Steering/Suspension - Noise Diagnosis And Repair
Retailer Technical Journal 19467Suspension noise-analysis and repair instructions
Date: 09-08-2008
Reference: TNN 21-26
Note!
If using a printed copy of this Retailer Technical Journal, first check for the latest online version.
Note!
This document supersedes TNN 76-08 dated 5-19-2008 and RTJ 19467 released 07-29-2008; repairs 1, 2B, and 8 have been updated. Please update your files.
AFFECTED VEHICLES:
TABLE OF CONTENTS:
Description:
This document aims to assist technicians in determining the origin of different types of suspension noises, and provide instructions for repairs.
For a successful repair, it is essential that the noise be analyzed and verified with the customer, specifically, what type of noise and in what type of driving situations does the customer have the concern?
For warranty claims, it is very important to provide as much data as possible on these issues, including a clear description of customer concern, the performed repair and success of repair stated in the QW90 repair text. If this information is missing, the claim may be denied.
We strongly encourage the use of chassis ears in the analysis process; a labor operation is provided at the end of this TNN.
Service:
FRONT SUSPENSION NOISE
1. Control arm hydro bushing
Complaint:
Creaking / squeaking noise while driving on uneven roads, and also over road bumps.
Cause analysis:
If the complaint is a knocking noise, then it is not from the control arm hydro bushing.
Correction:
Replace the control arm if a creaking / squeaking noise occurs from this bushing.
New Part numbers:
* 31277343, left, S80, V70
* 31277344, right, S80, V70
* 31277345, left, XC70
* 31277346, right, XC70
Concerned vehicles:
124 Chassis: 000001-095200
135 Chassis: 000001-080756
136 Chassis: 000001-055833
136 Chassis: 000001-055833
2A. Subframe rear bushing - Knocking noise from subframe
Complaint:
Knocking noise from front subframe rear bushing, noise occurs when turning, accelerating/braking or driving with high side loads. Slip-Stick occurs between the bushing and subframe sleeve.
Cause analysis 1:
Disconnect the anti roll-bar: noise gone indicates that the cause could be the subframe bushings.
Cause analysis 2:
Use a pry bar to move the subframe and listen for noise (see photo of pry bar [circled] and subframe).
Product Modification:
A new subframe was introduced in production from:
124-077517, 135-047660, 136-034274.
The new sub-frame's bushing tube is more narrow, which allows the bushing to fit more tightly.
Correction:
First, check if the subframe bushings have contact with the reinforcement plate as described in Repair 2B. If there is no contact between bushing and reinforcement plate, then replace the subframe rear bushing according to VIDA and TNN 21-26.
Note!
Do not use grease when installing the bushings.
Note!
When installing the new bushings, apply epoxy adhesive between subframe and bushing. Recommended epoxy glue is:
^ Volvo part number 9511027, 3M DP8005 epoxy adhesive.
^ Volvo part number 9512950, glue gun kit.
^ Volvo part number 1161730, nozzle for glue gun kit.
Notes on Volvo epoxy glue:
^ There is a "best before" date on a label on the glue. Do not use the glue after this date.
^ The Volvo epoxy glue has a pot (working) time of 3 minutes. Do not allow glue to harden on tools or other surfaces it is not intended for.
^ It is important to let the glue set properly before the subframe is installed in the car, follow instructions on glue tube.
An alternative epoxy glue is LORD 305 epoxy glue. Notes on LORD 305 epoxy glue:
^ LORD 305 is available on the Internet at www.ellsworth.com.
^ LORD 305 has a shelf life of one year from date of shipment, in its original unopened container. Do not use the glue beyond its shelf life date.
^ LORD 305 has a pot (working) time of one to two hours. Do not allow glue to harden on tools or other surfaces it is not intended for.
^ It is important to let the glue set properly before the subframe is installed in the car, follow instructions on glue tube.
2B. Subframe rear bushing - Conflict with reinforcement plate and bushing
Complaint:
Groaning or clunking noise from front suspension, especially when turning or driving over speed bumps.
Cause analysis:
Use chassis ears to locate the noise.
Correction:
If the noise is caused by a rubbing conflict between the rear bushing and reinforcement plate, or the bushing show signs of wear, or the cause to the problem is that the bushing is not in the correct position in the sub-frame metal tube, then replace the sub-frame bushing according to VIDA and TNN 21-26 / RTJ 19128.
Bushing new design: P/N 31201148 (all variants excl. S80 V8). Bushing for S80 V8: P/N 30760944.
Note!
Do not use grease when installing the bushings.
Note!
When installing the new bushings, apply epoxy adhesive between sub-frame and bushing. Recommended epoxy glue is:
^ Volvo part number 9511027, 3M DP8005 epoxy adhesive
^ Volvo part number 9512950, glue gun kit
^ Volvo part number 1161730, nozzle for glue gun kit.
Notes on Volvo epoxy glue:
^ There is a "best before" date on a label on the glue. Do not use the glue after this date.
^ The Volvo epoxy glue has a pot (working) time of 3 minutes. Do not allow glue to harden on tools or other surfaces it is not intended for.
^ It is important to let the glue set properly before the sub-frame is installed in the car, follow instructions on glue tube.
An alternative epoxy glue is LORD 305 epoxy glue. Notes on LORD 305 epoxy glue:
^ LORD 305 is available on the Internet at www.ellsworth.com.
^ LORD 305 has a shelf life of one year from date of shipment, in its original unopened container. Do not use the glue beyond its shelf life date.
^ LORD 305 has a pot (working) time of one to two hours. Do not allow glue to harden on tools or other surfaces it is not intended for.
^ It is important to let the glue set properly before the sub-frame is installed in the car, follow instructions on glue tube.
3. Loose nuts for front sway bar link (anti roll bar link)
Complaint:
Knocking noise while driving on uneven roads and also over road bumps.
Cause analysis:
Visual analysis and torque check.
Correction:
Re-torque the nuts to 52 lb.ft. (70 Nm).
4. Steering gear knocking noise
Complaint:
Knocking noise while driving slowly over road irregularities (vehicles with standard steering gear without speed sensitive steering only).
Cause analysis:
Noise appears when inner ball joint (inside bellows) starts moving (stick-slip). Disconnect tie-rods from knuckles and rock the vehicle. Noise gone indicates that it could be the inner ball joints.
Correction:
Replace inner ball joints.
Note!
This repair is valid for S80 MY07 only.
5. Rumbling noise from Steering column
Complaint:
Rumbling noise from the steering column, this can be heard if a customer is driving 20-25 mph (32-40 kph) on a cobblestone type road surface, the steering column starts to vibrate and you get the rumbling noise.
Cause analysis:
See Complaint description.
Correction:
Replace steering column.
Note!
This repair is valid for S80 MY07 only.
6. Clonk / Plop Noise front suspension
Complaint:
Clonk / plop nose from the front shock absorbers while driving over road bumps.
Cause analysis:
See description under Correction.
Correction:
Lift the car on a hoist. Fold up the bellows (# 4 in illustration) and install sound insulation tape part number 9182432 on top of the white plastic sleeve (circled), four (4) parts for each side of the vehicle.
Note!
Part number 9182432 contains one piece of tape; order quantity eight (8) if performing repair on both sides of the car.
Install the tape as close as possible to the metal rod, but not touching it.
Note!
It is very important that this particular material is used.
7. Knock from front suspension when driving over speed bumps at higher speeds
Complaint:
A knocking noise can be heard from the front suspension when driving over speed bumps at higher speeds, approx. 30 mph (48 kph) or higher.
Cause analysis:
This can be caused by the lower spring seat touching the inner fender when the springs are compressed. First identify if there is any touching condition, look for witness marks on inner fender / spring seat.
The plastic rivets for the inner fender may also come loose, causing a rattling noise from the inner fender.
Correction:
If the concern is confirmed, use a hot-air gun to heat the plastic. When plastic is warm and soft, modify the shape to allow more space for the spring seat, usually 2-4 mm (0.08-0.16 in.) is enough.
Note!
A new inner fender was introduced in production from chassis numbers 124-057650, 135-007361. This repair is only valid for vehicles below these chassis numbers.
REAR SUSPENSION NOISE
8. Rear Bump rubbers
Complaint:
Creaking / squeaking noise while driving on uneven roads and also over road bumps when passengers are sitting in the rear seat.
Cause analysis:
With two people in the rear seat, rock the vehicle side to side and listen for the noise.
The bump rubbers are in contact with the control arms.
Correction:
Replace the rear bump stop rubber.
PN 31277310, 2 pcs, for cars with code 3 or 4 in the Chassis code (last position).
PN 31277311, 2 pcs, for cars with code 5 in the Chassis code (last position).
Concerned vehicles:
124 Chassis: 000001-094472
135 Chassis: 000001-079256
136 Chassis: 000001-054527
9. Loose nuts for rear sway bar link (anti roll bar link)
Complaint:
Knocking noise while driving on uneven roads and also over road bumps.
Cause analysis:
Visual analysis and torque check.
Correction:
Re-torque the nuts to 45 lb.ft. (60 Nm).
10. Rattling noise from Tie-blade bushing
Complaint:
Rattling noise when driving on uneven roads.
Cause analysis:
Visual. Metal tie-blade loose / displaced in the bushing (circled items in photo).
Correction:
Replace complete component (longitudinal stay).
Note!
This repair is valid for S80 MY07 only.
ACTIVE CHASSIS
11. 4C Active chassis rumbling noise
Complaint:
In vehicles with 4C active chassis, a rumbling noise can be heard while driving slowly on uneven roads at 12-20 mph (19-32 kph).
Cause analysis:
When pulling the fuse for the suspension module (SUM), the noise is almost gone. The problem is most likely caused by software in the SUM causing working noise in the dampers valves.
Correction:
If the 4C system is quieter when the fuse is pulled, reinstall the fuse and download new software for the SUM, part number 31268876.
This software can reduce the rumbling noise by approx. 50-70%.
WARRANTY CLAIM INFORMATION