plastic clips on the brackets.

Note: Remove the fuel filter bracket on the right bracket.

Carefully lower the sub-frame.

Remove components from the sub-frame

Note: The support arm, track rod, lower control arm and stub axle are removed from the sub-frame as one unit.





Remove
- the support arms from sub-frame
- the track rods
- the stub axle from the upper control arm
- the anti-roll bar control arms from the upper control arm
- the anti-roll bar from the sub-frame

Installing the sub-frame

Install components on the sub-frame





Install
- the upper control arm according to Installing the upper control arm, refer to Control Arm, Service and Repair.
- the anti-roll bar on the new sub-frame. Tighten to 80 Nm.

Note: Support arm, track rod, lower control arm and stub axle are installed on the new sub-frame as one unit.





Install
- the stub axle to the upper control arm. Do not tighten so hard that the toothed segment goes into the bushing on the wheel unit.
- the support arms on the sub-frame. Finger tighten
- track rods on the sub-frame. Finger tighten
- the lower control arm on the sub-frame. Finger tighten.





- Install a M12x70 mm screw with a nut in the hole for the anti-roll bar on the control arm, as a help when measuring.
- Check the height measurement on the control arm. If necessary adjust the height measurement with a tie strap.
- Tighten the stub axle to the upper control arm to 50 Nm.
- Install anti-roll bar control arms to the upper control arm. Tighten to 80 Nm.

Note: Counterhold the ball joint so as not to damage the boot.

Reinstall the sub-frame





- Hint: Make up two centering sleeves which are then placed on the rear mountings for the sub-frame. This will make it easier to center the rear suspension. Measured at the centering sleeves A=20mm, B=13mm, C=50mm.
Place the sub-frame on a lifting table.
- Lift up the sub-frame enough to be able to install the EVAP canister. Tighten to 25 Nm.
- Lift the sub-frame completely to the bodywork.
Release the lower control arms from the sub-frame.

Note: Ensure that the brake pipes are not crimped at the sub frame mountings.





Install
- the brake line mounting stays on the sub-frame bracket. Tighten to 25 Nm
- the brake pipe in the clips on the sub-frame brackets





- Note: Use new screws for the sub-frame mountings.

- Slide up the centering sleeves in the two rear mountings on the sub-frame.
- Install the screw. Tighten lightly.
- Install the screws for the front mountings on the sub-frame (install the screws through the brackets).
- Install the screw for the bracket.
- Tighten all the front mountings to 80 Nm.
- Remove the screw for the rear mountings on the sub-frame. Remove the centering sleeves.
- Reinstall the screw for the rear mountings on the sub-frame. Tighten to 80 Nm.
- Install the fuel filter and holder on the right bracket. Tighten to 25 Nm.

Remove the lifting table.

Finishing





- Pop rivet the exhaust pipe heat deflector into the left rear subframe mounting.
- Install the fender liner. Tighten the fender liner with the plastic nut.





Install
- the parking brake cable mounting in the sub-frame. Tighten to 25 Nm.
- the mounting for parking brake cable on the track rod
- the exhaust system.
- the springs and shock absorbers.

Note: At the same time, tighten the track rods and support arms to the sub-frame. Tighten to 80 Nm.

Use tensioner 999 5659 according to Tensioner 999 5659 User instructions.





Press the cable sleeve guide sleeve into place in mounting.





Install
- the expander on the mounting for the mechanical cable.
- the expander between the brake shoes
- the return spring.
Check the function.





Install
- the brake disc and locating pin. Tighten to 10 Nm.
- the brake caliper. Use new screws. Tighten to 60 Nm.
- the ABS sensor. Tighten to 10 Nm.
- the ABS line on the holder on the stub axle.
- the wheels.
Align the wheels, refer to Alignment, Service and Repair.
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