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HOMESERVICE MANUALSVOLVO1992240 BASE, 4D SEDAN, AUTOMATIC, AW70LREPAIR AND DIAGNOSIS (SINGLE PAGE)DRIVELINES & AXLESDIFFERENTIALS & DRIVE AXLESOVERHAULDIFFERENTIAL ASSEMBLYINSTALLATION & ADJUSTMENT (1045)
1992 Volvo 240 Base, 4D Sedan, Automatic, AW70L

Installation & Adjustment (1045)

1992 Volvo 240 Base, 4D Sedan, Automatic, AW70LSECTION Installation & Adjustment (1045)
  1. Install complete differential in rear axle housing. Install oiled adjusting nuts with new lubricated "O" rings and seals. Install Washer (5871 ) with one adjuster nut. Install magnetic stand with dial indicator. Place measuring tip of dial indicator on opposite side of housing. See Fig 1 .
    Fig 1: Placing Measuring Tip Of Dial Indicator On Opposite Side Of Housing
    G92A01957
  2. Using Wrench (5371 ), tighten adjuster nuts on both sides. See Fig 2 . Turn adjuster nuts until a slight backlash can be felt on ring gear and dial indicator just begins to give a reading. Rotate differential housing several times to center roller bearings.
    Fig 2: Tightening Adjuster Nuts
    G92C01958
  3. Position a dial indicator on differential case. Place measuring tip on one ring gear tooth, approximately .12" (3 mm) from larger end of tooth. Hold pinion steady and move ring gear back and forth against measuring tip. Acceptable backlash is .004-.006" (.10-.15 mm), but should be set as near as possible to .005" (.13 mm). Maximum variation between 3 measuring points should be no more than 0-.001" (0-.03 mm).
  4. To adjust backlash, use Wrench (5371 ) and move nuts in or out as necessary. See Fig 3 . After adjustment, preload housing one notch on both sides. Rotate differential 5 turns and check backlash. Adjust if necessary. Adjustments can be made with preloaded bearings.
    Fig 3: Adjusting Backlash Using Wrench
    G92E01959
  5. Using liquid gasket sealer, install rear cover and tighten bolts to 18 ft. lbs. (24 N.m). To complete preload, tighten adjuster nuts one more notch on both sides.
    NOTE: If old bearings were reused, tighten adjuster nuts 1/2 notch.
  6. Lock adjuster nuts with lock washers and tighten to 30-41 ft. lbs. (40-56 N.m). Install drive shafts. On one drive shaft and one hole for drive shaft flange, install an M10 bolt approximately .75" (20 mm) long with a flat washer. Use a wrench with an extension to prevent drive pinion from turning.
  7. Turn drive shaft with a torque wrench. Torque should not exceed 26 ft. lbs. (35 N.m). If not to specification, recheck differential bearing preload. Install side mountings for lower bushings. Tighten bolts to 30-41 ft. lbs. (40-56 N.m). Remove final drive from fixture and install counterweight. Tighten counterweight bolts to 15-21 ft. lbs. (20-28 N.m).
RENDER: 1.0x

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