1982 VOLVO 940 Service Repair Manual

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70019401960 Specifications
Section
4 Power Transmission
Tig ht enin g to rqu es
Nm ftlb
Drive plate-torque converter M 8 ................ .............. . 17-27 12-20
M10x 1.25 ......... .............. . 41-50 30-36
Torque converter -engine, M 10 .............................. . 35--50 25--36
M12 ........................ ...... . 55--90 40-65
Valve body -transmission gearcase ....................... .... . 7-9 5--6.5
Plate above parking detent ............ ............ ........... . 9--11 6.5--8 .0
Rear case -gearcase .............................. ......... . 20-26 14-19
Strainer - valve body -gearcase ................ ............ . . 7- 9
5--6.5
Governor -balance -pawl .......... ......................... . 9--11 6.5--8.0
Oil pump -separator plate .................. ................ . . 9--11 6.5--8 .0
B 4 cylinder -gearcase ...................................... . 9--11 6.5--8 .0
Plug -separator plate, M 14 .................................. . 34-46 25--33
M20 ....... ................ ...... ..... . 43- 57
31-41
Torque converter casing -separator plate -gearcase ........... . 40-52 29-38
Oil pan -gearcase .......................................... . 7-9 5--6.5
Drive plate -output shaft .................................... . 85--115 61-83
Blind plug, oil pan .................... ................. ...... . 13-17 9--12
Oil filler tube -oil pan ....................................... . 85--115 61-83
Group 45 Propeller shaft
/'
Tightening torque, flange bolts,
steel
joint M 8 ....................... ...... ..............•..
M10 ......................... .. ................ .
rubber joint ...................................... ......... . *Use service kit 9122130-9, socket 9995381 -2
ikd@
1 39 137
30 Nm (22 ft Ibs) + angle-tighten 60°*
50 Nm (36 ft Ibs)
80 Nm (58 ft Ibs)
Group 46 Rear axle
Rear axle , 740 , 760* , 780 -1987, 940 , 965
Reduction ratio ...................................... ....... . 3 .31:1, 3.54:1 , 3.73:1, 3 .91:1, 4 .10 :1 Axial throw, crown wheel ..................................... . Max 0.08 mm Max . 0.003 in Backlash ... ................................................ . 0 .12-0.18 mm 0 .004-0.007 in Preload torque, pinion bearings, new .......................... . 2.5--3.5 Nm 1.8-2.5 Ibs used ...... ... ................ . 1.8-3.4 Nm 1.3-2.5 Ibs
Preload, differential bearings ................................. . 0 .05--0 .08 mm 0.0019-0 .0032 in Clearance , speedometer sensor -pulse wheel .... .. ........... . 0 .5--1.2 mm 0 .020-0.047 in Radial runout outer diameter, pulse wheel ........ : .. : ......... . Max . 0.3 mm Max . 0.0118 in Lubricant ....... . ........................................... .
See page 9
*1988--only 5- doors.
151
III 1 .... 1 III ·111 III ·111 III ·111

70019401960 Specifications
Section
4 Power Transmission
Tightening torqu es
Pinion drive flange, pinion with spacer .......... ........ ....... .
pinion with compression
sleeve ' ............ .
Differential bearing caps .............................. ...... . .
Crown
wheel " .. ............................ .......... ...... .
Wheel nuts ...... ............................... .. .......... .
Lock nut -speedometer sensor .
............................. .
• Do not exceed specified torque .. Use new bolts.
I Final drive 760 /780 4-door 1988-, 960
Reduction ratio ................................... .......... .
Axial throw , crown wheel ..................................... .
Backlash ............... .................................... .
Pinion bearing
preload , new .................................. .
old ........ .. ..... .................... .
Differential bearing, preload .................................. .
Clearance , speedometer' -impulse wheel ....... ............... .
Radial throw , outer diameter, impulse wheel ....... ............. .
Lubricant.
..... ............................................. .
T ightening torque s
='.. Coupling flange -pinion (nut) ................................ .
Crown
wheel -differential housing bolt + 60 deg . angle-tightening.
Wheel nuts .. ............................. .................. .
Impulse sender -rear casing (bolt) ............................ .
Rear casing -
final drive (bolt) ................................ .
Side bracket -final drive (bolt) ............................... .
Lock washer -adjustment nut
(bolt) ........................... .
Balance weight -final drive (bolt) ............................. .
Oil drain plug ............................................... .
Oil filler plug ................................................ .
Drive shaft
bolts (+900 angle tightening) ....................... .
Drive shaft nuts,
(+600 angle tightening) ............... ........ .
152
Nm ttlb
200-250 147-185
180-280 130-207
45-60 33-44
90-110 66-81
85 63
25-40 18-29
3.54:1, 3.73:1, 3.91:1
Max 0.08 mm (0.0032 in)
0.1-0. 16 mm (0.04--0 .006 in)
1.2-2.8 Nm (0.87 -2.0 ft Ib)
1.0-2.5 Nm (0.72-1 .8 ft Ib)
1 + 1 notches on each side
0.35-0.75 mm (0.014--0.030 in)
Max.
0.2 mm (0. 008 in)
See page 9
Nm
180-280
35
85
8-12
20-28
40-56
40-56
20-28
27-40
27-40
30
140
ftlb
(133-207)
(26)
(63)
(6-9)
(14--20)
(29-40)
(29-40)
(14--20)
(20-29)
(20-29)
(22)
(103)

70019401960 Specifications
Section
5 Brakes
Section 5 Brakes
fJy ~~
132426
B rake fluid
Grade................................... .... ... ............ DOT 4
Fron t wheel brakes
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Brake disc, outer diameter, .. .................... .. .... mm (in)
thickness new
............................ . mm (in)
change at
........ ........... .............. mm (in)
Alt I Alt" Alt III Alt IV
! non -
ve ntil ated
ve ntilat ed ventilated
ventil ated
('Jumbo')
I
280 (11.0) 287 (11.3) 262 (10.3) 280 (11.0)
14 (0.55)
22 (0.87)
22 (0.87) 26 (1.02)
11.0 (0.43) 20.0 (0.79) 20 .0 (0. 79) 23.0 (0.91)
run-out -1987 ... ....... .. ................. mm (in)
max 0.08 (0.003)
1988-.................. ........... mm (in)
Brake pad thickness, new .
............................ mm (in)
min
.... ............ ........... ... mm (in) max
0
.06 (0.0024)
I 11.5 (0.453)
('Jumbo' 12.0 (0.472)
3
(0. 12)
Rear wheel brakes
Sta ndard Multi -link
Brake disc, outer diameter ....... ...................... mm (in) 281 (11.06)
265 (11.04)
thickness, new ............................. mm (in)
change at
............... ........ mm (in)
runout .
...................... ............. mm (in)
Brake pad thickness , new .
..... ....... ............... . mm (in) 9
.6 (0.378)
10 (0.393)
I
min 8.4 (0.330) 8 (0.314)
max
0.10 (0.0039)
0.08 (0.003)
10
(0. 393)
8 (0.314)
min ............ .................. mm (in)
2 (0.078) 2 (0.078)
T ight enin g torque s
Nm ftlbs
Attaching , bolts , front brake calipers ........................... . 100 (74)
rear brake calipers ............................ .
58 (43)
caliper bracket ....................... ....... . .
48 (35)
front dust
shield .................... ... (approx .)
24 (18)
rear dust
shield ................ ....... (approx.)
brake
caliper, slide pin ................... ..... .
40 (29)
"I 34
(25) II Wheel nuts ................................................. .
85 (63) II II Attaching nuts, master cylinder ..... ................... (approx.) 30 (22) II II Bleeder screws, front ......................... ........ (approx .)
5 (4) II ·11 rear ...... .......... ................. (approx .)
4.5 (3.3) II
Brake pipe unions ...... .......... ............ ............... .
14 (10) Brake hoses to nipple ....................................... .
17 (12)
Nipple to caliper ......... ................................... .
17 (12)
153

70019401960 Specifications
Section
5 Brakes
Parking brake
123427
Brake drums, radial runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max 0.15 mm
out of round . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max
0.2 mm
Full braking effect after adjusting at . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 notches
when checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max
11 notches
154 max
0.0059 in
max 0.0078 in
-r

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70019401960 Specifications
Section
6 Suspension and steering
Section 6 Front end and steering
Group 60 Wheel alignment
(Empty vehicle)
Front wheel alignment
Caster ..................................................... 4.5-5.5°
Cambe r*
... ................................... ........ ..... -0.2 -+0.8 °
• Difference between left and right-hand locks must not exceed o.r.
Toe-in
All variant s*
Angle (2 (X) A-a 8-b C-c
18'±8' 3.2±1
.3 mm 2.3±1.2 mm 2 .1 ±0.9 mm
0 .12±0.05 in 0.0 .9±0.05 in 0.08±0.04 in .-
• In order to simplify workshop routines, the same values apply to all 740/940/960 models from 1982. Older values may still be
found in some manuals and are not incorrect, though now sup­planted by these newer values.
All measurements to be carried out on an empty vehicle. Dimensions are noted at hub height in the form of an angular
measurement a or as the difference in mm between the front and rear edges of the wheels at points A, B or C (the tire tread,
shoulder and wheel rim edge respective ly).
Ball joints
Max axial play with normally loaded front end, 3 mm
(0.12 in)
Max radial play, 0.5 mm (0.02 in).
Wheel alignment, rear wheels
(
Multi -link )
Negative Camber IfJl
'legall. umb .. 113' -1.0
;l
+
a +a ~ -0.
r;-~ -0.6
P--I I­
ii I-i . IT -'. ! . -.1-Un k arm angle (n)
-0
-0
.
Un k a~ angle (a)
-4 -'.-3 "';-2 1 +i +2 + +4 1-
-~~ u ~ 1"'--H---. 1-i-J:-L
_. f-L -\-;-_1_ i-'-1.L?.4 h-
"Lllft~~~~
L.l. f:l+ ~:; +fJ~ .
: I : . : . ill I I I I I m t I " " "! i _ J . ,. . I Positive Camber I~) H 1-1 I I II II ~ t ,I. L LLLu....L1 143 720
Camber
Diagram shows correct Camber (fj) in relation to position of
lower links (a).
Examp le: angle of lower link is +2°, correct Camber is
0 .05 ° (negative Camber). Tolerance = ±0.25°.
143721
155
·ltl III ·ltl It •. ·ltl III ·ltl 'It ·It '

70019401960 Specifications
Section
6 Suspension and steering
A
Toe-in
Meas ured as ang le
Toe -in ( ----------.-.--..---Spec ificat ion
Toe-in measurement (B-A) should be is 0.5±0.8 mm, mea ­
sured at C, see left.
Note: Camber must always be adjusted before Toe-in.
Toe-in tolerance
B 143 724
Measure Toe-in of unladen vehicle, according to above .
Apply sufficient load to obtain a lower link angle of 8°± 1 o .
Repeat Toe-in measurement and compare results.
Max. difference = 3' per wheel.
-c
143723
Group 61 Front wheel suspension
Tightening torque -85 Nm (63 ft. Ib)
95 Nm (70 ft Ib)
~~-.'"
~~======~~C r~M12: 85 Nm (63 ft Ib) ~:./ M 14: 140 Nm (102 ft Ib)
135 398
Nm ft Ib
Control arm to ball joint , nut .................................. . 60 44
Ball joint to spring strut + 1/4 turn .............. ................ . 30 22
Steering rod to steering arm .......................... (approx.) 60 44
Upper bearing -body ............................... (approx.) 40 29
Upper bearing -shock absorber, -1984 ............... (approx .) 150 111
1985- .... ........... (approx.) 70 50
Front crossmember to body. . . . . . . . . . . . . . . . . . . . . . . . . . (approx.) 95 70
Whee l nuts ......... .. ................................ .. ... . . 85 63
Front wheel hub -stub axle +450 angle -tightening
nut
(1988-models) ................................. . ....... . 100 74
156
143 722

(
70019401960 Specifications
Section 6 Suspension and steering
Group 64 Steering
Steeri ng gear
Cam gear
Numbers of turns, lock to lock ...................... .......... .
Steering ratio .
.............................................. .
Clearance between pre-tensioning piston and cover ............. .
Frictional torque, measured on input shaft ...................... .
Checking servo
balance:
pump pressure when measuring steering wheel torque ........ .
torque
on steering wheel . ............................. ..... .
max deviation between right and
left locks ................... .
Lubrication, type
............................................ .
quantity .
........................................ .
Hydraulic fluid ..... .... ..................................... .
/
ZF
Numbers of turns, lock to lock ................................ .
Steering ratio
............................................... .
Clearance between pre-tensioning piston and cover ............. .
Frictional torque, measured on input shafl. ..................... .
Checking servo
balance:
pump pressure when measuring steering wheel torque ........ .
torque un steering
wheel ................................... .
max deviation between right and
left locks ................... .
Lubrication, type
............................................ .
quantity
........................... .............. .
Hydraulic fluid .............................................. .
Servo pump
132 430 136 000
A B
Max
pressure, early type (A, B,C) ............................ . .
late type of "C" ....... .... ..................... .
type
"0" ................... .... 0-' .•• •••••.••...
960 , B 6304 F ................................. .
132429
3 .5
16.9:1
0.0~.12 mm
0.6-1.7 Nm
0 .0019-0.0047 in
5.3 in. lb.
1.2 MPa 171 psi
3 .5-4.5 Nm 31-40 in. lb.
1 Nm 9 in. lb.
Grease, Volvo PIN 1161001-1
100
grams
See page 14
3.5 16.9:1
0.025-0.05 mm
0.6-2.1 Nm
0.0010-0.0020
0.4-1.5 ft Ib
1.2 MPa 171 psi
3.4-4.5 Nm 31-40 in lb .
1 Nm 0.7 ft Ib
Grease Volvo PIN 1 161 001-1
100
grams
See page 14
C
7 .6-8.3 MPa
9 .3-10.0 MPa
10 .0-11.0 MPa
9.3-10.0 MPa
D
1081-1180 psi
1323-1422 psi
1422-1564 psi
1323-1422 psi
157
I

70019401960 Specificatidns
Section
6 Rear wheel suspension
Tightening torques
Nm ftlb
Steering column 760 1988-............................. .. ... .
24 17
Steering wheel nut .
........ ................................. . 34
25
Steering column, universal joints
.............................. .
24 17
Steering gear -
cr 44 32
Steering
rod - outer ' ball joints ........................ (approx .) 70 52
Steering arm -outer
ball joints ........................ (approx.) 60 44
Group 65 Rear wheel suspens ion
Tightening torques (Multi-link)
Nm ft Ib
Link to lower , wheel beBring housing, nut +900~ngle tighten ..... . 50 37
Link to
lowen'rear axle crossmember, nut +900 angle tighten ..... . 50 37
Stud to body ................................................ .. . 70 51
Support arm mount lto body, nut +900 angle tighten ............. . 70 51
Support arm to body, bolt .................................... . 48 35
Support arm to mount, nut + 1200 angle
tighten ................. . 125 91
Support
arm to wheel bearing housing, bolt +90 angle tighten ... . 60 44
Link to upper wheel bearing housing, nut ...... ................ . 115 83
Link
to rear axle upper front crossmember, nut +600
angle tighten ............................................. . 70 51
Link to rear axle upper rear crossmember, nut .................. . 85 61
Track rod to wheel bearing housing, bolt ..................... .. . 85 61
Track rod to rear axle crossmember, nut ....................... . 70 51
Rear axle crossmember (front) to body, bolt +600 angle tighten .. . 70 51
Rear axle crossmember (rear) to body, bolt +600 angle tighten ... . 70 51
Final drive (front) to rear axle crossmember, bolt ................ . 160 116
Final drive (rear) to rear axle crossmember, bolt
................ . 160 116
Cable bracket to rear axle cross member, nut
................... . 24
17
Shock absorber to support arm, nut ........................... . 56 41
Shock absorber to body, bolt ................................. . 85 61
Wheel stud to shaft +600 angle tighten ........................ . 140 102
Wheel
bearing housing buffer, nut. ............................ . 24 17
Backplate to rear wheel bearing housing, bolt
.................. . 24
17
Brake caliper to wheel bearing housing, nut ..
.................. . 60 43
158