Service Manual Trucks · Gas cutting torch Metal grinder Welding machine Reamer (0.652 inch) 9 Group 71 Tools Special Tools The J-38460-A is a digital protractor, available from

Service ManualTrucks

Group 710–500

Frame Rails and CrossmembersVN/VHD

PV776-TSP143123

Foreword

The descriptions and service procedures contained in this manual are based on de-signs and methods studies carried out up to August 2000.

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, supplementary ser-vice 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 a refer-ence to an S.R.T. (Standard Repair Time).

Service procedures which do not include an operation number in the title are for gen-eral information and no reference is made to an S.R.T.

The following levels of observations, cautions and warnings are used in this ServiceDocumentation:

Note: Indicates a procedure, practice, or condition that must be followed in order tohave the 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 oc-cur.

Volvo Trucks North America, Inc.Greensboro, NC USA

Order number: PV776-TSP143123

© 2000 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, me-chanical, photocopying, recording or otherwise, without the prior writtenpermission of Volvo Trucks North America, Inc..

ContentsGeneral .................................................................................................... 3

Frame Rails and Crossmembers ........................................................... 3

Specifications ......................................................................................... 5Frame Rails ........................................................................................... 5

Tools ........................................................................................................ 9Standard Tools and Equipment ............................................................. 9Special Tools ....................................................................................... 10Special Equipment ............................................................................... 11

Design and Function ........................................................................... 13Frame Rails and Crossmembers ......................................................... 13

Troubleshooting ................................................................................... 35HUCK-FIT® Fastener Troubleshooting ................................................ 35

Service Procedures ............................................................................. 37Frame Rail, Replacement .................................................................... 37Frame Alignment, Checking ................................................................ 43Frame Alignment, Adjustment ............................................................. 44Intermediate Crossmember, Replacement (Rivets Under the FlameFlange) ................................................................................................. 45Intermediate Crossmember, Replacement (Bolted and ExposedRivets) .................................................................................................. 46Closing Crossmember, Replacement .................................................. 47Engine Crossmember, Replacement ................................................... 47Rear Suspension Crossmember (Bogie), Replacement ..................... 49Frame Length, Adjustment .................................................................. 51Body Bound Bolt, Installation .............................................................. 56HUCK-FIT® Fastener, Removal ........................................................... 56HUCK-FIT® Fastener, Installation ........................................................ 57

Feedback

Operation Numbers

1

2

Group 71 General

GeneralFrame Rails and Crossmembers

The information in this manual covers specifications, tools, designs, function and ser-vice procedures for VN/VHD Frame Rails and Crossmembers. This information isessential for maintenance and proper serviceability of the Frame Rails and Crossmem-bers.

3

4

Group 71 Specifications

SpecificationsFrame RailsMaterial ............................................................................................... 758.4 MPa (110,000 psi) yield heat treated steel

Distance between rails

Front ............................................................................................................................................ 1080 ± 2 mm (outside)

Rear ............................................................................................................................................................ 836 −4.6+2.7 mm

Frame rail end taper .................................................................................................................................................. 27�

Available Frame Heights and Thicknesses

Frame height Frame thickness

266 mm (VN) .................................................................................................................................... 6 mm, 7 mm, 8 mm

300 mm (VN) .............................................................................................................................................. 7 mm, 8 mm

300 mm (VHD) ........................................................................................................................... 7 mm, 8 mm, 11.1 mm

5


Bolt Hole PatternsHole spacing with Volvo T-Ride suspension .................................... 60 mm (2.26 in.) (vert) x 50 mm (1.97 in.) (horiz)

(applicable only from 1685 mm (65.2 in.) from front edge of the rail and rearward)

W7001187

A 60 mm (2.36 in.)

B 60 mm (2.36 in.)

C 60 mm (2.36 in.)

D 60 mm (2.36 in.)

E 60 mm (2.36 in.)

F 50 mm (1.97 in.)

G 43 mm (1.69 in.)

H 60 mm (2.36 in.)

I 60 mm (2.36 in.)

J 60 mm (2.36 in.)

K 43 mm (1.69 in.)

L 50 mm (1.97 in.)

Note: Hole size for this spacing must be 15.5 mm (0.61in.) long.

6


Hole Spacing With All Suspensions Except Volvo T-Ride

Front axle crossmember and forward ............................................................... 60 mm (2.26 in.) (vert) x 50 mm (horiz)

Rear of front axle crossmember ............................................................ 76.3 mm (3 in.) (vert) x 50.8mm (2 in.) (horiz)

W7001188

A 74.1 mm (2.92 in.)

B 50.8 mm (2.00 in.)

C 50.8 mm (2.00 in.)

D 50.8 mm (2.00 in.)

E 74.1 mm (2.92 in.)

F 76.0 mm (3.00 in.)

G 56.8 mm (2.24 in.)

H 50.8 mm (2.00 in.)

I 50.8 mm (2.00 in.)

J 50.8 mm (2.00 in.)

K 56.8 mm (2.24 in.)

L 76.0 mm (3.00 in.)

Note: Hole size for this spacing must be 17 mm (0.66in.) long.

7


Tightening Torques, Frame Rail Bolts(for property class 10.9 bolts and property class 10 nuts)

Bolt Size Torque

M6 ........................................................................................................................... 12 ± 2 Nm (9 ± 1.5 ft-lb)

M7 ........................................................................................................................... 22 ± 3 Nm (16 ± 3 ft-lb)

M8 ........................................................................................................................... 30 ± 5 Nm (22 ± 4 ft-lb)

M10 ......................................................................................................................... 60 ± 10 Nm (44 ± 7 ft-lb)

M12 (bolts crossmembers together) ...................................................................... 105 ± 20 Nm (78 ± 13 ft-lb)

M14 (bolts crossmembers to frame) ...................................................................... 200 ± 33 Nm (148 ± 24 ft-lb)

M16 (bolts crossmembers to frame) ...................................................................... 275 ± 45 Nm (204 ± 34 ft-lb)

M18 ......................................................................................................................... 360 ± 55 Nm (267 ± 44 ft-lb)

M20 (bolts cab mounts to frame) ........................................................................... 540 ± 90 Nm (400 ± 67 ft-lb)

M22 ......................................................................................................................... 730 ± 120 Nm (541 ± 90 ft-lb)

M24 ......................................................................................................................... 900 ± 140 Nm (667 ± 111 ft-lb)

Proper frame bolt thread engagement ........................................................ Max. 13 mm past nut, min. two (2) threads

8

Group 71 Tools

ToolsStandard Tools and Equipment

All listed tools and equipment are not required for each service procedure. Review theservice procedure to be performed to determine which tools and equipment will be re-quired.

Torque wrenchTape measureC-clampsDrift pinsHammerMetal sawGas cutting torchMetal grinderWelding machineReamer (0.652 inch)

9

Group 71 Tools

Special ToolsThe J-38460-A is a digital protractor, available fromKent-Moore (telephone: 800–328–6657.)

W7000708

The J-44771 Frame Rail Guide Support is available fromKent Moore (telephone: 800–328–6657.)

W7001140

10

Group 71 Tools

Special Equipment

The following special equipment may be required forwork on the frame rails and crossmembers. This equip-ment can be ordered from your manufacturer.

W0000397

The HUCK® Manufacturing 940INTRKTV tool kit is avail-able from your local HUCK® distributor and consists of:

1 Nose assembly 99-1481 – This nose assembly isdesigned for use with the 16 mm (5/8”) fastener andattaches to the model 585 hydraulic installation tool.

2 Model 585 hydraulic installation tool – This hand-held tool has a 3.5 m (12 ft.) hose assembly that is

attached to the model 940 POWERIG® hydraulicunit.

3 Model 940 POWERIG® hydraulic unit – Thisportable 110V electric power unit provides hydraulicfluid under pressure to the model 585 hydraulic in-stallation tool. (This tool is also available in 220V.)

11

Group 71 Tools

The Digital Angle Gauge. The Anglemaster is a digitalinclinometer, available from Dana-Spicer (telephone:419–535–4300.)

Drill with Magnetic base.

W0001876

Plumb Bob.

W0001877

Threaded rods, 1/2 in. diameter, 1200 mm (48 in.) long(2 required) with 12 nut.

W0001878

12

Group 71 Design and Function

Design and FunctionFrame Rails and Crossmembers

The frame for the VN/VHD series has frame sidememberdesigns for vehicles produced by Volvo Trucks NorthAmerica. The designs include two sidemember heights,three sidemember thicknesses, and a flared shape.

The frame height is constant for the entire length of therail. The rail height is either 266 mm, called the Low Pro-file frame, or 300 mm, called the High Profile frame. Thelow profile frame may have a thickness of either 6 mm, 7mm, 8 mm or 11.1 mm. The high profile height framemay a have thickness of 7 mm, 8 mm or 11.1 mm(VHD). The rails of the frame are separated at the frontedge a distance of 1080 mm (outside edges). From aposition just rearward of the front engine crossmemberto a position just forward of the rear engine crossmem-ber the rails are tapered closer together. From that point

to the rear edge, the distance is 836 mm (inside edges).

Note: Frame dimensions are specified in millimeters dueto design. To obtain the approximate dimension ininches, multiply mm by 0.03937.

Because the frame rails are made of a high strengthheat-treated steel, only the frame modifications detailedin this information are permitted, in order to ensure thatthe structural integrity of the rails is maintained.

In conjunction with the new frame design, the allowablebolt hole patterns in the frame web are specified andmust be strictly followed.

W7001181

V 1080 mm (42.5 in.)

W 836 mm (32.9 in.)

X 266 mm (10.48 in.)

Y 300 mm (11.82 in.)

13


W7001180

VN/VHD Frame rails with crossmembers:

1 Axle Forward with extension (VHD)2 Axle Back with extension (VHD)3 VN4 Axle Forward (VHD)5 Axle Back (VHD)

The frame consists of two steel side rails joined by sev-eral crossmembers. The frame for the VN/VHD seriesmodels is made in a variety of configurations to allowflexibility in adapting the frame for different transport re-quirements.

See the following design information:

• “Side Members” page 15

• “Crossmembers” page 17

• “Mountings and Brackets” page 24

• “Fasteners” page 25

• “Frame Material Behavior” page 26

14


Side MembersThe side members, or frame rails, are constructed of 760MPA (110,000 psi) yield heat treated steel. There areseveral combinations of side member height and thick-nesses. The smaller height, referred to as the Low Profileframe, has a web height of 266 mm, and may be either 6mm, 7 mm, 8 mm or 11.1 mm (VHD) thick. The largerheight, referred to as the High Profile frame, has a heightof 300 mm and may be either 7 mm or 8 mm thick.

W7001182

X 266 mm (10.48 in.)

Y 300 mm (11.82 in.)

These combinations of height and thickness provide forthe variety of load and usage characteristics necessaryto meet the hauling requirements of nearly any tractor.The flange width is a constant 90 mm for all combina-tions of web height and thickness.

Unlike previous frame designs, the side members arenot an equal distance apart for their entire length. Whenviewed from the side, the side members appear straight.Viewed from above, the frame rails are flared outwardfrom a point just forward of the rear engine crossmem-ber. This design provides for increased lateral, vertical,and torsional stiffness. The result is improved vehicleintegrity, handling, accident avoidance, and collision en-ergy absorption. Widening the frame at the front alsominimizes the need for cut outs in the frame flange toadapt the side members to various vendor engines.

Regardless of the frame rail height, thickness, andlength, the basic frame design and dimensions are thesame. The front rail separation is 1080 mm, as mea-sured from the outside of the frame rails, because thefront crossmember bolts to the outside of the rails. Theseparation at the rear end is 836 mm, as measured fromthe inside, because the closing crossmember is boltedbetween the rails. The separation is a constant 836 mmat a point 1635 mm from the front.

W7001183

X 1080 mm (42.5 in.)

Y 836 mm (32.9 in.)

15


A standard hole pattern is designated for the frame railweb. For vehicles with a complete Volvo T-Ride suspen-sion, the hole pattern is 60 mm vertically between holesand 50 mm horizontally. These dimensions apply to theweb behind the rear bend and forward of the rearmostsuspension component for the rear axles. For vehicleswith other than Volvo T-Ride suspension, the pattern is60 mm vertically and 50 mm horizontally from behind theforward spring hanger to the intermediate crossmember,and 3 in. vertically by 2 in. horizontally from the frontaxle crossmember to the rearmost suspension compo-nent for the rear axles. See “Bolt Hole Patterns” page 6.

The rear end of the frame is either cut straight or is ta-pered at a 27 degree angle. There are three differentclosing crossmembers to accompany the style of frametermination.

W7000378

Tapered frame end with tapered closing crossmem-ber

W7000379

Straight frame end with splay closing crossmember

W7001005

VHD frame with closing crossmember

16


Crossmembers

W7001043

VN Frame and Crossmember

1 Front Crossmember

2 Front Engine Crossmember

3 Rear Engine Crossmember

4 Transmission Crossmember

5 Intermediate Crossmember

6 Front-of-Axle Crossmember

7 Rear Suspension Crossmembers

8 Closing Crossmember

9 Rear Engine Support Brackets

10, 11 Front Spring Hanger

12, 13 Bumper Mounting Bracket

17


W7001008

VHD Frame and Crossmember

1 Front Crossmember

2 Front Engine Crossmember

3 Rear Engine Crossmember

4 Transmission Crossmember

5 Intermediate Crossmember

6 Front-of-Axle Crossmember

7 Rear Suspension Crossmembers

8 Closing Crossmember

9 Rear Engine Support Brackets

10, 11 Front Spring Hanger

12, 13 Bumper Mounting Bracket

18


The crossmembers provide a high degree of torsionalstiffness to the frame. They allow the vehicle to handlethe side forces caused by turns and uneven road condi-tions. Improved crossmember design and positioning forthe VN/VHD series models has resulted in reducedweight, enhanced frame stability, improved truck han-dling, and reduced noise and vibration.

The crossmember components are to be treated as aunit. Each consists of a beam and end plates. Wherebeams and end plates are riveted together, they mustnot be separated. If replacement is necessary, the re-placement beams must be cut in the center and weldedtogether after the end plates have been mounted to theframe rails. The front engine crossmember is an excep-tion to this, in which case, the rivets are replaced bybody bound bolts.

Note: The numbers in the crossmember descriptionsthat follow refer to the numbers on the frame and cross-member diagram at the beginning of the Crossmemberssubsection.

Front CrossmemberThe front crossmember connects the front ends of theside rails. It is 4 mm thick and has large holes to allowmaximum air flow to the radiator and charge air cooler. Itis physically bolted to the front crossmember and bumpermounting brackets, which are bolted to the side rails.

W7000376

Fig. 1: VN

19


Front Engine CrossmemberThe second crossmember is the front engine crossmem-ber. It is riveted to the front spring hangers, which arebolted to the side members. It is designed to support theforward end of the front suspension and the front enginemount, which is a single point suspension at the centerof the crossmember. The crossmember is universal inthat it can accommodate engines made by Volvo or byother manufacturers. This crossmember is simply rotated180� from the Volvo engine position to adapt to othervendor engines.

Unique brackets have been designed for fitting eachvendor engine to the VN/VHD series engine mounts. Be-cause the second crossmember coincides with thespring hangers, it provides support against side-bendingforces generated by driving in curves. W0001879

Fig. 2: VHD

Rear Engine CrossmemberThe next crossmember is the rear engine crossmember.It is supported by the rear engine support brackets andprovides support against side loads that occur during ve-hicle turning. This crossmember is attached to the rearengine mounting brackets. If the vehicle is equipped witha Volvo transmission, the brackets are bolted to the en-gine flywheel housing. For vendor transmissions, thebrackets are bolted to the clutch housing.

Transmission CrossmemberThe transmission crossmember is the first crossmemberrear of the transmission. The stiffness of this crossmem-ber is improved over earlier models due to widerend-plate attachment flanges. Its higher placement onthe frame provides greater structural strength. It is posi-tioned so that there is sufficient prop-shaft clearancewithout having to bend the crossmember.

The rivets that connect the beam to the end plates onthis crossmember are covered by the frame flange andare not accessible.

20


Intermediate CrossmemberThe intermediate crossmember functions as the anchor-age for the prop-shaft center bearing mounting inaddition to its normal function. Longer wheelbase vehi-cles may have one or two additional intermediatecrossmembers installed.

Note: Removal of the transmission and intermediatecrossmembers requires cutting the old crossmember inhalf and unbolting the end plates from the frame. Instal-lation requires cutting the new crossmember in half,bolting the halves in place, and welding them together.

CAUTION

Possible material failure. The quality of the weld on areplacement crossmember is important to the struc-tural strength of the crossmember. All crossmemberwelding must be performed by a certified welder toguarantee the integrity of the crossmember. Failure toproperly perform the weld could result in failure of thecrossmember.

Front-of-Axle CrossmemberThe front-of-axle crossmember exists mainly to providesupport for the suspension system. This particular cross-member is used on vehicles equipped with the VolvoOptimized Air Suspension (VOAS) and the four–springleaf spring suspension. An aluminum front axle cross-member is available for reduced weight.

W7000374

21


Rear Suspension CrossmemberThere are a variety of rear suspension crossmembersdesigned to accompany the axle suspension systemsthey support. Because of the higher stresses and load-ing taken up at the rear suspension, this crossmemberhas larger flanges than the other crossmembers.

The rear suspension crossmembers shown at right arefor 4x2 tractor with leaf springs or air ride (top), 6x4 trac-tor with leaf springs or Volvo Optimized Air Suspension(middle), and 6x4 tractor with T-Ride (bottom).

W7000419

W0001880

22


Closing CrossmemberThe closing crossmember keeps the separation of theframe rail ends fixed at 836 mm. The frame rail ends areeither tapered at a 27 degree angle, or are cut straight.There is a crossmember designed for each of theseconditions.

W7000375

Fig. 3: Closing Crossmember

W7001010

Fig. 4: Closing Crossmember with tow hook

23


Mountings and BracketsThe engine mounting system consists of brackets con-structed of ductile iron castings and rubber cushionisolators. With Volvo transmissions, the rear mount at-taches to the engine flywheel housing. The rear mountsattach to the clutch housing on all vendor transmissions.

Various brackets have been designed to adapt the Volvoengine front isolators and cushions to vendor engines.The rubber cushions on the engine mounts are tuned toa precise vertical, longitudinal, and lateral stiffness. Thefine tuning of the mount cushions enhances truck perfor-mance by isolating engine vibrations and noise from thechassis cab. These cushions have the ability to dampenforces caused by frame distortion when driving off roador on poor roads. The front and rear cushions are de-signed differently to allow a higher degree of movement.

The engine mounts minimize the motion of the engine.In addition, they provide for easy service to the engine.These advantages apply to all of the engines availablewith the VN/VHD series models.

The fuel tank mountings are J-brackets that support andattach the fuel tank(s) to the chassis. Dual fuel tanks arestabilized by an additional crossover brace. They alsosupport the steps up to the cab.

24


FastenersThe crossmembers are connected to the frame rails us-ing metric flange bolts. The beams and end plates ofindividual crossmembers are either bolted to one an-other using metric flange bolts, or are riveted. Wheneverreplacement of metric flange bolts is necessary, theymust be replaced with identical hardware. In caseswhere rivets are used to connect beams and end plates,they must not be disturbed because this will affect thestructural integrity of the crossmember.

Some crossmember beams are riveted to the end plates.In cases where the rivets are accessible and must be re-moved, they should be replaced with a 16 mm bodybound bolt. These special bolts are manufactured with ashank diameter that is slightly larger than the outer di-ameter of the thread so that the load is not placed onthe threaded portion of the bolts.

To make proper use of body bound bolts, the holes thatwill be used must be reamed to a diameter of 0.79 mm(0.031 in.) larger than the thread diameter. Proper join-ing of the crossmember and end plates or brackets isaccomplished when the shank of the body bound bolt isin complete contact with the crossmember and inserts atleast 2/3 of the way into the hole in the component onthe nut side but does not extend out of the hole.

W7000383

1 Body bound bolt2 Crossmember3 Elastic stopnut4 Hardened flat washer5 End plate or spring bracket

Some components are fastened to the frame usingHUCK Spin® fasteners. If these fasteners must be re-placed, metric flange bolts of the same size should beused.

Huck fasteners can usually be removed by using an airimpact wrench.

For Description information see: “Huck-Fit® Fasteners”page 30.

For Troubleshooting and Diagnostics information see:“HUCK-FIT® Fastener Troubleshooting” page 35.

For Service Procedure information see: “HUCK-FIT®

Fastener, Removal” page 56and “HUCK-FIT® Fastener,Installation” page 57, “HUCK-FIT® Fastener, Installation”page 57.

CAUTION

Possible component damage. Never mix HUCK® Spinfasteners and flange fasteners within a hole pattern.Mixing fastener types could cause the flange bolts tocome loose.

W7000440

HUCK® Spin bolt and collar

25


Frame Material BehaviorFrame StrengthThe amount of stress that a frame rail can withstand is afunction of several factors. The most important of theseare the Section Modulus and the Yield Strength. Sec-tion Modulus is a measure of the strength of a framemember cross section. It is based on the height, thick-ness, and shape of the cross section, as well as thewidth of the flange. It does not account for the materialused in that side rail. Yield Strength is a measure of thestrength of the material used, and is measured in MPa(or psi). It is the maximum amount of force that can beapplied to the material to stretch or twist it and still haveit return to its original shape. These two factors are mul-tiplied to produce the measure of strength known asResisting Bending Moment (RBM). Generally, whenthe allowable level of RBM is exceeded, the frame willlikely experience failure. The degree of failure is relatedto how much the RBM was exceeded and the method bywhich it was exceeded.

The frame is designed to absorb the energy associatedwith stresses produced by normal operation of the vehi-cle, including the higher stresses involved in off roaduse. The frame is unlikely to experience failure as longas the conditions assumed in design are not exceeded.The failures usually occur in situations when either themaximum allowable stress levels are exceeded or themaximum levels have been reduced.

The cause of frame failures are placed into one of threeclassifications:

1 Collisions2 Excessive bending moment3 Localized stress concentration

26


Frame FailureFrame failure resulting from collision can be in the form ofcracks, bends, twists, or broken rails or crossmembers.

Excessive bending moment failures are caused by over-load, improper weight distribution, or misapplication ofthe vehicle. Excessive bending moment failure will occurat different areas on various types of vehicles. The resultwill usually be twisted or cracked frame rails.

Localized stress concentration failures may be the resultof exceeding allowable bending moment, however, bend-ing moment levels encountered during normal operationwould not be high enough to cause a failure. Incidentalto the failure is the condition of localized stress concen-tration. Possible causes for exceeding allowable bendingmoment could be high bending loads concurrent with se-vere torsional loads as may be found in off road service.Points of localized stress concentration may also be theresult of one or several of the following:

• Poor body or fifth wheel mounting• Improper special equipment or accessory installation• Improper reinforcements• Loose bolts• Defective material

Special equipment or accessory installation can causehigh stress concentration due to the method of attach-ment or the weight of the equipment. Holes should neverbe drilled through the flanges. Rapid changes of SectionModulus, which could occur during operations such asadding a large mounting plate for supporting specialequipment, should be avoided. Heavy equipmentmounted across the flanges or on the web of a side railmay produce enough stress concentration to cause fail-ure at the nearest crossmember, bracket, or other framestiffener, or through a nearby hole in the frame flange.

27


Improper reinforcement or attachment of the reinforce-ment may cause more difficulty than the originalproblem. Creation of localized stress concentrations mayreduce the frame’s load carrying capacity below its valueprior to adding reinforcements.

Frame failure may be complete failure (breakage) of theframe or partial failure (frame misalignment). The list be-low describes several of the possible frame misalignmentconditions that could be caused by exceeding bendingmoment.

Sag: Refers to a frame or side rail that is bent DOWNfrom its proper position.

Bow: Refers to a frame of side rail that is bent UP fromits proper position.

Diamond: Refers to a condition in which one entire siderail is moved forward or rearward of its correct alignmentin relation to the other side rail.

Twist: Refers to a condition where the entire frame hasbeen twisted. One rail appears to slope upward and theother appears to slope down.

Sidesway: Refers to a side rail that is bent inward oroutward of its proper position from the other rail.

28


Minimizing Frame FailureThe potential for frame failures can be reduced or elimi-nated by operating the vehicle within the design limitsand not creating areas of local stress concentration. Ob-servance of the following guidelines will greatly minimizethe chances of frame failure.

Vehicles should only be used for the purposes for whichthey were designed.

1 Avoid overloading vehicles.

2 Load vehicles evenly; avoid localized overloading.

3 Dump trucks should never be used to spread loads.

4 Tank trucks should have baffles.

5 Avoid excessive fifth wheel positions.

6 Avoid vehicle operation on extremely rough terrain.

Note: Only the following repairs/modifications are per-mitted on the VN/VHD series frame.• Drilling holes for the attachment of equipment in ac-

cordance with the specified hole pattern.• Cutting the frame to shorten it (never attempt to

lengthen the frame).• Welding is only permitted on the riveted type cross-

members for replacement and on the frame railends to shorten them.

Observe the following recommendations when altering aframe rail.

1 Avoid abrupt changes in section modulus.

2 Never drill holes in frame rail flanges.

3 Ensure holes drilled in the frame rail web arespaced according to the hole pattern specifications.

4 Use existing holes whenever possible.

5 Do not cut holes with a torch.

6 Do not cut notches in the rails.

7 Do not use rivets for attaching equipment throughholes in the frame. Always use a proper size Class10.9 tighten flange bolts and Class 10 nut.

8 Welding should only be performed by a certifiedwelder.

29


Huck-Fit® FastenersThe HUCK-FIT® fastening system, which consists of thefastener and installation tooling, was designed to meettoday’s high-strength industrial fastening needs.

The unique tension-tension method of the Lockbolt in-stallation enables these fasteners to consistently retainmore than 95% of their initial clamp force, providing asmuch as 10–20% higher clamp force and tensile strengththan conventional threaded fasteners. The swaged collardesign resists vibration, eliminating the back-off problemencountered with threaded nuts and bolts.

The installation tooling allows easy operation and elimi-nates the need for specialized welding or tighten training.

Once the fastener is installed, visual inspection of the fullswage is sufficient to verify correct installation. This is insharp contrast to traditional threaded fasteners, for whichinstallation accuracy and inspection depend on the cali-bration of tighten equipment.

The fasteners are removable, which makes them both ex-ceptional and practical. The unique swaging action of thelockbolt collar provides very high break-loose and back-off resistance. However, with enough applied force, thecollar can be removed without cutting. Standard impact-type tighten tooling can be used to remove the collar.

W7001149

Fig. 5: Huck-Fit bolt

1 Pull Grooves2 Pin Helix3 Breakneck

Groove4 Pintail

W7001150

Fig. 6: Head Markings

1 Grip Markings2 Huck Symbol3 Property class

30


W7001151

Fig. 7: Hex Base Flange Collar

W7001152

Fig. 8: Collar Markings

1 Huck Symbol2 Property class

31


Identification

W7001147

Fig. 9: Typical Flange Bolt to Huck Bolt Crossover (Reference Grade 8 Flange)

1 S34X62278397081

2 S343X62258397060

3 S343X622839709

4 S343X62208397078

5 S343X62178397077

6 S343X6215839706

7 S343X62128397075

8 S344X62008397202 NUT

9 MHCH-R16U8075532 COLLAR

10 HUCK P/NVTNA P/N

11 MHFF-DT16 -158075528

12 MHFF -DT16 -258075529

13 MHFF-DT16 -358075530

14 MHFF-DT16 - 458075531

15 GRIP NO.

32


Volvo vehicles currently use 16 mm (5/8”) fasteners. Fas-tener selection is based on the thickness of material tobe clamped. The fasteners have a ”grip” number. Thegrip number is stamped into the head of each pin, andrepresents the midpoint of the grip range (expressed inmillimeters) for that particular pin. The 16 mm pin isavailable with a grip marking of 17. This pin has a griprange of 10–24 mm. The 16 mm pin can also be identi-fied by the raised nipple at the center of the pin head.

Grip No. mm Range (min-max)

Decimal Range (min-max)

10 5 - 15 (0.19 - 0.59)

15 10 - 20 (0.39 - 0.78)

20 15 - 25 (0.59 - 0.98)

25 20 - 30 (0.78 - 1.18)

30 25 - 35 (0.98 - 1.37)

35 30 - 40 (1.18 - .1.57)

40 35 - 45 (1.37 - 1.77)

45 40 - 50 (1.57 - 1.96)

50 45 - 55 (1.77 - 2.16)

55 50 - 60 (2.96 - .2.56)

65 60 - 70 (2.36 - 2.75)

70 65 - 75 (2.55 - 2.95)

75 70 - 80 (2.75 - 3.15)

W7001148

Fig. 10: VTNA Flange bolt-to-bolt crossover

1 Pin-Tail2 Pin-Tail

Break Area3 Collar4 Huck Bolt

33

34

Group 71 Troubleshooting

TroubleshootingHUCK-FIT® Fastener Troubleshooting

Fault Reason Remedy

Inoperative POWERIG® Check power source.

Loose or disconnected control cord Check and tighten securely.

Tool fails to operate

Loose or faulty hydraulic hose couplings Check and tighten securely, or replacefaulty couplings.

Tool operates in reverse Reversed hose connections betweenPOWERIG® and tool

Check and correct hose connections.

Tool leaks hydraulic oil Depending on where leak occurs, defectiveor worn O-rings, loose hydraulic hose con-nection at tool

Check and replace O-rings and back-up rings, or tighten hydraulic hose.

POWERIG® not operating properly. Pumpmotor rotation reversed

See POWERIG® instruction manual.Hydraulic oil overheats

Restriction in hydraulic line Check and tighten couplings, and re-place if necessary.

Low or erratic hydraulic pressure supply See POWERIG® instruction manual.

Defective or excessively worn piston O-ringin tool

Replace O-ring and back-up rings.

Tool operates erratically andfails to install fastener properly

Excessive wear or scoring of sliding sur-faces of tool parts

Check and replace defective parts.

Operator not sliding nose completely ontofastener pin-tail

Instruct operator in proper installationmethods.

Incorrect fastener length Use correct length fastener.

Worn or damaged jaw segments Check and replace jaw set.

Metal chips accumulated in pull grooves ofjaw segments

Clean jaw segments.

Pull grooves on fastener pin-tail stripped during pull stroke

Excessive sheet gap Eliminate excessive gap.

Improper tool operation See fault ”Tool operates erratically andfails to install fastener properly.”

Collar of fastener not com-pletely swaged

Scored anvil in nose Check and replace anvil.

Tool ”hangs up” on swagedcollar

Improper tool operation See fault ”Tool operates erratically andfails to install fastener properly.”

35

Group 71 Troubleshooting

Fault Reason Remedy

Pin-tail of fastener fails tobreak.

Pull grooves on fastener stripped See faults ”Tool operates erratically andfails to install fastener properly” and”Pull grooves on fastener pin-tailstripped during pull stroke.”

Jaw segments do not main-tain proper position in collet.

Improper operation of jaw follower Check spring and install correct numberof follower O-rings. Clean before re-assembling.

Hydraulic couplers leak oil. Defective or worn O-ring in coupler body Replace O-ring and back-up ring.

Pin-tail fails to eject from noseassembly.

Bent or broken pin-tail ejector Replace pin-tail ejector.

36

Group 71 Service Procedures

Service Procedures7113-03-02-01Frame Rail, Replacement

Before working on a vehicle, set the parking brakes,place the transmission in neutral, and block thewheels. Failure to do so can result in unexpectedvehicle movement and can cause serious personal in-jury or death.

Never work under or around a vehicle unless it is sup-ported on jack stands of adequate rating. Failure touse adequate jack stands can result in the vehiclefalling, which can cause serious injury or death toanyone under the vehicle.

WARNING

Fuel leaked or spilled onto hot surfaces or electricalcomponents can cause a fire. Clean up fuel spills im-mediately.

WARNING

Always wear appropriate eye protection to prevent therisk of eye injury due to contact with debris or fluids.

WARNING

Use a hoist or get assistance when lifting componentsthat weight 23 kg (50 lb) or more. Make sure all liftingdevices such as chains, hooks, or slings are in goodcondition and are of the correct capacity. Make surehooks are positioned correctly. Always use a spreaderbar when necessary. The lifting hooks MUST NOT beside loaded. Failure to follow these warnings may re-sult in personal injury.

WARNING

Before beginning any service work on any part of theair system, be certain that the air pressure has beenreleased. Failure to do so may cause a component toviolently separate, which can result in serious per-sonal injury.

Removal1Park the vehicle on a level surfacewith transmission in neutral and thefront wheels chocked. Raise the hood.

2Remove the mounting screws from thetop and bottom of the bumper.

3Remove the support rods from the leftand right sides of the bumper and re-move the bumper.

4Disconnect the headlamp and foglampconnectors and remove the hoodspring.

5Remove the hood splash shields onthe left and right sides of the hood.Disconnect the hood restraint cylin-ders.

6Remove the fasteners to the hoodpivot and remove the hood.

37


7

W7001177

1 Hoist2 Transmission Jack3 Jack stand

Support the engine and transmissionjack with a hoist and transmission jack.

8Remove the battery box cover and dis-connect the batteries.

9Remove the battery hold-down strapand remove the batteries.

10Remove the battery cable hold-downbracket to the frame rail and discon-nect the windshield wiper fluid pump.

11Disconnect the supply and return linesto the windshield washer reservoir.Remove the clamp that secures thedrain valve pull cords to the air tanks.

12Remove the air tank straps and the airtanks.

13

W7001186

1 Frame Rail Guide Support2 Air Jack Stand

Remove the battery tray mountingbolts. Remove the battery and air tanksupport brackets.

Note: Some applications may requiresupporting the rear cab suspension.

14Using tool J–44771, support the framerail being removed with jack standsand frame rail guide supports, whichare distributed equally throughout thelength of the frame rail.

Note: A minimum of three jack standsand frame rail guide supports of ade-quate rating should be used for thisprocedure.

J-44771

15Disconnect the fuel supply and returnline. Remove the fuel tank and fueltank J- brackets.

16Remove the inner fender splash shieldand the lower bracket on the side ofthe vehicle being worked on.

17Remove the fasteners to the frontclosing crossmember and the fasten-ers to the tow hook on the side of thevehicle being worked on.

18Remove the fasteners to the frontspring hanger and remove the bumpersupport bracket.

Note: Support the front engine sup-port crossmember.

38


19

W7001185

1 Jack Stand

Support the radiator with a jack stand.Remove the radiator support bracketand the lower radiator isolator mounton the side of the vehicle beingworked on.

20Remove the pitman arm from thesteering gear.

21Stabilize the steering gear and removethe fasteners that mount the steeringgear.

22Remove the front axle bump stop fromthe frame rail on the side of the vehi-cle being worked on.

23Remove the Air Conditioning line sup-port brackets inside the frame rail andremove the upper shock absorber bolt.

24Remove the steering shaft carrierbearing bracket and/or the powersteering reservoir bracket.

25Remove the rear A/C line supportbracket, the bulkhead fitting and thewheel speed sensor from the frontbrake.

26Disconnect the hood release cable andremove the hood tube mount bracket.

27Remove the ground wire and theground stud located on the frame railforward of the front cab support.

28Remove any air valves, wiring and/orair line brackets under the cab insideand outside of the frame rail.

29

W7001177

1 Hoist2 Transmission Jack3 Jack Stand

Support the front of the cab with ajack stand and remove the front cabsupport.

30Remove the lower spring pin on therear spring hanger to the front axle us-ing tool 9996791.

9996791

31Remove the rear spring hanger on thefront axle.

32Remove the transmission mountbracket and the transmission cross-member mounting bracket on theframe rail being removed.

39


33Remove the fuel cooler and/or fuel wa-ter separator.

34Remove the air dryer and/or purgetank.

35Remove all the remaining clippingbrackets from the wiring or air-line har-nesses located inside and outside ofthe frame rail.

36Remove any remaining air valves thatare mounted inside or outside theframe rail.

37Support the vertical exhaust pipe inplace, then remove the supportbracket for the exhaust.

38Support the rear suspension cross-member with a jackstand, then removethe upper shock brackets and thebump stops from the rear suspension.

39Remove all existing fasteners from therear suspension on the frame rail thatis being removed.

40Remove all existing fasteners to thecrossmembers on the frame rail beingremoved.

41

W7001179

1 Frame Rail Guide Support2 Air Jack Stand

Slide and push the frame rail back-ward, while simultaneously moving thejack stands, one after the other, to therear of the frame rail. This will ade-quately support the frame rail while itis being removed.

InstallationNote: Do not tighten fasteners until they have beenproperly installed. This will help maintain proper framealignment and will assist in obtaining proper height be-tween the frame rails.

1Slide and push the frame rail forward,while simultaneously moving the jackstands, one after the other, to the frontof the frame rail. This will adequatelysupport the frame rail while it is beingreplaced.

2Install all fasteners and crossmemberson the frame rail being replaced.

3Install fasteners from the rear suspen-sion on the frame rail that is beingreplaced.

4Install the upper shock brackets andthe bump stops to the rear suspension.

5Support the vertical exhaust pipe inplace, then install the support bracketfor the exhaust.

40


6Install the air valves to the inside andoutside of the frame rail.

7Install all clipping brackets for thewiring or air-line harnesses to the in-side and outside of the frame rail.

8Once this step is complete, go backand tighten fasteners that have beeninstalled from steps 1 through 7 as fol-lows: M14: tighten to a torque of 200 ±33 Nm (148 ± 24 ft-lb), M16: 275 ± 45Nm (204 ± 34 ft-lb).

200 ± 33 Nm(148 ± 24 ft-lb)275 ± 45 Nm(204 ± 34 ft-lb)

9Install the fuel cooler and/or fuel waterseparator.

10Install the air dryer and/or purge tank.

11Install the transmission mount bracketand the transmission crossmembermounting bracket on the frame rail be-ing replaced.

12Install the rear spring hanger on thefront axle.

13Install the lower spring pin on the rearspring hanger to the front axle using9996791.

9996791

14Install the front cab support.

15Install any air valves, wiring and/or airline brackets under the cab inside andoutside of the frame rail.

16Install the ground wire and the groundstud located on the frame rail forwardof the front cab support.

17Connect the hood release cable andinstall the hood tube mount bracket.

18Install the rear A/C line supportbracket and remove the bulkhead fit-ting and wheel speed sensor from thefront brake.

19Install the steering shaft carrier bear-ing bracket and/or the power steeringreservoir bracket.

20Install the A/C line support bracketinside the frame rail and install the up-per shock absorber bolt.

21Install the front axle bump stop to theframe rail on the side of the vehiclebeing worked on.

22Stabilize the steering gear and installthe fasteners that mount the steeringgear.

23Install the pitman arm to the steeringgear.

24

W7001185

1 Jack Stand

Install the radiator support bracket andthe lower radiator isolator mount.

41


25Install the fasteners to the front springhanger and reinstall the bumper sup-port bracket.

26Install the fasteners to the front closingcrossmember and the fasteners to thetow hook on the side of the vehicle be-ing worked on.

27Install the inner fender splash shieldand the lower splash shield supportbracket to the frame rail.

28Install the battery tray mounting fas-teners and install the battery and airtank support brackets.

29Once this step is complete, go backand tighten fasteners that have beeninstalled from steps 8 through 26, asfollows: M14: tighten to a torque of200 ± 33 Nm (148 ± 24 ft-lb), M16:275 ± 45 Nm (204 ± 34 ft-lb) and M20:540 ± 90 Nm (400 ± 67 ft-lb).

200 ± 33 Nm(148 ± 24 ft-lb)275 ± 45 Nm(204 ± 34 ft-lb)540 ± 90 Nm(400 ± 67 ft-lb)

30Install the air tank straps and the airtanks.

31Reconnect the supply and return linesto the wind shield washer reservoir.Reinstall the clamp that secures thedrain valve pull cords to the air tanks.

32Install the battery cable hold downbracket to the frame rail and reconnectthe windshield wiper fluid pump.

33Install the battery hold down strap andremove the batteries.

34Install the battery box cover and re-connect the batteries.

35Reconnect the fuel supply and returnline. Install the fuel tank and the fueltank J- brackets.

36Reinstall the engine and transmissionjack. Reinstall the hoist and transmis-sion jack.

37Check the frame alignment and makesure everything is installed and prop-erly tightened to specifications.

38Install the fasteners to the hood pivotblocks and install the hood.

39Install the hood splash shields on theleft and right sides of the hood. Con-nect the hood restraint cylinders.

40Connect the headlamp and foglampconnectors and install the hood spring.

41Install the support rods from the leftand right sides of the bumper and in-stall the bumper.

42Install the mounting screws from thetop and bottom of the bumper.

42


7113-06-02-01Frame Alignment, Checking


1

W7001183

X 1080 mm (42.5 in.)

Y 836 mm (32.9 in.)

Measure the distance between theoutside edges of the front edge of theframe rails. The dimension must be1080 ± 2 mm.

2Measure the distance between the in-side edges of the rear end of theframe rails. The dimension must be836 −4.6

+2.7 .

3Ensure the vehicle is on a level areaof the shop floor.

4Make a mark on the floor directly be-neath the front lower edge of eachframe rail, and one directly beneaththe rear lower edge of each rail.

5Move the vehicle away from the marks.

6Refer to “Frame Alignment, Adjust-ment” page 44. Measure from themark for the front of the right frame railto the rear of the left frame rail (this isdimension A).

7Measure from the mark for the front ofthe left frame rail to the rear of theright frame rail (this is dimension B).This dimension must be the same asdimension A.

8If any of the dimensions noted are notwithin tolerance, align the vehicleframe.

43


7113-05-02-03Frame Alignment, Adjustment


Total wheel vehicle alignment may be necessary. Forproper specifications for wheel vehicle alignment, referto:

ServiceBulletin

601–06Wheel Alignment Steer and Drive AxlesVN/VHD

IMPACT Function Group 601Information Type: Bulletin"Alignment Specifications and Proce-dures”.

1Ensure all crossmember mountingbolts are loose.

2Remove the front bumper and anyother obstructions to the front cross-member.

3Remove the front crossmember andthe bumper mounting brackets.

4

W7001184

X 1080 mm (42.5 in.)

Insert a 1/2 in. (12 mm) threaded rod,approximately 48 in. (1200 mm) long,through the uppermost front cross-member mounting bracket hole in oneframe rail.

5Run four nuts onto the rod so that theyare between the frame rails.

6Insert the rod through the uppermosthole in the other frame rail.

7Run a single nut onto the rod on theoutside of both rails.

8Repeat the steps for inserting athreaded rod in the lowest front cross-member mounting bracket hole.

44


9

W7001183

X 1080 mm (42.5 in.)

Y 836 mm (32.9 in.)

Adjust the position of the inner andouter nuts to set the distance betweenthe front outer edges of the frame railsto 1080 ± 2 mm.

10Tighten the nuts while ensuring thedistance between the rails remains at1080 ± 2 mm.

11Refer to “Frame Alignment, Adjust-ment” page 44. Adjust the position ofone of the rails until the crosswise di-mension is the same both ways(A = B).

12Adjust the distance between the rearend of the rails until the distance be-tween the inside edges is836 −4.6 mm

+2.7 mm .

13Re-verify all dimensions. Readjust ifnecessary.

14Tighten the mounting fasteners on allcrossmembers. See “TighteningTorques, Frame Rail Bolts” page 8.

7112-03-02-02Intermediate Crossmember, Re-placement (Rivets Under theFlame Flange)

Before working on a vehicle, set the parking brakes,place the transmission in neutral and block thewheels. Failure to do so can result in unexpectedvehicle movement and can cause serious personal in-jury or death.

Removal1Park the vehicle on a level surfacewith the transmission in neutral andthe front wheels chocked.

2Remove the closing crossmember.

3Remove the harness supports be-tween the closing and the intermediatecrossmembers.

4Remove the rear light bar.

5Remove the intermediate crossmem-ber from the vehicle by sliding it out ofthe frame rail.

Note: For intermediate crossmemberswith riveted beams, located forward ofthe rear suspension crossmembersmust be removed. See “Rear Suspen-sion Crossmember (Bogie),Replacement” page 49.

45


Installation1Install the intermediate crossmember.Tighten fasteners to a torque of 200 ±33 Nm (148 ± 24 ft-lb).

200 ± 33 Nm(148 ± 24 ft-lb)

2Install the harness supports betweenthe intermediate and the closing cross-member. Tighten fasteners to a torqueof 200 ± 33 Nm (148 ± 24 ft-lb).

200 ± 33 Nm(148 ± 24 ft-lb)

3Install the closing crossmember.Tighten fasteners to a torque of 200 ±33 Nm (148 ± 24 ft-lb).

200 ± 33 Nm(148 ± 24 ft-lb)

4Install the light bar. Tighten fastenersto a torque of 200 ± 33 Nm (148 ± 24ft-lb).

200 ± 33 Nm(148 ± 24 ft-lb)

7112-03-02-03Intermediate Crossmember,Replacement (Bolted and Ex-posed Rivets)


Removal1Remove any equipment which ob-structs crossmember replacement.

2Remove fasteners or rivets from theinstalled crossmember beam. Removethe beam from the end plates.

3If required, unbolt and remove the endplates from the frame rails.

Installation1If required, bolt the new end plates tothe frame rails. Do NOT tighten.

2For bolted beams, bolt the new beamto the end plates.For riveted beams, bolt the beam tothe end plates using body bound bolts.Perform body bound bolt installation inaccordance with the procedure in thismanual.

3Tighten the end plate-to-the frame railfasteners. Tighten the beam-to-endplate fasteners. Tighten both fastenersas follows: M14 tighten to a torque of200 ± 33 Nm (148 ± 24 ft-lb).

200 ± 33 Nm(148 ± 24 ft-lb)

46


7112-03-02-04Closing Crossmember, Re-placement


Removal1Remove taillight assemblies and wiringharness clamps.

2Remove closing crossmember fasten-ers.

3

WARNING


For air suspension, disconnect and re-move air line for left side rear air bagand remove left side upper shock ab-sorber bracket. Also remove levelingvalve assembly on 4x2 tractor.

4Remove closing crossmember.

Installation1Place new closing crossmember be-tween the frame rails.

2Install and tighten the crossmemberfasteners. Tighten fasteners to atorque of 200 ± 33 Nm (148 ± 24 ft-lb).

200 ± 33 Nm(148 ± 24 ft-lb)

3For air suspension, install upper shockabsorber bracket and air line for leftside rear air bag. On 4x2 tractor, in-stall leveling valve assembly.

4Install taillight assemblies and wiringharness clamps.

7112-03-02-05Engine Crossmember, Replace-ment


WARNING

Do not remove the coolant fill cap (or cap on the ex-pansion tank) if the coolant is hot; wait until coolanttemperature is less than 50� C (120� F). Otherwise,scalding steam or fluid may escape under pressure,which can cause serious injury.

WARNING

Coolant may be combustible. Coolant leaked orspilled onto hot surfaces or electrical components cancause a fire. Clean up coolant spills immediately.

WARNING


47



2Remove the ABS modulator valvesfrom the front engine crossmemberand/or the frame rails on both sides ofthe front engine crossmember.

3Support the frame rail on both sides ofthe front engine crossmember and re-move the front spring pins. This step isfor VNM and VNL models only.

4Support the front of the engine with ahoist.

5Drain the coolant into a suitable con-tainer. Disconnect the lower radiatorhose and air cooler hose. This step isfor VNM and VNL models only.

6Remove the fasteners that hold thefront engine isolator mount to the frontengine crossmember.

7Slowly raise the engine with the hoistto separate the isolator from the cross-member.

8Remove the fasteners that mount thefront engine crossmember to thespring hangers on the VHD. For theVNM and VNL models, remove thefasteners that mount the spring hang-ers to the frame rail. For the VHD axleforward, remove the frame bracket onone side to assist in the removal of thefront engine crossmember. For theVHD axle back, remove the front en-gine mount isolator from the engine toassist with the removal of the front en-gine crossmember.

9Remove the front engine crossmem-ber.

Installation1Install the front engine crossmember.

2Install the front engine mount isolatoron the VHD axle back. Tighten fasten-ers to a torque of 105 ± 20 Nm (78 ±13 ft-lb). Install the frame bracket onthe VHD axle forward, or install thespring hanger fasteners to the framerail on the VNM and VNL models.Tighten fasteners to a torque of 200 ±33 Nm (148 ± 24 ft-lb).

105 ± 20 Nm(78 ± 13 ft-lb)200 ± 33 Nm(148 ± 24 ft-lb)

3Lower the engine and install the frontengine mount isolator to the front en-gine crossmember.

4Connect the lower radiator hose andthe air cooler hose on the VNM andVNL models. Fill the radiator withcoolant.

5Install the front spring pins on theVNM and VNL models. Tighten fasten-ers to a torque of 851 ± 15 Nm (63 ±11 ft-lb).

851 ± 15 Nm(63 ± 11 ft-lb)

6Install the front ABS modulator valves.Tighten fasteners as follows: M10:tighten to a torque of 60 ± 10 Nm (44± 7 ft-lb).

60 ± 10 Nm(44 ± 7 ft-lb)

48


7112-03-02-06Rear Suspension Crossmem-ber (Bogie), Replacement



2Remove the rear light bar and mudflaps.

3Remove the closing crossmember.See “Closing Crossmember, Replace-ment” page 47.

4Remove the harness support bracketsthat are located between the rear sus-pension crossmember and the closingcrossmembers.

5Remove the airline support bracketslocated under the rear suspensioncrossmember.

6

WARNING


Remove the brake valves and brakehoses that are mounted to, or locatedat, the rear suspension. Also removethe Traction Control Valve (TCS)mounted to the frame rail if the vehicleis equipped with TCS.

7

W0000411

Using jack stands, support the nose ofthe first and second drive axles andthe rear section of the frame rails.

8Remove the bump stops and the uppershock brackets for the rear drive axle.

9Remove the intermediate crossmem-ber. See “Intermediate Crossmember,Replacement (Bolted and ExposedRivets)” page 46.

10This step only applies to trucks withthe Volvo Optimized Air Suspension.For proper information on removingfasteners for the spring hangers referto:

ServiceManual

710-500Volvo Optimized AirSuspension from5/99.

IMPACT Function Group 7114Information Type: Re-pair“Spring Hanger, Re-placement”

Remove the fasteners for the springhangers on the rear drive axle ontrucks equipped with the Volvo Opti-mized Air Suspension.

11Remove the V-torque rod on trucksequipped with the Volvo T-Ride.

49


12Remove the leaf spring assembly oneach side of the suspension on trucksequipped with the Volvo T-Ride.

13Support the saddle bracket on eachside of the suspension on trucksequipped with the Volvo T-Ride.

14Remove the fasteners to the saddlebracket on each side of the rear sus-pension on trucks equipped with theVolvo T-Ride.

15Remove the fasteners to the V-torquerod on the first drive axle at the framebracket if the truck is equipped withthe Volvo T-Ride.

16Remove the remaining fasteners to therear suspension (Bogie) crossmemberand remove the rear suspension (Bo-gie) crossmember.

Installation1Once this step is complete, go backand tighten fasteners that have beeninstalled from steps 1 through 7 as fol-lows:

2Install the rear suspension (Bogie)crossmember. Install and tighten fas-teners as follows: M14: tighten to atorque of 200 ± 33 Nm (148 ± 24 ft-lb), M16: 275 ± 45 Nm (204 ± 34 ft-lb).

200 ± 33 Nm(148 ± 24 ft-lb)275 ± 45 Nm(204 ± 34 ft-lb)

3Install the fasteners between the V-torque rod and the frame bracket andapply the proper torque to trucksequipped with the Volvo T-Ride. M14:tighten to a torque of 200 ± 33 Nm(148 ± 24 ft-lb), M16: 275 ± 45 Nm(204 ± 34 ft-lb).

200 ± 33 Nm(148 ± 24 ft-lb)275 ± 45 Nm(204 ± 34 ft-lb)

4Install the fasteners to the saddlebrackets and apply the proper torqueon trucks equipped with the Volvo T-Ride. M14: tighten to a torque of 200 ±33 Nm (148 ± 24 ft-lb), M16: 275 ± 45Nm (204 ± 34 ft-lb).

200 ± 33 Nm(148 ± 24 ft-lb)275 ± 45 Nm(204 ± 34 ft-lb).

5Install the leaf spring assembly oneach side and tighten the U-bolts tothe saddle caps on trucks equippedwith the Volvo T-Ride. Tighten the U-bolts to a torque of 500 ± 75 Nm (369± 55 ft- lb).

500 ± 75 Nm(369 ± 55 ft-lb)

6Install the fasteners to the spring hang-ers on the rear drive axle and applyproper tighten on trucks equipped withthe Volvo Optimized Air Suspension.

7Install the intermediate crossmemberand tighten the fasteners to a torqueof 200 ± 33 Nm (148 ± 24 ft-lb).

200 ± 33 Nm(148 ± 24 ft-lb)

8Install the upper shock brackets andthe bump stops and the tighten fasten-ers.

9Install the brake valves and hoses lo-cated near the rear suspensioncrossmember.

10Install and properly tighten the V-torque rod, on trucks equipped withthe Volvo T-Ride. Tighten the V-torquerod nuts (axle housing) to a torque of310 ± 50 Nm (228 ± 37 ft-lb). Tightenthe V–torque rod bolts (chassisbracket) to a torque of 320 ± 50 Nm(236 ± 37 ft-lb).

310 ± 50 Nm(228 ± 37 ft-lb)320 ± 50 Nm(236 ± 37 ft-lb)

11Install all the harness and airlinesmounting brackets.

12Install the light bar and mud flaps.

50


13Install the closing crossmember. See“Closing Crossmember, Replacement”page 47.

14Remove any supports for the framerails and the drive axle.

7113-05-02-04Frame Length, Adjustment


WARNING

Always wear appropriate eye protection to prevent therisk of eye injury due to contact with debris or fluids.

Note: Total wheel vehicle alignment may be necessaryafter completing this procedure. Refer to the appropriateservice information.

Note: The only approved alteration to the frame is short-ening of the vehicle wheelbase by moving the rearaxle(s) forward and cutting the excess frame from theend. Frame rails are not to be spliced or extended.

WARNING


WARNING


1

W0000411

Place the vehicle on jack stands at thenormal ride height. Do not jack the ve-hicle up.

2Remove the driveshaft.

3Unbolt the fifth wheel angle irons fromthe frame and remove the fifth wheeland the angle irons as an assembly.

4Mark the frame at the existing wheel-base (centerline of the rear axle forsingle axle and center between axlesfor a tandem axle).

5Unbolt the existing suspension brack-ets, hardware, and crossmembers.

6Unbolt and remove any other brackets,hoses, or electrical wiring that obstructthe area of the frame to be altered.

7Remove any intermediate crossmem-ber that will no longer be needed.

8Make a template of the hole patternfor the rear suspension using the ex-isting wheelbase and hole pattern asreference points.

9Determine the new wheelbase for thevehicle and mark on the frame rails.

51


10Mark and drill the new holes neces-sary to accommodate the rear axlecrossmember at its new position.Holes must be placed in accordancewith the specifications given in “BoltHole Patterns” page 6.

11Unbolt the rear axle crossmember endplates from the frame and move thecrossmember to its new position.

12Bolt up the suspension and crossmem-bers. Tighten the fasteners as follows:M14 200 ± 33 Nm (148 ± 24 ft-lb).M16: 275 ± 45 Nm (204 ± 34 ft-lb).

200 ± 33 Nm(148 ± 24 ft-lb)275 ± 45 Nm(204 ± 34 ft-lb)

13Remove the jack stands from underthe frame.

14Determine the appropriate overhangfrom the table below.

Overhang

AxleType

StraightEnd

Taperedend*

Taperedend**

4x2 838 mm 813 mm 889 mm

6x4 1371mm

1346mm

1422mm

* for bar type mud flap brackets** for spring type mud flap brackets

15

W7001167

1 Desired end of frame2 Current end of frame

Measure rearward from the new cen-terline of the rear axle (4x2) or fromthe new centerline of the bogie (6x4)the overhang amount. Mark that pointon the frame rails as the desired endof frame.DO NOT CUT THE FRAME.

16

W7001168

1 Desired end of frame2 Rough cut3 28.5 mm (266 mm frame)

36.0 mm (300 mm frame)

For tapered rail ends only, mark theframe rail at a point 28.5 mm (266 mmframe height) or 36 mm (300 mmframe height) past the mark for de-sired end of frame. This is the roughcut mark.

52


17

W7001169

1 Desired end of frame2 Rough cut

For straight rails, cut the excess frameoff at the mark for desired end offrame. For tapered rails, cut the ex-cess frame off at the mark for roughcut.

18If the frame ends will be straight, bolttwo splay crossmembers back to backusing M12 bolts and nuts. tighten thebolt to 105 ± 20 Nm (142 ± 27 ft-lb).

Note: Splay crossmembers must bepainted prior to installation.

105 ± 20 Nm(142 ± 27 ft-lb)

19Insert the closing crossmember be-tween the frame rails and slide it as farforward as possible.

Note: Steps 20 through 29 for cutting,beveling, and welding the frame webapply only to vehicles that require a ta-pered closing crossmember.

20

W7001170

1 Desired end of frame2 Rough cut3 See table for dimensions

Mark a wedge shape on the frameweb for cutting. Refer to the table be-low for dimensions.

Frame ThicknessFrameHeight

6 mm 7 mm 8 mm

266mm

236.4 ±2 mm

232.6 ±2 mm

228.7 ±2 mm

300mm

N/A 299.3 ±2 mm

295.4 ±2 mm

21

W7001171

1 Drill hole here2 See table for dimensions

Drill a 24 mm diameter hole with cen-ter at the upper corner of the wedge(12 mm below the bottom of the upperflange).

53


22Verify the angle of the wedge is27 ± 0.25�.

23

W7001172

1 Desired end of frame2 Rough cut

Cut out the wedge.

24

W7000390

Bevel the outer edges of the cuts to45�.

25

W7000408

Bend the upper flange down until itmakes contact with the web.

Note: It may be necessary to heat theflange in order to bend it.

26Verify the proper fit up of the taperedcrossmember before welding.

27

W7000413

WARNING

Eye injury hazard. Wear eye protection during weld-ing. Failure to wear eye protection could result insevere eye injury and blindness.

Weld the cut edges of the web to-gether.

54


28

W7000414

Cut off the end of the frame rail at thedesired end frame mark.

29Repeat the cutting and weldingprocess for the other frame rail.

30

W7000391

Measure, mark and drill holes in theframe to accommodate the closingcrossmember.

31Grind the end of the frame and thewelded areas smooth and paint allbare metal frame surfaces.

32

W7000378

W7000379

Slide the closing crossmember intoplace. Tighten tapered crossmemberbolts to 275 ± 45 Nm (203 ± 33 ft-lb).

275 ± 45 Nm(203 ± 33 ft-lb)

33Mark and drill holes for the fifth wheelangle irons. Bolt the fifth wheel as-sembly to the frame and tighten boltsto 275 ± 45 Nm (203 ± 33 ft-lb).

275 ± 45 Nm(203 ± 33 ft-lb)

34Install and tighten an appropriate sizemetric flange bolt into each frame railweb hole that is not used.

35Measure distance from transmissionpinion to axle pinion, and record thedistance. Have a certified drivelineshop alter the drive shaft for this dis-tance.

36Install the drive shaft.

37Check the pinion angles and rideheight, and make corrections if neces-sary.

55


7119-02-02-01Body Bound Bolt, Installation1

WARNING

Always wear appropriate eye protection to prevent therisk of any eye injury due to the contact with debris orfluids.

CAUTION

Only use a reamer with clockwise rotation. Do not re-verse rotation to remove the reamer. Use a drill with amaximum 350 rpm no-load speed. Always use cuttingoil. Failure to follow these precautions will result indamage to the reamer.

Ream the holes in the crossmemberand end plates or bracket to 16.56 mm(0.652 in.).

2Clean out any metal chips that remainin the holes.

3

W7000383

1 Body bound bolt2 Crossmember3 Elastic stopnut4 Hardened flat washer5 End plate or spring bracket

Measure the thickness of the endplate or spring bracket.

4Multiply the thickness from Step 3 by66%.

5Measure the thickness of the cross-member.

6Add the thickness values from Steps 3and 5. This is maximum bolt shanklength.

7Add the thickness values from Steps 4and 5. This is minimum bolt shanklength.

8Select a body bound bolt with a shanklength between the minimum andmaximum shank length.

9Install the body bound bolts in eachhole that was reamed. Place a hard-ened steel washer and a stop nut oneach bolt.

10Tighten the nuts to 225 ± 37.5 Nm(166 ± 28 ft-lb). Hit the bolt with abrass hammer several times duringtorquing to insure proper seating.

225 ± 37.5Nm(166 ± 28 ft-lb)

7113-01-02-01HUCK-FIT® Fastener, Removal1An air impact wrench can generally beused to remove the fasteners. Alwaystry to remove the collar with an air im-pact wrench first. If you encounterdifficulty, increase air pressure to themaximum for your equipment to obtainbest results. If the air impact wrenchfails to remove a fastener, the collarmust be split or cut.

56


2

W7001135

Fig. 11: Huck-Fit Fastener

1 Cut through collar and pin at this location.2 Swaged area.

Note: Use this method of removal onlyif the fastener cannot be removed withan air impact wrench or hydraulic split-ter.A hydraulic collar splitter is availablefrom HUCK®. If the splitter is availableto you, it should be used. Make the cutjust above the collar’s hex flange. Tohelp avoid damage to other compo-nents, use an 1/8” metal shield with ahole that fits around the hex portion ofthe collar.

7113-02-02-01HUCK-FIT® Fastener, Installa-tionTo install the fasteners, select the correct grip range pin.To ensure flush pin seating, the hole size for 16 mm(5/8”) pins must be 17.1–17.5 mm (use an 11/16” drillbit). Holes as small 16 mm can be used, but the holeshave to be chamfered on the head side to ensure properhead pin seating.

Note: Never reuse fasteners. Huck-Fit fasteners are notserviceable or reusable.

1

W7000306

Fig. 12: Threading the collar onto the bolt

Insert pin (bolt) through prepared hole.

2Slide the collar over the pin-tail andhand tighten.

3

W7000307

Fig. 13: Swaging of the collar

Place hydraulic tool nose assemblyover pin-tail and squeeze the trigger.

4The nose assembly pulls on the pin-tail, drawing the work pieces together.The anvil pushes on the collar.

57


5

W7000308

Fig. 14: Completing the swage of the collar

The tool continues pulling on the pin-tail, moving the anvil forward andswaging the collar into the lockinggrooves of the pin (bolt) therebyachieving clamp.

6

W7000309

Fig. 15: Pin-tail breaking off

When the tool completes the swage,the pin-tail breaks off the bolt.

7The tool automatically ejects itself offthe collar.

Inspection

1

W7000310

Fig. 16: Dimensional limitations

Visually inspect the installed fasteneras follows:

• Check for a complete swage (“D”dimension)

• Check for proper pin protrusion(“B” dimension)

Diameter 16mm (5/8")

A max. 0.6mm (.023")

B max. 10.6mm (.417")

C max. 17.7mm (.696")

D max. 24.1mm (.948")

Should ”A” or ”B” dimensions exceedthe given values, the fastener is out-of-grip. A ”C” dimension less than thegiven value indicates an incompleteswage. A ”D” dimension greater thanthe given values indicates an incorrector worn anvil on the installation tool. Ifany of these conditions are present,the fastener is installed incorrectlyand must be replaced.

58


2

W7000301

Fig. 17: Bolt turned inboard

HUCK® bolts can be turned in or out-ward as tool limitations may require.

3

W7000302

Fig. 18: Less than a flush break

Bolt pin-break to be flush or greaterthan the collar length. A recessed pin-break less than flush with the collar isunacceptable.

4

W7000303

Fig. 19: Flange bolts and bolts

Do not mix bolts and flange boltswithin a hole pattern unless a specificexception is documented.

5

W7000304

Fig. 20: Scored collar

If the collar is scored, the tool anvil isworn and should be replaced.

59

60

Feedback

One of our objectives is that workshop personnel should have access to correct andappropriate service manuals where it concerns fault tracing, repairs and maintenanceof Volvo trucks.In order to maintain the high standards of our literature, your opinions and experiencewhen using this manual would be greatly appreciated.If you have any comments or suggestions, make a copy of this page, write down yourcomments and send them to us, either via telefax or mailing directly to the addresslisted below.

To

Volvo Trucks North America, Inc.

Dept. 516 Service Publications

7825 National Service Road

P.O. Box 26115

Greensboro, NC 27402-6115

USA

Fax (336) 393-3170

From

..........................................................................

..........................................................................

..........................................................................

..........................................................................

..........................................................................

..........................................................................

..........................................................................

Comments/proposals

................................................................................................................................................................................

................................................................................................................................................................................

................................................................................................................................................................................

................................................................................................................................................................................

................................................................................................................................................................................

................................................................................................................................................................................

................................................................................................................................................................................

................................................................................................................................................................................

................................................................................................................................................................................

................................................................................................................................................................................

................................................................................................................................................................................

................................................................................................................................................................................

................................................................................................................................................................................

Concerns Service Manual: ...............................................................................................................................

Operation Numbers

7112-03-02-02 Intermediate Crossmember, Replacement (Rivets Under the Flame Flange) . . . . 457112-03-02-03 Intermediate Crossmember, Replacement (Bolted and Exposed Rivets) . . . . . . 467112-03-02-04 Closing Crossmember, Replacement . . . . . . . . . . . . . . . . . . . . . . . 477112-03-02-05 Engine Crossmember, Replacement . . . . . . . . . . . . . . . . . . . . . . . 477112-03-02-06 Rear Suspension Crossmember (Bogie), Replacement . . . . . . . . . . . . . . 497113-01-02-01 HUCK-FIT® Fastener, Removal . . . . . . . . . . . . . . . . . . . . . . . . . 567113-02-02-01 HUCK-FIT® Fastener, Installation . . . . . . . . . . . . . . . . . . . . . . . . 577113-03-02-01 Frame Rail, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377113-05-02-03 Frame Alignment, Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 447113-05-02-04 Frame Length, Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517113-06-02-01 Frame Alignment, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 437119-02-02-01 Body Bound Bolt, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 56

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

Volvo Trucks Canada, Ltd.6490 Vipond Drive, Mississauga, Ontario L5T 1W8

http://www.volvotrucks.volvo.com

PV776-TSP143123 (1000) 8.2000 © Volvo Trucks North America, Inc., 2000

Documents

Service Manual Trucks · Gas cutting torch Metal grinder Welding machine Reamer (0.652 inch) 9 Group 71 Tools Special Tools The J-38460-A is a digital protractor, available from