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DService Manual

TrucksGroup 72

Volvo Optimized Air SuspensionVN VERSION2

From build date 3.2005

20176793

DForeword

The descriptions and service procedures contained in this manual are based on designsand methods studies carried out up to June 2006.

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, supplementaryservice 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 areference to an V.S.T. (Volvo Standard Times).

Service procedures which do not include an operation number in the title are for generalinformation and no reference is made to an V.S.T.

Each section of this manual contains specific safety information and warnings whichmust be reviewed before performing any procedure. If a printed copy of a procedure ismade, be sure to also make a printed copy of the safety information and warnings thatrelate to that procedure. The following levels of observations, cautions and warningsare used in this Service Documentation:

Note: Indicates a procedure, practice, or condition that must be followed in order to havethe 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 occur.

Volvo Trucks North America, Inc.Greensboro, NC USA

Order number: 20176793

© 2006 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,mechanical, photocopying, recording or otherwise, without the prior writtenpermission of Volvo Trucks North America, Inc.

USA22272.ihval

DContents

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

Specifications ......................................................................................... 5Tightening Torques ................................................................................ 5Ride Height and Pinion Angle Specifications ......................................... 6Suspension Applications ........................................................................ 7

Tools ........................................................................................................ 9Special Tools .......................................................................................... 9Special Equipment ............................................................................... 10

Design and Function ........................................................................... 11Rear Suspension ................................................................................... 11

Volvo Air Suspension ........................................................................... 11Rear Suspension Airline Routing ......................................................... 17

Troubleshooting ................................................................................... 19Rear Suspension Troubleshooting ......................................................... 19

Volvo Optimized Air Suspension .......................................................... 19

Service Procedures ............................................................................. 23Air Suspension, Adjustment (Ride Height and Driveline Calculation) .. 23U-bolt Torque, Adjustment ................................................................... 34Load Leveling Valve, Adjustment ......................................................... 38Load Leveling Valve, Replacement ...................................................... 41Leveling Rod, Replacement ................................................................. 45Crossbeam (Pedestal), Replacement .................................................. 46Z-Spring, Replacement ........................................................................ 48Radius Leaf Spring, Replacement ....................................................... 52Torque Rod, Replacement ................................................................... 56Torque Rod Frame Rail Bracket, Replacement .................................... 58Spring Hanger, Drive Axle, Replacement ............................................ 58Wear Plate (Pad), Replacement .......................................................... 62Rear Suspension Shock Absorber Bracket, Replacement .................. 64Rear Suspension Shock Absorber, Replacement (One) ..................... 66Top Plate, Replacement ....................................................................... 67Bottom Plate, Replacement ................................................................. 70Axle Seat, Replacement ...................................................................... 73Rear Suspension Air Spring, Replacement ......................................... 75Suspension Dump Switch, Replacement ............................................ 76Tandem Alignment, Adjustment ........................................................... 76Permanent Fastener, Removal ............................................................ 80

Operation Numbers

1

DGroup 72 Volvo Optimized Air Suspension General

General

Basic Description

W7001341

This information covers specifications, serviceprocedures, ride height adjustments, calculations, andpinion angles for the Volvo Optimized Air Suspensionproduced since November 2004. Information in thismanual is essential to maintain proper serviceabilityand proper ride height set by the manufacturer for theVolvo Optimized Air Suspension.

3

DGroup 72 Volvo Optimized Air Suspension Specifications

Specifications

Tightening TorquesLocation Diameter Grade Torque

M20 SAE 8.1 STD 38K 6X4

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

M22 SAE 8.1 STD 40K 6X4, 4X2

575 ± 75 Nm (424 ± 55 ft-lb)

Radius Spring to Spring Hanger Bracket M22 10.9 625 ± 35 NM (475 ± 25 ft-lb)

Air Spring Crossbeam (Pedestal) to Leaf M12 10.9 105 ± 20 Nm (77 ± 15 ft-lb)

Air Spring to Crossbeam (Pedestal) M12 8.8 50 ± 10 Nm (37 ± 7.5 ft-lb)

Torque Rod to Frame-Mounted Bracket M16 10.9 320 ± 50 Nm (236 ± 37 ft-lb)

Torque Rod to Axle Housing M16 10.9 320 ± 50 Nm (236 ± 37 ft-lb)

Shock Absorber Bracket to Frame M14 10.9 200 ± 45 Nm (148 ± 33 ft-lb)

Shock Absorber to Bracket (Upper andLower)

M16 8.8 275 ± 45 Nm (203 ± 33 ft-lb)

Bracket for Load Leveling Valve to Frame M14 10.9 200 ± 45 Nm (148 ± 33 ft-lb)

Load Leveling Valve Control Arm to Leveron Valve and Air Bag Pedestal

M6 8.8 10 ± 1.5 Nm (7 ± 1 ft-lb)

Spring Hanger Bracket to Frame M14 10.9 200 ± 45 Nm (148 ± 33 ft-lb)

5


Ride Height and Pinion Angle Specifications6X4 VOAS

Frame Height mm (in.) Bogey Spread mm. (in.) Ride Height mm (in.)(unloaded)

Pinion Angle ( )(first drive axle)

Pinion Angle ( )(second drive axle)

Meritor RT40-145

266 (10.47) 1320 (52) 220 ± 5 (8.66 ± 0.2) 2.5 ± 1 13.0 ± 1

RRH200 1520 (60) 220 ± 5 (8.66 ± 0.2) 2.5 ± 1 11.5 ± 1

300 (11.81) 1320 (52) 203 ± 5 (7.99 ± 0.2) 2.5 ± 1 13.0 ± 1

RRH180 1520 (60) 203 ± 5 (7.99 ± 0.2) 2.5 ± 1 11.5 ± 1

266 (10.47) 1320 (52) 170 ± 5 (6.69 ± 0.2) 2.5 ± 1 13.0 ± 1

RRH160 1520 (60) 170 ± 5 (6.69 ± 0.2) 2.5 ± 1 13.0 ± 1

Dana 404

266 (10.47) 1320 (52) 220 ± 5 (8.66 ± 0.2) 2.5 ± 1 12.0 ± 1

RRH200 1520 (60) 220 ± 5 (8.66 ± 0.2) 2.5 ± 1 10.5 ± 1

300 (11.81) 1320 (52) 203 ± 5 (7.99 ± 0.2) 2.5 ± 1 12.0 ± 1

RRH180 1520 (60) 203 ± 5 (7.99 ± 0.2) 2.5 ± 1 10.5 ± 1

266 (10.47) 1320 (52) 170 ± 5 (6.69 ± 0.2) 2.5 ± 1 12.0 ± 1

RRH160 1520 (60) 170 ± 5 (6.69 ± 0.2) 2.5 ± 1 12.0 ± 1

Eaton DST 40

266 (10.47) 1320 (52) 220 ± 5 (8.66 ± 0.2) 2.5 ± 1 8.0 ± 1

RRH200 1550 (61) 220 ± 5 (8.66 ± 0.2) 2.5 ± 1 2.5 ± 1

300 (11.81) 1320 (52) 203 ± 5 (7.99 ± 0.2) 2.5 ± 1 8.0 ± 1

RRH180 1550 (61) 203 ± 5 (7.99 ± 0.2) 2.5 ± 1 2.5 ± 1

Meritor MT40-14*M

266 (10.47) 1350 (53) 220 ± 5 (8.66 ± 0.2) 2.5 ± 1 2.5 ± 1

RRH200 1550 (61) 220 ± 5 (8.66 ± 0.2) 2.5 ± 1 2.5 ± 1

300 (11.81) 1350 (53) 203 ± 5 (7.99 ± 0.2) 2.5 ± 1 2.5 ± 1

RRH180 1550 (61) 203 ± 5 (7.99 ± 0.2) 2.5 ± 1 2.5 ± 1

4X2 VOAS with any Axle

266 (10.47) RRH-200 220 ± 5 (8.66 ± 0.2) 3.5 ± 1

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 anglescannot be adjusted at the same time for 6X4s, the rideheight should be adjusted to the minimum cancellation

error angle for the intermediate prop shaft, then loweredby 10 mm.

Note: Working angles are measured at the forward axlejoint or rear axle joint; See “Calculation Form” page 33.

6


Suspension ApplicationsNote: There are two vehicle suspension ride heightversions. The RRH-180 and RRH-200 have a stampedsheet metal torque rod bracket (on the axle) and adifferent torque rod. The vehicles with this version areequipped with a Meritor axle. The other version is theRRH-160, this suspension has a cast iron torque rodbracket and is available on all Dana/Eaton axles as wellas Meritor. The difference between the two versions isthat the bumpstop has changed and this has impacted thetotal suspension travel that is available.

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, enginehorsepower/torque, axle type/model, axle ratio, and/or vehicle tire size.

7

DGroup 72 Volvo Optimized Air Suspension Tools

Tools

Special ToolsFor special tools ordering instructions, see service information in group 08.

J42189Air line release tool

W0001198

J44773Air line release tool

W0001874

J44544Adjustment socket

W0001815

J44684Ride height gauge

W00019609

DGroup 72 Volvo Optimized Air Suspension Tools

85107240Tandem alignment

W7001340

J36795Tandem axle calipers

W0001985

Special EquipmentFor special equipment ordering instructions, see service information in group 08.

Anglemasterdigital inclinometer

W7000250

J38460–ADigital protractor

W7000708

J38460–25Bracket, used along with the Kent-Moore digital protractoror the Dana-Spicer digital inclinometer for checking pinionangles

W7000726

10

DGroup 72 Volvo Optimized Air Suspension Design and Function

Design and Function

Rear Suspension

Volvo Air Suspension

W7001341

The design of the Air-Ride Suspension has been refinedby Volvo Trucks North America. The result of thisrefinement process is the Volvo Optimized Air Suspension.This new Suspension is a rear air suspension withimproved ride characteristics and increased durability.

CAUTION

The Volvo Optimized Air Suspension is set at thefactory. Changing the ride height will affect thedriveshaft angles and may cause driveline vibrationand/or shorten component life.Ride height adjustments must be performedin accordance with all documented serviceprocedures.

Air Suspension, Adjustment (Ride Height and Driveline Calculation)Ride height has a direct relationship with drivelinepinion angles. It is critical to maintain all ride heightspecifications as recommended by Volvo Trucks NorthAmerica, Inc. (VTNA).

Interaxle cancellation (equal forward and rear interaxleU-joint angles) is the key to reduced driveline vibrations

and increased component life. “Air Suspension,Adjustment (Ride Height and Driveline Calculation)” page23, describes how to achieve interaxle cancellation bymaintaining the proper ride height and pinion angles.

11


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.

W7001342

Wear PlateThe wear plate (pad) is constructed of the sameUltra-High Molecular Weight Polyethylene as earlier wearplates. This material provides an extremely smoothsurface for the spring to contact and virtually eliminatesthe noise associated with the metal-to-metal contactof other suspension designs. The Volvo Optimized AirSuspension wear plate mounts with a single fastener intoa pocket 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.

W7001343

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 the6 x 4 may be longer than the first drive axle.

W7001344

12


Radius Leaf SpringThe radius leaf spring is crucial to the vehicle’s alignment.The radius leaf spring has an improved bushing forincreased 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 theradius 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 redesignedto improve strength while reducing weight. The VolvoOptimized Air Suspension crossbeam uses only fourmounting bolts (two on each end) for easy installation ofthe Z-spring.

W7001346

Axle SeatThe axle seat defines the axle pinion inclination. It hasbeen refined to eliminate the extra spacers necessaryin earlier 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 “Axle Seat,Replacement” page 73.

W7001347

13


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.

W7001348

Top PlateThe top plate (upper clip) is located at the top of theZ-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 top platealso helps maintain a secure surface for U-bolts whenthe nuts are tightened.

W7001349

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.

W7001350

14


Leveling RodThe Volvo Optimized Air Suspension uses a levelingrod that is factory adjusted and set to accurately controlthe dimensions of the air springs, prevent inappropriateadjustments, and avoid unnecessary servicing.

W7001351

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

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

The Volvo Optimized Air Suspension height valveincorporates an integrated dump feature that eliminatesthe need for a separate valve and allows the rear to belowered when driving out from under an uncoupled trailer.

W7001362

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

W7001353

15


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 maintain lateralalignment of the rear axle or axles for the suspension.

Note: Different models of torque rods should not beinterchanged.

W7001345

Suspension Dump SwitchThe air suspension dump switch is used to lower the truckwhen uncoupling trailers. It then enables you to return tothe raised position (“ride”) for a better ride.

To “dump” air from the system (to lower the suspension),select the “UNCOUPLE” position (push down the latchand press in the bottom part of the switch) on thesuspension control switch to deflate the air springs.

To fill the system (to return to the normal ride height),select the “RIDE” position (Press the top part of theswitch in) on the suspension control. This restores thesuspension to operating height.

CAUTION

The vehicle must never be driven with the air springsdeflated. Damage to air suspension parts will occur ifsprings are not inflated properly.

W3001341

W3005345

Fig. 1: Suspension dump switch location

16


Rear Suspension Airline Routing

W7001364

17

DGroup 72 Volvo Optimized Air Suspension Troubleshooting

Troubleshooting

Rear Suspension Troubleshooting

Volvo Optimized Air SuspensionProblem 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

Excessive 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

19


Volvo Optimized Air Suspension Ride Height and Driveline Angle CheckFlow Diagram

W7000749

1 See “Air Suspension, Adjustment (Ride Height and Driveline Calculation)” page 232 See “Interaxle U-joint Angle Cancellation Check (Calculation)” page 263 See “Load Leveling Valve, Adjustment” page 384 See “Forward Axle Pinion Angle to Frame Check” page 305 See “U-bolt Torque, Adjustment” page 34

20


Visual Inspection of Air Spring DamageType of Air Spring Damage Cause

Holes rubbed in sidewall — Worn bushingsMisalignment

Loose internal bumper — Suspension out of alignment

Loose girdle hoop Girdle hoop torn loose — Improperly set or inoperative leveling valve/pressureregulator

Top plate concave — Broken or wrong shock

Loose internal bumper — Leveling valve or pressure regulator

Hole in girdle hoop area — Pressure set too lowBottom-out/abrasion

Hole in top plate junction area — Overloaded vehicle

Holes rubbed in sidewall — Wrong air spring (too tall)

Bellows cut in circle at top plate junction — Inoperative leveling valve andor pressure regulator

Circumferential cutsBellows cut in circle at piston juncture — Inoperative leveling valve and orpressure regulator

Top plate convex — Broken or worn shock

Bellows separated from top plate — Broken shocks or leveling valve set toohigh

Air leak at top plate fitting — Improperly set or inoperative levelingvalve/pressure regulator

Over Extension

Leaking at end closure (reversible style) — Defective upper stop/wrong airspring (too short)

21

DGroup 72 Volvo Optimized Air Suspension Service Procedures

Service Procedures7281-05-02-01

Air Suspension, Adjustment (Ride Height and Driveline Calculation)You must read and understand the precautions andguidelines in Service Information, group 70, "GeneralSafety Practices" before performing this procedure.If you are not properly trained and certified in thisprocedure, ask your supervisor for training beforeyou perform it.

CAUTION

The Volvo Air Suspension is set at the factory.Changing the ride height will affect the driveshaftangles and may cause driveline vibration and/orshorten component life. Ride height adjustmentsmust be performed in accordance with alldocumented service procedures.

Note: After work has been performed on the airsuspension, wheel realignment may be required.

For proper specifications for checking the wheelalignment, refer to service information in group 601regarding “Wheel Alignment, Steer and Drive Axles”Other special equipment: J–38460–A,J–38460–25

23


Air Suspension Ride Height Check1

W7000765

1 Load leveling valve

2 Ride height

3 Axle center line

4 Crossbeam

Before you can accurately calculate the ride height,prepare the vehicleusing these steps:

• Measurements must be performed on an unloadedvehicle.

• Park the vehicle on a levelsurface.

• The steer and rear drive axle tires must be at normaloperating

pressure.

• Free and center all suspension joints by slowly movingthe vehicle back and forth twice without using thebrake. When coming to a complete stop, make surethe brakes (parking and service) are released.

• Front wheels must be pointed straight ahead.

2Chock the front wheels on the vehicle.

3Dump (release) the suspension air (see “SuspensionDump Switch, Replacement ” page 76).

DANGER

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

Start the engine and fill the suspension with air. Turn offthe engine.

4

W7001354

The ride height is the distance from the axle centerline tothe bottom of the frame rail. The ride height must bewithin specifications. See“Ride Height and Pinion Angle Specifications” page 6.

To accurately measure ride height:

a. Measure from the ground to the bottom of theframe rail (1).

b. Locate the axle centerline (the center hole on theend of the hub works best) using a steel rule or anappropriate tool (2). Measure from the ground tothe axle centerline (3).

c. Calculate the difference between (1) and (3). Thedifference is the ride height (4).

d. Ride height should fall within specifications (seeabove).

24


5Record the measurement for calculation (refer to“Calculation Form” page 33). If the measurement isnot within the specified range, it must be correctedbefore proceeding. If the ride height is not adjusted tospecification, check for the following:

• Excessively worn wear plates (pads).

Note: Wear plates (pads) must be replaced in pairs(left and right on same axle); see “Wear Plate (Pad),Replacement” page 62.

• Damaged spring hanger.

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

• Damaged leveling rod.

• Faulty load leveling valve.

Replace the components asnecessary, then adjust the suspension ride height (see“Load Leveling Valve, Adjustment” page 38).

6Re-measure the ride height following instructions shownin step 4. Repeat as necessary until the measurementis within specifications.

7Proceed to “Interaxle U-joint Angle Cancellation Check(Calculation)” page 26.

25


Interaxle U-joint Angle Cancellation Check (Calculation)You must read and understand the precautions andguidelines in Service Information, group 70, "GeneralSafety Practices" before performing this procedure.If you are not properly trained and certified in thisprocedure, ask your supervisor for training beforeyou perform it.

1The steps from “Air Suspension Ride Height Check”page 24 must be performed before continuing withthis procedure.

Note: All angle measurements are relative to levelground.

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 protractoror recommended tool. Record the measurement forcalculation (refer to “Calculation Form” page 33).

Note: Wipe surface clean of dirt and debris beforetaking measurement.

J-38460-A

26


3

W7001355

1 Digital Protractor J-38460

2 Bracket J-38460–25

Measure the interaxle shaft angle (B) using therecommended tools. Record the measurement forcalculation (refer to “Calculation Form” page 33).


4Calculate : B – A = DThe interaxle angle minus the forward axle angle will givethe value (D) (refer to “Calculation Form” page 33).

27


5

W7001194






1 Ride Height


3 Frame Rail

W7000253

Measure the rear axle angle (C) using the recommendedtools. Record the measurement for calculation (refer to“Calculation Form” page 33).


6Calculate: C – B = EThe rear axle angle minus the interaxle angle will givethe value (E). Record the measurement for calculation(refer to “Calculation Form” page 33).

7Calculate: D – E = FRecord the measurement for calculation (refer to“Calculation Form” page 33).

Compare the value of angle (F) with the followingguidelines:

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

If (F) is between –4 and –1, no adjustment isnecessary.

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

For procedures on lowering orraising ride height, refer to “Load Leveling Valve,Adjustment” page 38.

28


8Proceed to “Forward Axle Pinion Angle to FrameCheck” page 30.

29


Forward Axle Pinion Angle to Frame CheckYou must read and understand the precautions andguidelines in Service Information, group 70, "GeneralSafety Practices" before performing this procedure.If you are not properly trained and certified in thisprocedure, ask your supervisor for training beforeyou perform it.

1

W7001356

1 Digital protractor

Place a protractor or recommended tool on top of theframe. “Zero-out” protractor or recommended tool.

J-38460-A

30


2

W7001194






1 Ride Height


3 Frame Rail

W7000252

Measure the forward axle angle (P), using the “zeroedout” protractor or recommended tool.

3The angle (P) measurement must be within the specifiedrange. See “Ride Height and Pinion Angle Specifications”page 6. If angle (P) is outside the specifications, it mustbe corrected. Check for the following:

• Excessively worn wear plates (pads).

Note: Wear plates (pads) must be replaced in pairs(left and right on same axle); see “Wear Plate (Pad),Replacement” page 62.

• Damaged spring hanger.

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

• Damaged leveling rod.

• Broken/loose U-bolts.

• Faulty load leveling valve.

Replace the components asnecessary, then adjust the suspension ride height (see“Load Leveling Valve, Adjustment” page 38).

31


4Repeat all steps in “Air Suspension Ride Height Check”page 24, “Interaxle U-joint Angle Cancellation Check(Calculation)” page 26, and “Forward Axle Pinion Angle toFrame Check” page 30.

Note: If, after the second attempt, the axle pinion anglesare still not within specification, perform the “U-boltTorque, Adjustment” page 34, as a last attempt to correctthe axle pinion angles.

32


Calculation Form

Use this form to record the measurements for calculating ride height and checking pinion angles (all angle measures arein degrees).

MEASUREMENTS

ANGLEINITIAL FINAL

1) MEASURE THE RIDE HEIGHT:

Ride Height must be within specification. See "Ride Height Pinion AngleSpecifications" page 6.If ride height is not within specification, it must be corrected beforecontinuing.

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 AirSuspension Troubleshooting" page 23.

For the forward axle angle P (relative to frame)measurement specifications see “Ride Height and PinionAngle Specifications” page 6.

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

33


7214-05-02-01U-bolt Torque, Adjustment

You must read and understand the precautions andguidelines in Service Information, group 70, "GeneralSafety Practices" before performing this procedure.If you are not properly trained and certified in thisprocedure, ask your supervisor for training beforeyou perform it.

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

DANGER

Failure to properly support the front of the axle housingmay result in the axle rolling forward, causing seriousinjury or death.

Support the front of the axle housing with an adequatejack.

Note: Always replace both U-bolts at a particular axleposition. The longer of the two U-bolts is positioned tothe rear side of the axle housing.

2Loosen the U-bolts enough to allow the bottom plate/rearshock absorber bracket to be slightly free from the axlehousing. Lower the jack slightly, approximately 10 –15 mm (0.38 – 0.50 in.).

Note: Any time you work on the suspension, make sureyou loosen both sides of the suspension on an axle atthe same time. It is difficult to realign all parts with theopposite side of the axle restricting motion.

3Check for dirt or debris in the U-bolt threads. Clean thethreads if necessary and coat with a light wax-basedlubricant.

Note: Lubricating the threads with motor oil is notrecommended because of the detergent additives.

34


4Tighten the U-bolt nuts so that there is no movement inthe bottom plate/rear shock absorber bracket.

Note: Whenever the U-bolts are loosened and/or thesuspension components attached to the axle are beingworked on, make sure that the locating features on eachcomponent are properly engaged so that the componentsare properly positioned together.

Note: Make sure that the pin in the radius leaf spring hasnot been pushed out of position. If the pin is correctly set,make sure that the pin is placed in its proper positionrelative to the axle seat and Z-spring before clamping itwith the U-bolts.

5

W7000750

Tighten U-bolts using a cross pattern shown above.Tighten using a five step process as follows:

First:

Position 1: M20: 40 Nm (29 ft-lb)


Second:



Third:



Fourth:



Fifth:

Position 1: M20: 500 ± 75 Nm (370 ± 55 ft-lb)


Note: The applied torque should be 500 ± 75 Nm (370 ±55 ft-lb) for M20 and 575 ± 50 Nm (440 ± 55 ft-lb) for M22U-bolts while keeping the U-bolt perpendicular to theaxle. Inspection torque should be a minimum of330 Nm (243 ft-lb) and 380 Nm (280 ft-lb) 10 hoursafter assembly.

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

6Road-test the vehicle to seat components, then re-tightenthe U-bolt nuts.

7Re-perform the procedure: “Air Suspension, Adjustment(Ride Height and Driveline Calculation)” page 23. Ifaxle pinion angles are still outside the specifications,proceed with Method 2.

35


Method 21

W7000752

DANGER

Failure to properly support the front of the axle housingmay result in the axle rolling forward, causing seriousinjury or death.



2Loosen the U-bolts enough to allow the bottomplate/rear shock absorber bracket to be slightlyfree from the axle housing. Lower the jack slightly,approximately 10 –15 mm (0.38 – 0.50 in.).

Note: Any time you work on the suspension, make sureyou loosen both sides of the suspension on an axle atthe same time. It is difficult to realign all parts with theopposite side of the axle restricting motion.



4Tighten the U-bolt nuts so that there is no movement inthe bottom plate/lower shock absorber bracket.

36


5

W7000750

Tighten U-bolts using a cross pattern shown above.Tighten using a five step process as follows:

First:



Second:



Third:



Fourth:



Fifth:



Note: The applied torque should be 500 ± 75 Nm (370 ±55 ft-lb) for M20 and 575 ± 50 Nm (440 ± 55 ft-lb) for M22U-bolts while keeping the U-bolt perpendicular to the axle.Inspection torque should be a minimum of 330 Nm (243ft-lb) and 380 Nm (280 ft-lb) 10 hours after assembly.

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

6Repeat the procedure: “Air Suspension, Adjustment(Ride Height and Driveline Calculation)” page 23.

37


7641-05-02-01Load Leveling Valve, Adjustment


1Park the vehicle on a level surface, place the transmissionin neutral and chock the front wheels.

2

W7001203

A Alternate tool position for checking RideHeight.

1 Adjustment Socket J-44544

2 Ride Height Gauge J-44684

DANGER

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

To raise or lower the suspension ride height, use a ratchetand extension, along with Kent Moore tool numberJ–44544. Place tool inside the hole in the frame rail. Thehole is located on the left side, behind the 1st drive axle.

3Position the ride height gauge such that it is clamped,either to the top or bottom flange of the frame rail.Make sure the rod for the ride height gauge rests ontop of the axle housing.

38


4

W7001204

A Alternate tool location for checking RideHeight.

1 Axle Housing

2 Ride Height Gauge

The scale on the ride height gauge is used to read theride height from the top flange on the frame rail.

J-44684

5

W7001056

A Raise

B Neutral

C Lower

The suspension ride height is changed by turning theload leveling valve clockwise (to raise) or counterclockwise (to lower).


39


7Start the engine to build up air pressure to check the rideheight (see “Air Suspension Ride Height Check” page24). The ride height must be within specifications. See“Ride Height and Pinion Angle Specifications” page 6.

8Perform the “Interaxle U-joint Angle Cancellation Check(Calculation)” page 26, and the “Forward Axle PinionAngle to Frame Check” page 30.

40


7641-03-02-01Load Leveling Valve, Replacement


CAUTION

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

Removal1Chock the front wheels on vehicle and release theparking brakes.

2Dump (release) the suspension air (For “SuspensionDump Switch, Replacement” information, refer to the“Electrical General Manual”).

3Remove rod from the load leveling valve handle.

4Remove the bolt that mounts the leveling valve bracket tothe frame.

5Note the air line positions and orientation to the fittings inthe valve. Disconnect the air lines, and remove the valve.

41


6

W7001390

1 Valve2 Supply Port3 Plug4 Delivery Port5 Control6 Exhaust Tube

Swap fittings (or position new fittings) to the replacementvalve.

Note: This is for vehicles built since March 2005.

7Transfer the bracket from the faulty valve to thereplacement valve. Tighten the screws as follows:

M8: 30 ± 5 Nm (22 ± 4 ft-lb).

Note: For vehicles built prior to March 2005, use partnumber 85108667.

M8: 30 ± 5 Nm (30 ± 5 ft-lb)85108667

42


Installation1

W7001391

W7001393

PN:20837841

Lay the valve in the frame and install the air lines.

2Install the bolt through the valve bracket and the frame.Tighten the mounting bolt as follows:

M14: 200 ± 33 Nm (148 ± 24 ft-lb).

M14: 200 ± 33 Nm (148 ± 24 ft-lb)

3Connect the leveling rod to the arm. Tighten the rod nutas follows:

M6: 10 ± 1.5 Nm (7 ± 1 ft-lb).

M6: 10 ± 1.5 Nm (7 ± 1 ft-lb)

43


4When completed, start the engine to build up airpressure, then check the ride height (see “Air SuspensionRide Height Check” in Group 72, “Volvo Optimized AirSuspension, VN VERSION 2, From build date 11.2004”).

The ride height must be within required specifications.Refer to “Ride Height and Pinion Angle Specifications”in Group 72, “Volvo Optimized Air Suspension, VNVERSION 2, From build date 11.2004”.

44


7647-03-02-01Leveling Rod, Replacement


Removal


2Unbolt leveling rod from load leveling valve arm andcrossbeam (pedestal). Remove from vehicle.

Installation

3Install leveling rod. Note position of washer. Tighten bothnuts as follows:

M6: 10 ± 1.5 Nm (7 ± 1 ft-lb).

Note: Mount in same hole in the crossbeam (pedestal)as the original leveling rod. Do not crimp or tighten clampat lower end of the leveling rod at this time.

M6: 10 ± 1.5 Nm (7 ± 1 ft-lb)

4When completed, start the engine to build up air pressureto check the ride height (see “Air Suspension RideHeight Check” page 24).

The ride height must be within the following specifications:See “Ride Height and Pinion Angle Specifications”page 6.

45


7262-03-02-03Crossbeam (Pedestal), Replacement


Removal

1Raise the rear suspension and support the frame withjack stands, maintaining the approximate ride height.Dump (release) the suspension air to relieve air pressurefrom the air springs.

2Remove the nuts that hold the air bags to the crossbeam(pedestal plate). Push the air springs out of thecrossbeam and forward.

3

W7000707

Remove the nuts and bolts that hold the crossbeam to theZ-springs and remove the crossbeam.

Installation

4Install the crossbeam to the Z-spring with the nuts andbolts. Tighten the bolts as follows:

M12: 105 ± 20 Nm (77 ± 15 ft-lb).

M12: 105 ± 20 Nm (77 ± 15 ft-lb)

46


5

CAUTION

Over-tightening will damage the air spring.

Install the air springs back onto the crossbeam andtighten the nuts as follows:

M12: 50 ± 10 Nm (37 ± 7.5 ft-lb).

6When completed, jack up the rear of the truck, removethe jack stands and lower the vehicle. Start the engine tobuild air pressure to raise the air suspension.

47


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


Removal

1Chock the front tires and release the parking brake.

2Remove the shock absorber.

3Remove the Z-spring retaining pin.

4Remove the fasteners mounting the air bellows supportbar to the top rear of the Z-spring.

48


5

W7001139

W7000752

DANGER

Failure to properly support the front of the axle housingmay result in the axle rolling forward causing personalinjury or death.

Using a floor jack or hoist, lift the weight off of the springand support with jack stands under the frame.

Note: Never install jack directly under the crossbeam.The crossbeam is not designed to support vehicle weight.

Note: The front of the axle housing should also besupported to prevent the axle from rolling forward duringservice.

49


6

W7001357


Remove the Z-spring U-bolt nutsand bottom shock mount.

7Remove the U-bolts and top spring mounts.

8Lift up on Z-spring and move towards the rear of thetruck, then lift up and out.

Note: You may need to raise or lower the axle slightly toremove tension from the Z-spring before removal.

Installation

9Position the Z-spring over the radius spring, making sureto line up the center pins.

10Position the U-bolts and top brackets.

11Position the bottom shock bracket and start all U-bolt nuts.

12Secure the U-bolt nuts.

Note: Before tightening the U-bolt nuts, position thesuspension at approximately the normal ride height andmake sure the bolts holding the crossbeam (pedestalplate) to the Z-spring are loosened. This will help provideproper alignment for the Z-springs.

Note: To ensure proper tightening, refer to “U-boltTorque, Adjustment” page 34.

50


13Lower the weight down onto the Z-spring and start thebolts in the air bellows mounting bolts.

Note: To align the Z-spring with the radius leaf springit may be necessary to slightly raise or lower the axle.It may also be necessary to loosen the U-bolts on theopposite side of the axle for alignment.

14Secure the air bellows support bar mounting bolts.

15Install the front Z-spring retaining pin.

16Install the shock absorber and tighten as follows:

M16: 220 ± 35 Nm (162 ± 26 ft-lb)

M16: 220 ± 35 Nm (162 ± 26 ft-lb)

17Check the tandem alignment and adjust, if necessary. Forproper specifications for checking the wheel alignment,refer to service information in group 601 on “WheelAlignment, Steer and Drive Axles”

18Apply the parking brake and remove the wheel chocks.

51


7224-03-02-02Radius Leaf Spring, Replacement


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

Removal

1Chock the front tires and release the parking brake.

2Remove the shock absorber.

3Remove the Z-spring retaining pin.

4Remove the fasteners mounting the air bellows supportbar to the top rear of the Z-spring.

52


5

W7000752

W7000725

DANGER

Failure to properly support the front of the axle housingmay result in the axle rolling forward causing personalinjury or death.

Using a floor jack or hoist, lift the weight off of the springand support with jack stands under the frame.

Note: Never install jack directly under the crossbeam.The crossbeam is not designed to support vehicle weight.

Note: The front of the axle housing should also besupported to prevent the axle from rolling forward duringservice.

6Note: Always replace both U-bolts at a particular axleposition. The longer of the two U-bolts is positioned tothe rear side of the axle housing.

Remove the Z-spring U-bolt nutsand bottom shock mount.

7Remove the U-bolts and top spring mounts.

8Lift up on Z-spring and move towards the rear of thetruck, then lift up and out.

Note: You may need to raise or lower the axle slightly toremove tension from the Z-spring before removal.

53


9

W7001358

Remove the center bolt, then remove the radius leafspring.

Installation

10Position the radius leaf spring and install the center boltas follows:

M14: 217 ± 20 Nm (160 ±15 ft-lb)

Note: Whenever the U-bolts are loosened and/or thesuspension components attached to the axle are beingworked on, make sure that the locating features on eachcomponent is properly engaged so that the componentsare positioned together properly.

M14: 217 ± 20 Nm (160 ±15 ft-lb)

11Position the Z-spring over the radius spring, making sureto line up the center pins.

12Position the U-bolts and top brackets.

13Position the bottom shock bracket and start all U-bolt nuts.

14Secure the U-bolt nuts.



54


15Lower the weight down onto the Z-spring and start thebolts in the air bellows mounting bolts.

Note: To align the Z-spring with the radius leaf springit may be necessary to slightly raise or lower the axle.It may also be necessary to loosen the U-bolts on theopposite side of the axle for alignment.

16Secure the air bellows support bar mounting bolts.

17Install the front Z-spring retaining pin.

18Install the shock absorber and tighten as follows:

M16: 220 ± 35 Nm (162 ± 26 ft-lb)

M16: 220 ± 35 Nm (162 ± 26 ft-lb)

19Check the tandem alignment and adjust, if necessary. Forproper specifications for checking the wheel alignment,refer to service information in group 601 on “WheelAlignment, Steer and Drive Axles”

20Apply the parking brake and remove the wheel chocks.

55


6521-03-02-04Torque Rod, Replacement


Removal

1

W7000716

Remove the two (2) bolts securing the torque rod to theframe rail side bracket.

2Remove the two (2) bolts securing the torque rod to theaxle housing bracket.

Note: These may be Huck®; style fasteners, whichrequire additional effort for removal. See “PermanentFastener, Removal” page 80.

3Remove the (4) bolts securing the torque rod bracketto the frame rail.

Installation

4Install the (4) bolts securing the torque rod bracketto the frame rail.

5Note: Use only approved fasteners.Install two (2) bolts through the torque rod at the axlehousing bracket.

6Install two (2) bolts holding the torque rod to the framerail side bracket.

56


7Secure all mounting bolts for the torque rod and thebracket. Tighten rod bracket as follows:

M16: 271 ± 27 Nm (200 ± 20 ft-lb).

M16: 271 ± 27 Nm (200 ± 20 ft-lb)

8Reattach any wires or air line clippings to the torque rod.

57


6529-03-02-02Torque Rod Frame Rail Bracket, Replacement


Removal

1

W7000716

Remove the bolts through the torque rod at the framerail side bracket.

2Remove the fasteners to the torque rod frame rail bracketat the frame rail, and remove the bracket.

Note: These may be Huck® style fasteners, which requireadditional effort for removal.

Installation

3Install bolts to the torque rod frame rail bracket atframe rail.

Note: Use only approved fasteners.

4Install bolts through the torque rod at the frame railside bracket.

5Tighten the bolts to tighten rod. Tighten rod bracketas follows:

M16: 271 ± 27 Nm (200 ± 20 ft-lb).

M16: 271 ± 27 Nm (200 ± 20 ft-lb)

6Re-attach any wires or air line clippings to the torquerod frame rail bracket.

7114-03-02-04Spring Hanger, Drive Axle, Replacement


58


Removal

1

W7001358

Park the vehicle on a level surface with the transmissionin neutral and chock the front wheels.

2

W7001139

Jack up the vehicle to remove the weight off of the spring,and support it with jack stands of adequate rating.

Note: These may be Huck® style fasteners, whichrequire additional effort for removal. See “PermanentFastener, Removal” page 80.

Note: The ABS modulator valve may need to be removedin some applications.

3Remove the pin and roller from the spring hanger.

4Remove the adjusting bolt from the hanger that securesthe radius spring.

59


5

W7001358

Remove the bolts from the spring hanger.

Note: These may be Huck® style bolts.

6Remove the spring hanger.

Note: The Z-spring may need to be raised or lowered torelieve tension from the spring hanger for removal.

7Remove the wear plate (pad) from the old spring hangerand place it in the new spring hanger.

Note: If either wear plate needs replacement, theyshould be replaced in pairs.

60


Installation

8Install the spring hanger and the bolts. Tighten thebolts as follows:

320 ± 45 Nm (236 ± 33 ft-lb).

320 ± 45 Nm (236 ± 33 ft-lb)

9Install radius leaf spring bolts.

Note: Do not secure at this time.

M14: 217 ± 20 Nm (160 ±15 ft-lb)

M14: 217 ± 20 Nm (160 ±15 ft-lb)

10Check the tandem alignment.

Note: Adjust if necessary.

11Secure the radius spring adjusting bolt.

12Install the Z-spring roller and pin into the hanger.

13Raise the vehicle and remove the jack stands.

61


7269-03-02-06Wear Plate (Pad), Replacement


Removal

1

W7001358

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

Note: It is strongly recommended that the wear plates(pads) be replaced in pairs (left and right side) on thesame axle.

2Chock front wheels on vehicle.


4

W7000725

Jack the vehicle from under the rear of the Z-spring atthe crossbeam (pedestal plate) mounting until there issufficient gap between the wear plate and Z-spring toremove the wear plate.

Note: Jacking both the left and right sides simultaneouslywill help obtain a sufficient gap. Also, lifting (and properlysupporting) the rear of the chassis may increase thesize of the gap.

5Remove the split pin and the retaining pin holding thewear plate into the spring hanger (frame) bracket.

62


6Pry out the old wear plate.

Installation

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

Note: The thick end of the wear plate is always positionedto the rear of the vehicle.

8Jack from the rear of the Z-spring.

9Install the retaining pin and a replacement split pin intothe spring hanger (frame) bracket to hold the installedwear plate.

10Start engine to build air pressure to raise the airsuspension.

11Install the isolator (spring roller), retaining pin, and areplacement split pin in the spring hanger (frame) bracket,under the Z-spring.

12Ride height and axle pinion angle may requireadjustment. See “Air Suspension, Adjustment (RideHeight and Driveline Calculation)” page 23.

63


7614-03-02-06Rear Suspension Shock Absorber Bracket, Replacement


Removal

1

W7001064

Mark the mounting bracket bolt hole and remove theupper shock mounting bolt. Move shock and position outof the work area.

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

Note: These may be Huck® style fasteners, requiringadditional effort for removal. See “Permanent Fastener,Removal” page 80.

3Remove upper shock bracket.

Installation

4Install the shock bracket. Tighten fasteners as follows:

271 ± 27 Nm (200 ± 20 ft-lb).

Note: Use only approved fasteners.

271 ± 27 Nm (200 ± 20 ft-lb)

64


5Note: The shock mounting location in the upper bracketmay vary depending on the axle and frame configuration.On the 6x4 chassis with a frame rail height of 300 mm theshock is mounted to the upper holes on the first drive axle,and to the lower holes on the second drive axle. The firstdrive axle on a chassis with a 266 mm frame rail heighthas a special bracket with one set of holes only. On thesecond axle the shocks are mounted in the upper holes.On the 4x2 axles the shocks are mounted in the upperholes.Install shock, bushings, and upper shock mounting bolt.Tighten bolt as follows:

M16: 220 ± 35 Nm (162 ± 26 ft-lb)

Note: When replacing shocks, use only Volvo-approvedcomponents (shocks and bushings).

M16: 220 ± 35 Nm (162 ± 26 ft-lb)

65


7612-03-02-01Rear Suspension Shock Absorber, Replacement (One)


Removal

1

W7001064

Remove lower shock mounting bolt.

2Mark the mounting bracket bolt hole and remove theupper shock mounting bolt. Remove the shock.

Installation

3Note: The shock mounting location in the upper bracketmay vary depending on the axle and frame configuration.On the 6x4 standard chassis (frame rail height 300 mm)the shock is mounted to the upper holes on the first driveaxle, and to the lower holes on the second drive axle.The first drive axle on the low chassis (frame rail height266 mm) has a special bracket with one set of holesonly. On the second axle the shocks are mounted inthe upper holes.On the 4x2 axles the shocks are mounted in the upperholes.Install shock and bushings. Position the mounting bolt inthe correct bracket hole and tighten as follows:

M16: 220 ± 35 Nm (162 ± 26 ft-lb)

Note: When replacing shocks, use only Volvo-approvedcomponents (shocks and bushings).

M16: 220 ± 35 Nm (162 ± 26 ft-lb)

66


7222-03-02-06Top Plate, Replacement


Removal


2

W7000752


Note: Failure to properly support the front of the axlehousing may result in the axle rolling forward, which cancause serious injury or death to anyone under the vehicle.

3Remove nuts from the U-bolts, then remove the U-bolts.Leave lower shock bracket attached to shock absorber,but position bracket clear of the work area.

67


4

W7001357

Remove the top plate.

Installation

5Install the top plate.

Note: Make sure the alignment pin on the top plate isengaged into the pocket on the top surface of the Z-spring.



7Install the U-bolts.

Note: Whenever the U-bolts are loosened and/or thesuspension components attached to the axle are beingworked on, make sure that the locating features on eachcomponent are properly engaged so that the componentsare positioned together properly.


Note: Motor oil, because of detergent additives, is notrecommended.

68


9

W7000750

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

M20: 500 ± 75 Nm (370 ± 55 ft-lb).

M22: 575 ± 50 Nm or (425 ± 37 ft-lb).



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

10Note: Ride height and pinion angle may requireadjustment. See “Air Suspension, Adjustment (RideHeight and Driveline Calculation)” page 23.

11Check the wheel alignment.For alignment specifications, refer to service informationin group 601 on “Wheel Alignment, Steer and Drive Axles”

69


7222-03-02-08Bottom Plate, Replacement


Removal


2

W7000752



3Disconnect the shock from the bottom plate/lower shockabsorber bracket.

70


4

W7001357

Remove nuts from the U-bolts, then remove the bottomplate/lower shock absorber bracket.

71


Installation

5Install the bottom plate/lower shock absorber bracket andreconnect the lower shock absorber and U-bolt nuts.

Note: Whenever the U-bolts are loosened and/or thesuspension components attached to the axle are beingworked on, make sure that the locating features on eachcomponent are properly engaged so that the componentsare positioned together properly.



7

W7000750


M20: 500 ± 75 Nm (370 ± 55 ft-lb).

M22: 575 ± 50 Nm or (425 ± 37 ft-lb).



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

72


7222-03-02-05Axle Seat, Replacement


Removal


2

W7000752



3Remove nuts from the U-bolts, then remove the U-bolts.Leave lower shock bracket attached to shock absorber,but position bracket clear of the work area.

4

W7000725

Using a lift, raise the Z-spring from the axle seat, thenremove axle seat.

73


Installation

5

W7001357

Install the axle seat.



7

W7000750


M20: 500 ± 75 Nm (370 ± 55 ft-lb).

M22: 575 ± 50 Nm or (425 ± 37 ft-lb).



Note: Ride height and pinion angle may requireadjustment. See “Air Suspension, Adjustment (RideHeight and Driveline Calculation)” page 23.

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

74


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


Removal

1Support the frame (maintaining the approximate normalride height). Deflate air springs.

2

DANGER

Pneumatic components store compressed air and canseparate violently during disassembly or removal.Before servicing any part of the pneumatic (air)system, completely release the air pressure. Failure todo so can result in serious personal injury or death.

Remove air lines from air springs

3

W7000719

Note: Remove the upper mounting nut and bottom nut.

4Remove the air spring from chassis.

5Remove the fitting from air spring.

75


Installation

6Install fitting in the air spring

7Install air spring back onto the frame and 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)

9

CAUTION

Over-tightening will damage air spring.

Tighten lower nut as follows:

M12: 50 ± 10 Nm (37 ± 7.5 ft-lb).

10Install air lines into the air springs.

11Start engine to build pressure to inflate the airsuspension. Remove supports from frame

12Check ride height (see “Air Suspension, Adjustment (RideHeight and Driveline Calculation)” page 23).

Suspension Dump Switch, ReplacementYou must read and understand the precautions andguidelines in Service Information, group 70, "GeneralSafety Practices" before performing this procedure.If you are not properly trained and certified in thisprocedure, ask your supervisor for training beforeyou perform it.

For the suspension dump switch replacement procedurerefer to the “Electrical General Manual”.

6559-05-02-01Tandem Alignment, Adjustment


76


Rear Tandem Alignment Adjustment1

W7001361

1. Adjusting Washers

Loosen the M22 fastener on the left side that secures theadjusting washers for the rear tandem.

2

W7001360

Using the tandem alignment adjustment tool 85107240,move the adjusting washers to square the rear tandem tothe front tandem.

85107240

3Secure the M22 fastener and torque to 575 ± 75 Nm(424 ± 55 ft-lb).

575 ± 75 Nm (424 ± 55 ft-lb)

4Recheck the adjustment using tandem axle calipersJ36795.

J36795

Front to Rear Tandem Alignment Check1Pull the unit straight into the bay on a level surface and letthe unit roll to a stopped position, if possible (Do not applyparking brake). Chock the front steer tires.

2Using the tandem axle calipers, check the spacingbetween the front and rear tandem on the left side.Lock the calipers in place.

77


3Check the spacing on the right side to ensure that thedistance is the same on both sides.

Note: If alignment is within specifications, no furtherrepair is necessary.

Front Tandem Alignment Adjustment1

W7001361

1. Adjusting Washers

Loosen the M22 fastener on the left side that secures theadjusting washers for the rear tandem.

2

W7001360

With assistance in watching for the string to makecontact with both sides of the tire, move the adjustingwashers using the tandem alignment adjustment tool85107240, move the adjusting washers to square tandemto the frame.

Note: Check both sides for correct settings.

85107240

78


3Secure the M22 fastener and torque to 575 ± 75 Nm(424 ± 55 ft-lb)

575 ± 75 Nm (424 ± 55 ft-lb)

4With assistance, measure both sides for proper alignment.

Front Tandem Alignment Check1Pull the unit straight into the bay on a level surface and letthe unit roll to a stopped position, if possible (Do not applyparking brake). Chock the front steer tires.

2Connect a sturdy string to the left rear spring or hanger.Stretch the string around the outside of the front tandemtire at an approximate 3 o’clock position.

3With assistance in watching for the string to makecontact with both sides of the tire, measure from theframe to the string.

4Connect a sturdy string to the right rear spring or hanger.Stretch the string around the outside of the front tandemtire at an approximate 3 o’clock position.

5With assistance in watching for the string to makecontact with both sides of the tire, measure from theframe to the string.

Note: If alignment is within specifications, no furtherrepair is necessary.

79


7113-01-01-01Permanent Fastener, Removal


The fasteners used on the VOAS 1.5 suspension aredesigned to be permanent, helping to maintain aconsistent tight clamp. An installed fastener has a collarthat is cold-worked or “swagged” over the grooved pin.No amount of twisting or hammering will dislodge the pinfrom the collar. The collar must be cut longitudinally tothe extent of the swagged section. This may best beaccomplished with a small wheel grinder. Other optionsmay be to use a drill or chisel to create openings on thecollar wall.

W7001273

Fig. 2: Optional collar removal procedures

CAUTION

HUCKBOLT® Permanent Fasteners are clamped ata very high torque and they may release suddenly.Wear proper eye protection and keep your face atleast two feet away from the collar. Do not use acutting torch for removal.

1

W7001275

2 Swagged Section

Using a wheel grinder (preferred method) cut a longitudalgroove into the “swagged” section of the HUCKBOLT®

collar on two or more sides.

2

W7001274

After the collar has been opened over the length of theswagged portion on two or more opposing sides, thepin may become free. If not, additional collar materialneeds to be pulled away from the swagged section of thecollar using vice grips or a chisel.

80


3

W7001276

Remove the pin after sufficient material has been pulledaway from the swagged section of the collar.

Note: Any fastener that is removed should be replacedwith a fastener of equal or greater strength.

81

DOperation Numbers

7281-05-02-01 Air Suspension, Adjustment (Ride Height and Driveline Calculation) ...................................................... 23

7214-05-02-01 U-bolt Torque, Adjustment ........................................................................................................................ 34

7641-05-02-01 Load Leveling Valve, Adjustment ............................................................................................................. 38

7641-03-02-01 Load Leveling Valve, Replacement .......................................................................................................... 41

7647-03-02-01 Leveling Rod, Replacement ..................................................................................................................... 45

7262-03-02-03 Crossbeam (Pedestal), Replacement ...................................................................................................... 46

7224-03-02-03 Z-Spring, Replacement ............................................................................................................................ 48

7224-03-02-02 Radius Leaf Spring, Replacement ........................................................................................................... 52

6521-03-02-04 Torque Rod, Replacement ....................................................................................................................... 56

6529-03-02-02 Torque Rod Frame Rail Bracket, Replacement ........................................................................................ 58

7114-03-02-04 Spring Hanger, Drive Axle, Replacement ................................................................................................ 58

7269-03-02-06 Wear Plate (Pad), Replacement .............................................................................................................. 62

7614-03-02-06 Rear Suspension Shock Absorber Bracket, Replacement ....................................................................... 64

7612-03-02-01 Rear Suspension Shock Absorber, Replacement (One) .......................................................................... 66

7222-03-02-06 Top Plate, Replacement ........................................................................................................................... 67

7222-03-02-08 Bottom Plate, Replacement ..................................................................................................................... 70

7222-03-02-05 Axle Seat, Replacement .......................................................................................................................... 73

7261-03-02-03 Rear Suspension Air Spring, Replacement ............................................................................................. 75

6559-05-02-01 Tandem Alignment, Adjustment ............................................................................................................... 76

7113-01-01-01 Permanent Fastener, Removal ................................................................................................................. 80

D

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

Volvo Trucks Canada, Ltd.5600A Cancross Court, Mississauga, Ontario L5R 3E9

http://www.volvotrucks.volvo.com

PV776-20176793 (1000) 06.2006 © Volvo Trucks North America, Inc., 2006

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