Service Manual

D Trucks
Group61
Volvo 5.7, 6.7 Ton Front Axle
VT

20176980
 Foreword
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The descriptions and service procedures contained in this manual are based on designs
and methods studies carried out up to June 2006.

The products are under continuous development. Vehicles and components produced
after the above date may therefore have different specifications and repair methods.
When this is believed to have a significant bearing on this manual, supplementary
service 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

reference to an V.S.T. (Volvo Standard Times).

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

Each section of this manual contains specific safety information and warnings which
must be reviewed before performing any procedure. If a printed copy of a procedure is
made, be sure to also make a printed copy of the safety information and warnings that
relate to that procedure. The following levels of observations, cautions and warnings
are used in this Service Documentation:

Note: Indicates a procedure, practice, or condition that must be followed in order to have
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 the
product 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: 20176980

© 2006 Volvo Trucks North America, Inc., Greensboro, NC USA

All rights reserved. No part of this publication may be reproduced, stored in

retrieval system, or transmitted in any forms by any means, electronic,
mechanical, photocopying, recording or otherwise, without the prior written
permission of Volvo Trucks North America, Inc.
USA22505.ihval
 Contents

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Specifications ......................................................................................... 3
Front Axle ............................................................................................... 3
Torque Requirements ............................................................................ 3

Tools ........................................................................................................ 7
Special Tools .......................................................................................... 7

Design and Function ............................................................................. 9

Front Axle ................................................................................................. 9
Basic Description ................................................................................... 9
Volvo 5.7, 6.7, 9.0 Ton Front Axle ........................................................ 10

Troubleshooting ................................................................................... 15
Front Axle and Steering, Fault Tracing ................................................... 15
Fault Tracing ........................................................................................ 15
Preliminary Checks .............................................................................. 15
Hydraulic Tests .................................................................................... 15
Troubleshooting Charts ........................................................................ 16

Service Procedures ............................................................................. 29

Front End Wear, Check ........................................................................ 29
Wheel Angles, Check-Measure (All) .................................................... 36
Knuckle Stop Bold Adjustment (Turning Circle) ................................... 36
Curve Angles, One Axle, Checking ...................................................... 38
Kingpin Play ......................................................................................... 38
Curve Angles, One Axle, Adjustment .................................................. 41

Operation Numbers

1
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2
Group 61 Volvo 5.7, 6.7 Ton Front Axle Specifications

Specifications
Front Axle
Applications
Axle
Volvo 5.7 Front Axle
(Steer Axle)
Volvo 6.7 Front Axle
(Steer Axle)
Models
VT

VT

Note: *For more wheel cut information, see TR8145139.

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Rating
12,500 lbs

14,600 lbs
Hub
Unitized Only

Unitized Only
Maximum Wheel Cut*
50 degree

50 degree

Specifications
Knuckle Data Chart — Upper Roller Bearing and Presized Lower Bushing — No Reaming Required
Axle Models Knuckle Pin Size Bushing I.D. Installed Pin-to-Bushing
Clearance
Upper Lower Minimum Maximum
5.7, 6.7, 9.0 38.5 mm (1.5158 in.) 59.973 mm (2.3611 in.) 60.054 mm (2.3643 in.) 0.0010 mm 0.015 mm
(3.94 in) (0.001 in)
37.9 mm (1.4921 in) 59.954 mm (2.3604 in) 59.980 mm (2.3614 in)

Front Axle Alignment Specifications

For Front Axle Alignment Specifications, check Wheel
Alignments in Group 1.

Kingpin Play
Wear dimensions are as follows:

• Vertical Play — 0.254 mm (0.010 in)

• Lateral Play — 0.381 inches (0.015 in)

Wheel Bearing End Play

Wear dimensions are as follows:

• Wheel Bearing End Play — 0.0–0.1 mm

(0.0000–0.004 in)

Torque Requirements
Pitman Arm Retention
Pinch Bolt

Bolt Size Torque

5/8”-18 Grade 8 312–339 Nm
(230–250 ft-lb)
/4”-16 Grade 8
3
407–434 Nm
(300–320 ft-lb)
M20 x 1.5 400 ± 60 Nm
(295 ± 44 ft-lb)

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Group 61 Volvo 5.7, 6.7 Ton Front Axle Specifications

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Threaded Retaining Nut

Thread Torque
1–3/8”-12 556–624 Nm
(410–460 ft-lb)
1–1/2”-12 610–678 Nm
(450–500 ft-lb)
1–3/4”-12 678–746 Nm
(500–550 ft-lb)

Hex Head or 12–point Head Bolt

Bolt Size Torque

1
/2”-20 UNF 203–271 Nm
(150–200 ft-lb)
3/8”-24 UNF 81–149 Nm
(60–110 ft-lb)

Retainer Bolt

Bolt Size Torque

5/8”-18 UNF 305–373 Nm
(225–275 ft-lb)
3
/4”-16 UNF 610–678 Nm
(450–500 ft-lb)

Steering Shaft Universal Joints Pinch Bolts

Bolt Size Torque
3/8”-24 UNF 61–68 Nm
(45–50 ft-lb)
7/16”-20 UNF 129–163 Nm
(95–120 ft-lb)

Drag Link to Pitman Arm Pinch Bolts

Bolt Size Torque
5/8”-18 Grade 8 312–339 Nm
(230–250 ft-lb)

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Group 61 Volvo 5.7, 6.7 Ton Front Axle Specifications

Drag Link and Steering Cross Tube Clamp Pinch Bolts

M20 x 1.5
Bolt Size
5/8”-11 UNC

M16 x 2

Bolt Size
68–81 Nm

68–81 Nm
Torque

(50–60 ft-lb)

(50–60 ft-lb)

Drag Link to Pitman Arm or Steering Arm

Castle Nut

Torque
200 Nm minimum
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(148 ft-lb minimum)

5
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6
Group 61 Volvo 5.7, 6.7 Ton Front Axle Tools

Tools
Special Tools

J45996
Hubcap Remove/Install Tool D
For special tools ordering instructions, see service information in group 08.

W0002253

J45943A
Bushing Installer

W0002254

J8092
Shaft

W0002255

J45944
Knuckle Upper Cover and hubcap Remove/Install Socket

W0002256

J45945
Kingpin Removal Tool

W0002257

J47362
Wheel Hub Torx Socket, E20 Torx

W0002258

J47454
kingpin Nut Socket, 60 mm

W0002259
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Group 61 Volvo 5.7, 6.7 Ton Front Axle Tools

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X4C-LW-750
1000 ft-lb Torque Multiplier

W0002260

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Group 61 Volvo 5.7, 6.7 Ton Front Axle Design and Function

Design and Function

Front Axle
Basic Description
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W6001584

The information in this manual covers Specifications,

Design and Function, Troubleshooting, Service Repair
Procedures, and Preventive Maintenance for the Volvo
5.7, 6.7 and 9.0 Ton Front Axles.

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Group 61 Volvo 5.7, 6.7 Ton Front Axle Design and Function

Volvo 5.7, 6.7, 9.0 Ton Front Axle

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W6001589
1 Steering Knuckle (left)
2 Steering Lever (left)
3 Axle Center
4 Steering Lever (right)
5 Steering Knuckle (right)
6 Cross Steering Lever (right)
7 Cross Steering Tube Assembly
8 Cross Steering Lever (left)

The Volvo 5.7, 6.7, 9.0 Ton front axles is a drop-forged, On all axles, the steering knuckles are connected by the
heat-treated l-beam with reverse-Elliott construction. cross steering levers and cross steering tube to maintain
alignment.
Steering is accomplished by mounting a steering knuckle
on the front axle with a steering knuckle (king) pin so that On the Volvo 5.7, 6.7, 9.0 Ton front axles assemblies, the
each steering knuckle is free to pivot. Steering input to steering knuckles use nylon lower bushings and tapered
the steering knuckle (and subsequently the front wheels) roller upper bearings to provide a bearing surface for
is achieved through a drag link that is attached between the kingpin. Seals are used to exclude dirt and retain
the steering gear lever (pitman arm) and the steering lubrication inside the knuckle assembly. The front axles
lever that is rigidly mounted to the steering knuckle. are positioned on the vehicle by the springs that are
attached to the frame with support brackets.
While most vehicles have the steering lever attached to
the left knuckle, some vehicles are built to provide for Stable steering and normal tire life depend upon
right-hand steering. In this case, the linkage and steering maintaining balanced forces in the front end and steering
lever are mounted on the right-hand knuckle. In special system. To prevent undesirable effects from the various
cases, vehicles are provided with steering levers on both forces acting upon the front end, it is essential that
the right- and left-hand steering knuckles. On these wheel and tire assemblies be properly aligned and
vehicles, the steering linkage from the steering gear is balanced. Additionally, all components of the front axle,
connected to the left-hand steering knuckle with a power suspension and steering system must be maintained in
assist slave gear connected to the right-hand knuckle. good mechanical condition and proper adjustment.
The gear and power assist slave gear are interconnected
hydraulically to provide easier steering. The information covered in this manual deals with
front axle and steering specifications, maintenance,
troubleshooting, repair instructions, adjustments (which
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Group 61 Volvo 5.7, 6.7 Ton Front Axle Design and Function

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is contained within the repair instructions section) and steering system, to allow logical system diagnosis and
special tools. correction of trouble.

It must be noted that the steering characteristics of the All equipment and instruments used for checking or
vehicle are also dependent upon rear wheel alignment repairing the vehicle must be inspected and adjusted
and frame geometry, as well as wheels and tires. For at regular intervals to ensure accuracy. Inaccurate and
additional information, refer to the Volvo Service Manuals unsatisfactory work results when even these instruments
that cover these items. All information about vehicle are carelessly maintained or handled.
alignment can be found in Wheel Alignment, Group 1.
The technician performing front axle service should have
sufficient knowledge of the basic factors that affect the

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Group 61 Volvo 5.7, 6.7 Ton Front Axle Design and Function

Front Axle Maintenance

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General maintenance procedures for Volvo components
are detailed in Group 1. For periodic maintenance
instructions and intervals, refer to Function Group 1. Axle
alignment specifications are also given in Group 1.

Kingpin Upper Bearing

With the vehicle weight on the ground, apply the
recommended chassis lubricant to the upper bearing
grease fitting until grease purges from the joint between
the upper steering knuckle and the upper portion of the
axle eyelet. Ensure kingpin upper bearing is lubricated
with vehicle weight on the ground.

Kingpin Lower Bearing

With the vehicle raised off the ground and supported on
jackstands, lubricate the kingpin lower bushing. Raising
the vehicle off the ground ensures that grease will fill
the areas around the kingpin and bushing. Apply the
recommended chassis lubricant to the lower bushing
grease fitting until grease purges from the joint between
the lower steering knuckle and the lower portion of the
axle eyelet. Ensure kingpin lower bushing is lubricated
with the front of the vehicle raised off the ground and
supported on jackstands of adequate capacity.

DANGER
Do not work under a vehicle that is supported only on a
hydraulic jack. The hydraulic jack could fail suddenly
and unexpectedly, resulting in severe personal injury
or death. Always use jackstands of adequate capacity
to support the weight of the vehicle.

Steering Maintenance
At each inspection interval, inspect steering linkages,
including steering shaft U-joints and yokes, drag link and
cross steering tubes for damage or looseness. Also,
check ball sockets for boot damage, looseness or wear.
Also, at the same intervals, check the condition of the
steering gear mounting brackets and check all fasteners
for looseness. Inspect the steering gear, hoses, pump
and reservoir for leaks. Check the oil level in the power
steering reservoir and add the recommended oil if
necessary. (Refer to the Group 1 for recommended power
steering oil.)

At each inspection interval, check that the steering shaft

pinch bolts are tightened to specification (See “Steering
Shaft Universal Joints Pinch Bolts” page 4). Replace any
pinch bolts that are corroded or damaged.

Lube Intervals
See Group 1 for service intervals.

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Group 61 Volvo 5.7, 6.7 Ton Front Axle Design and Function

Front Axle Components

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W6001590
1 Steering Lever
2 Steering Lever Ball Stud
3 Kingpin Nut
4 Upper Seal
5 Knuckle Upper Cover
6 Kingpin Bearing
7 Hub Nut
8 Snap Ring
9 Lock Plate
10 ”D” Washer
11 O-ring
12 Lower seal
13 Nylon Bushing
14 Kingpin
15 Lower Cover
16 Cross Steering Lever Ball Socket
17 Cross Steering Tube Assembly
18 Cross Steering Lever
19 Axle Center
20 Stop Bolt Nut
21 Stop Bolt

Ball Socket (Tie Rod End) Assembly

This assembly is installed on each end of the cross
steering tube. The ball sockets (tie rod ends) are attached
to the cross steering levers on the steering knuckles.

Cross Steering Lever

These two arms are attached to the bottom of the
right-and left-hand steering knuckles, and are linked
together by the cross steering tube.

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Group 61 Volvo 5.7, 6.7 Ton Front Axle Design and Function

Cross Steering Tube (Tie Rod) Assembly

This tube connects the two cross steering levers and
includes the two cross steering ball socket assemblies.
These ball socket assemblies are screwed into the cross
steering tube ends, which allow the steering tube to be
adjusted for length.

Drag Link
This is the mechanical link between the steering lever and
the steering gear lever (pitman arm).

Knuckle Pins (Kingpins)

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These pins (one on each side) are used to attach the
steering knuckles to the axle center.

Pivot Center
This is the theoretical point on the knuckle pin axis where
it is intersected by the axis of the steering knuckle spindle.

Steering Gear Lever (Pitman Arm)

This lever is attached to the steering gear sector shaft
and is connected to the drag link. A timing mark is scribed
on the lever and must be aligned with a similar mark on
the steering gear sector shaft.

Steering Gear Sector Shaft

This is the output shaft of the steering gear to which the
steering gear lever (pitman arm) is attached.

Steering Knuckle
This is the movable portion of the axle that pivots on the
knuckle pins (kingpins).

Steering Knuckle Spindle

This is the steering knuckle that supports the hub
assembly, wheel and tire.

Steering Lever
This lever is attached to the top of the steering knuckle
and is used to transmit force from the drag link to the
steering knuckle, in order to turn the wheels

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Group 61 Volvo 5.7, 6.7 Ton Front Axle Troubleshooting

Troubleshooting

Front Axle and Steering, Fault Tracing

Fault Tracing
•
•

•
Chatter: Rapid, intermittent noise or vibration.
Diving or Darting: Tendency of the vehicle to
suddenly dive or dart from the direction of travel;
particularly when a tire runs over a hole or obstruction.
Resonant Ride: This condition is similar to shimmy in
that it occurs spontaneously at certain vehicle speeds
or in response to striking a bump. Changing vehicle
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•

•
Shimmy: Steer axle shimmy is described as prolonged
steering wheel vibration which occurs spontaneously
at certain vehicle speeds or in response to striking a
bump. Changing vehicle speed may cause shimmy
to stop. Shimmy may be present on smooth or rough
roads.
Tramp: A rhythmic and alternate bouncing of the front
speed may cause resonant ride to stop. Resonant wheels. Usually noticeable at higher speeds.
ride, like shimmy, may be present on smooth or rough • Wandering: Straying indiscriminately from side to
roads. However, this vibration is felt through the cab or side. Can occur at both low and high speeds.
seat instead of the steering wheel. • Wheel Fight: A continuous jerking of the steering
• Road Shock (Wheel Kick): A kick felt in the steering wheel in either direction on rough roads at all speeds.
wheel as the front wheels travel on uneven roads. It is Not violent, but annoying and tiring to the driver.
not noticeable on smooth roads.
• Leading: The tendency of the vehicle to pull in the
same direction at all times.

Preliminary Checks
When a customer comes to you with a problem related to Begin by checking the steered wheels: Make sure that
the vehicle steering, you can save a lot of time and work the tires are at the correct pressure, that they are properly
if you first verify the problem. Make sure you are both sized, and that they are not worn or damaged.
talking the same language about the same problem. If the
customer says that the truck is "hard to steer," find out Look for abnormal looseness or tightness in the steering
exactly what "hard to steer" means. Is it hard steering into linkage, ball sockets and kingpins, and then have the front
a right- or left-hand turn? Is it difficult only when turning end alignment checked.
the steering wheel while the truck is sitting still? Is the
A service replacement hose or fluid line may be misrouted
power steering intermittent, or is there no power assist
or may be too small in diameter, or it may be restricted in
at all?
some way. Reroute any hose that is kinked or sharply
If at all possible, and if it is safe to do so, test drive bent. Replace any hoses that are not the same as original
the truck. If you’re not familiar with the vehicle, let the equipment.
customer drive it while you ride along. Most driving is
Continue by checking the power steering fluid reservoir to
done with the truck hauling a load. Arrange for a load if
make sure that oil is up to the correct level.
one is required to reproduce the steering problem.
These are just some of the checks you should make
Once you have determined the problem or its symptoms,
before you turn to the steering gear or pump.
don’t jump right in to tear apart the steering gear or
pump. In most cases, the steering gear should be the last Refer to the following troubleshooting charts that explain
component checked. There are many other components what to diagnose for a particular steering problem. Match
in the steering system that could be causing the problem. the trouble symptom against the chart and follow the
You should check these first. recommended troubleshooting sequence. Doing so will
save you time and may prevent unnecessary repairs.

Hydraulic Tests
If the checks described thus far all prove satisfactory, it is that involves conducting hydraulic tests. For information
possible that the cause of the steering problem can be on Troubleshooting pressure and the flow of the steering
traced to a lack of pressure or insufficient flow. In this system, see Group 6, Steering.
case, you may have to do more detailed troubleshooting

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Group 61 Volvo 5.7, 6.7 Ton Front Axle Troubleshooting

Troubleshooting Charts

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Hard Steering Troubleshooting Chart

Possible Cause Correction

Lack of Lubrication
Steering gear, axle, steering system and chassis. Thoroughly lubricate all points.
Fifth Wheel
Damaged or galled. Repair or replace.
Poor lubrication. Lubricate as required.
Improperly positioned. Reposition. (Should be forward of rear axle on single drive
units and forward of tandem axle center line on tandem
drive units. Front axle should be loaded 80% to 100% of
rated capacity.)
Front Tires
Improper air pressure. Inflate to specification.
Unequal size or type. Match tires.
Poor condition or uneven wear. Replace as necessary. (Refer to manufacturer
recommendations for front end corrections.)
Caster
Too high. Set caster to specification.
Steering Gear Adjustment (Causing Binding)
Worm bearing preload too high. Check and adjust worm bearing preload.
Total mesh preload too high. Check and adjust total mesh preload (center gear as
specified).
Steering Gear Problems The following items require dismantling and repair of the
steering gear. Refer to the manufacturer service manual.
Roller gear binding in output shaft yoke. Check by backdriving the steering gear by the pitman arm.
Failure to backdrive indicates binding.
Input shaft or bearings worn. When checking worm bearing preload, torque wrench will
give an erratic reading. Correct as required.
Output shaft binding. Felt as a drag when input shaft is driving output shaft in
the backlash area. Drag also felt by oscillating output shaft
in the backlash area.
Steering Wheel, Shaft, Splines, U-Joints and Column
Binding. Inspect for proper lubrication, binding and excessive
looseness
U-joints out of phase, felt every 180 degrees. Rephase. (Align arrows on male and female spline.)
Steering Gear Mounting
Steering gear mounting causing a bind in gear housing. Check preloads while gear is mounted on frame.
Systematically loosen fasteners to detect uneven mounting
surface.
Drag Link Ends
Binding. If horizontal type, check ball for flat spot. If vertical type,
rotate stud to detect for binding.
Axle U-Bolts
Loose axle shifts on front springs. Check spring center tie bolt and center pin to make sure
they are properly seated. Torque U-bolts to specification.
Wheel Lug Nuts Loose Torque to specification.
Loose Ball Socket (Tie Rod End) Joints, Cross Steering Replace as required. Torque to specification.
Lever, Steering Lever

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Group 61 Volvo 5.7, 6.7 Ton Front Axle Troubleshooting

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Vehicle Loaded Unevenly Redistribute load.
Excessive Front Wheel Brake Drag Adjust brakes.
Power Steering Components
Insufficient pump pressure. Check pump. Replace as necessary.
Defective pressure relief valve. Replace as necessary.
Low fluid level. Fill power steering reservoir to correct level.
Control valve sticking. Repair or replace as necessary.
Defective booster cylinder or slave gear. Repair or replace as necessary.
Incorrect installation of reservoir. Check positioning of reservoir.
Front Axle
Wheel bearings worn. Replace as necessary.
Kingpin or thrust bearing loose, binding or seized. Repair or replace as necessary.
Bent. Replace axle.
Toe adjustment improper. Set toe to specification.

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Group 61 Volvo 5.7, 6.7 Ton Front Axle Troubleshooting

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Darting Troubleshooting Chart

Possible Cause Correction

Lack of Lubrication
Steering gear, axle, steering system and chassis. Thoroughly lubricate all points.
Steering Gear Mounting
Loose at frame or pitman arm, loose at output shaft. Torque fasteners to specification.
Steering gear causing a bind in gear housing. Check preloads while gear is mounted on frame.
Systematically loosen fasteners to detect uneven mounting
surface.
Drag Link Ends
Binding or loose. If horizontal type, check ball for flat spot. If vertical type,
rotate stud to detect for binding or looseness.
Drag Link Length
Too long or too short causing steering gear to operate off Center steering gear, set front wheels straight ahead,
center. adjust drag link length.
Note: Non-adjustable drag links are used on certain Volvo
chassis.
Toe Adjustment Improper Set toe to specification.
Axle U-Bolts
Loose axle shifts on front springs. Check spring center tie bolt to make sure it enters axle.
Torque U-bolts to specification.
Suspension (Front and Rear)
Weak or broken springs, or damaged air bags. Replace springs or replace air bags.
Worn shackle/spring pins and bushings. Replace as necessary.
Wheel Lug Nuts Loose Torque to specification.
Frame
Twisted, sprung, diamond-shaped. Have frame checked by specialist.
Loose Ball Socket (Tie Rod End) Joints, Cross Steering Replace as required. Torque to specification.
Lever, Steering Lever
Engine Mounts Broken or Loose Repair or replace as necessary.
Vehicle Loaded Unevenly Redistribute load.
Tandem
Out of alignment. Check and align to specification. (For the most current
alignment specifications, see Wheel Alignment, Group 1.)
Worn wheel bearings. Replace and adjust as necessary.
Excessive Front Wheel Brake Drag Adjust brakes.
Front Axle
Wheel bearings worn. Replace as necessary.
Kingpin or bearing/bushing binding or seized Repair or replace as necessary.
Bent. Replace axle.
Toe adjustment improper. Set toe to specification.
Inadequate knuckle-to-beam clearance (worn kingpin Measure knuckle vertical play. Replace worn parts as
upper bearing or lower bushing). required.

Wandering Troubleshooting Chart

Possible Cause Correction

Fifth Wheel

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Group 61 Volvo 5.7, 6.7 Ton Front Axle Troubleshooting

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Damaged or galled. Repair or replace as necessary.
Poor lubrication. Lubricate as necessary.
Improperly positioned. Reposition. (Should be forward of rear axle on single drive
units and forward of tandem axle center line on tandem
drive units. Front axle should be loaded 80% to 100% of
rated capacity.)
Front Tires
Improper air pressure. Inflate to specification.
Unequal size or type. Match tires.
Poor condition or uneven wear. Replace as necessary. (Refer to manufacturer
recommendations for front end corrections.)
Caster
Too low. Set caster to specification.
Steering Gear Adjustments
Worm bearing preload too low permitting end play. Check and adjust worm bearing preload.

Total mesh preload too low resulting in gear backlash. Check and adjust total mesh preload and center the
steering gear as specified.
Steering Gear Problems The following items require dismantling and repair of the
steering gear. Refer to the manufacturer service manual.
Roller gear binding in output shaft yoke. Check by backdriving the steering gear by the pitman arm.
Failure to backdrive indicates binding.
Input shaft or bearings worn. When checking worm bearing preload, torque wrench will
give an erratic reading. Correct as required.
Output shaft binding. Felt as a drag when input shaft is driving output shaft in
the backlash area. Drag also felt by oscillating output shaft
in the backlash area.
Steering Wheel, Shaft, Splines, U-Joints and Column
Loose. Check for proper lubrication, binding and excessive
looseness. Replace as specified by the manufacturer.
U-joints worn, felt every 180 degrees. Replace as necessary.
Steering Gear Mounting
Loose at frame or pitman arm, loose at output shaft. Torque fasteners to specification.
Drag Link Ends
Loose. If horizontal type, check ball for flat spot. If vertical type,
rotate stud to detect for binding or looseness.
Drag Link Length
Too long or too short causing steering gear to operate off Center steering gear, set front wheels straight ahead,
center. adjust drag link length. Note: Non-adjustable drag links
are used on certain Volvo chassis.
Suspension (Front and Rear)
Weak or broken springs, or damaged air bags. Replace springs or replace air bags.
Worn shackle/spring pins and bushings. Replace as necessary.
Wheel Lug Nuts Loose Torque to specification.
Loose Ball Socket (Tie Rod End) Joints, Cross Steering Replace as required. Torque to specification.
Lever, Steering Lever
Engine Mounts Broken or Loose Repair or replace as necessary.
Vehicle Loaded Unevenly Redistribute load.
Excessive Front Wheel Brake Drag Adjust brakes.

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Group 61 Volvo 5.7, 6.7 Ton Front Axle Troubleshooting

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Frame
Twisted, sprung, diamond-shaped. Have frame checked by specialist.
Front Axle
Wheel bearings worn. Replace as necessary.
Kingpin or bearing/bushing binding or seized Repair or replace as necessary.
Bent. Replace axle.
Toe adjustment improper. Set toe to specification.

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Group 61 Volvo 5.7, 6.7 Ton Front Axle Troubleshooting

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Too Much Free Play Troubleshooting Chart

Possible Cause Correction

Fifth Wheel
Damaged or galled. Repair or replace.
Poor lubrication. Lubricate as required.
Improperly positioned. Reposition. (Should be forward of rear axle on single drive
units and forward of tandem axle center line on tandem
drive units. Front axle should be loaded 80% to 100% of
rated capacity.)
Front Tires
Improper air pressure. Inflate to specification.
Unequal size or type. Match tires.
Poor condition or uneven wear. Replace as necessary. (Refer to manufacturer
recommendations for front end corrections.)
Caster
Too high. Set caster to specification.
Steering Gear Adjustment (Causing Binding)
Worm bearing preload too high. Check and adjust worm bearing preload.
Total mesh preload too high. Check and adjust total mesh preload (center gear as
specified).
Steering Gear Problems The following items require dismantling and repair of the
steering gear. Refer to the manufacturer service manual.
Input shaft or bearings worn. When checking worm bearing preload, torque wrench will
give an erratic reading. Correct as required.
Steering Wheel, Shaft, Splines, U-Joints and Column
Loose. Inspect for proper lubrication, binding and excessive
looseness. Replace as specified by the manufacturer.
U-joints out of phase, felt every 180 degrees. Replace.
Steering Gear Mounting
Loose at frame or pitman arm, loose at output shaft. Torque fasteners to specification.
Drag Link Ends
Loose. If horizontal type, check ball for flat spot. If vertical type,
rotate stud to detect for binding or looseness.
Drag Link Length
Too long or too short causing steering gear to operate off Center steering gear, set front wheels straight ahead,
center. adjust drag link length. Note: Non-adjustable drag links
are used on certain Volvo chassis.
Wheel Lug Nuts Loose Torque to specification.
Loose Ball Socket (Tie Rod) Joints, Cross Steering Replace as required. Torque to specification.
Lever, Steering Lever
Vehicle Loaded Unevenly Redistribute load.

21
Group 61 Volvo 5.7, 6.7 Ton Front Axle Troubleshooting

D
Front Axle
Wheel bearings worn. Replace as necessary.
Kingpin or bearing/bushing binding or seized Repair or replace as necessary.
Bent. Replace axle.
Toe adjustment improper. Set toe to specification.

22
Group 61 Volvo 5.7, 6.7 Ton Front Axle Troubleshooting

D
Leading (Pull) Troubleshooting Chart

Possible Cause Correction

Fifth Wheel
Damaged or galled. Repair or replace.
Poor lubrication. Lubricate as required.
Improperly positioned. Reposition. (Should be forward of rear axle on single drive
units and forward of tandem axle center line on tandem
drive units. Front axle should be loaded 80% to 100% of
rated capacity.)
Front Tires
Improper air pressure. Inflate to specification.
Unequal size or type. Match tires.
Poor condition or uneven wear. Replace as necessary. (Refer to manufacturer
recommendations for front end corrections.)
Caster
Unequal. (More than 1/2 degree difference between right Check for bent or twisted axle. Replace as necessary. Set
and left sides.) caster to specification.
Toe Adjustment Improper Set toe to specification.
Axle U-Bolts
Loose axle shifts on front springs. Check spring center tie bolt to make sure it enters axle.
Torque U-bolts to specification.
Suspension (Front and Rear)
Weak or broken springs, or damaged air bags. Replace springs or replace air bags.
Worn shackle/spring pins and bushings. Replace as necessary.
Wheel Lug Nuts Loose Torque to specification.
Loose Ball Socket (Tie Rod End) Joints, Cross Steering Replace as required. Torque to specification.
Lever, Steering Lever
Engine Mounts Broken or Loose Repair or replace as necessary.
Vehicle Loaded Unevenly Redistribute load.
Tandem
Out of alignment. Check and align to specification. (For the most current
alignment specifications, see Wheel Alignment, Group 1.)
Worn wheel bearings. Replace and adjust as necessary.
Excessive Front Wheel Brake Drag Adjust brakes.
Frame
Twisted, sprung, diamond-shaped. Have frame checked by specialist.
Front Axle
Wheel bearings worn. Replace as necessary.
Kingpin or bearing/bushing binding or seized Repair or replace as necessary.
Bent. Replace axle.
Toe adjustment improper. Set toe to specification.

23
Group 61 Volvo 5.7, 6.7 Ton Front Axle Troubleshooting

D
No Wheel Recovery Troubleshooting Chart

Possible Cause Correction

Lack of Lubrication
Steering gear. Inspect lubricant for metal shavings, water or excessive
thickness. Fill or replace with proper lubricant.
Axle, steering system and chassis. Thoroughly lubricate all points.
Fifth Wheel
Damaged or galled. Repair or replace.
Poor lubrication. Lubricate as required.
Improperly positioned. Reposition. (Should be forward of rear axle on single drive
units and forward of tandem axle center line on tandem
drive units. Front axle should be loaded 80% to 100% of
rated capacity.)
Front Tires
Improper air pressure. Inflate to specification.
Unequal size or type. Match tires.
Poor condition or uneven wear. Replace as necessary. (Refer to manufacturer
recommendations for front end corrections.)
Caster
Too low. Set caster to specification.
Steering Gear Adjustment (Causing Binding)
Worm bearing preload too high. Check and adjust worm bearing preload.
Total mesh preload too high. Check and adjust total mesh preload (center gear as
specified).
Steering Gear Problems The following items require dismantling and repair of the
steering gear. Refer to the manufacturer service manual.
Roller gear binding in output shaft yoke. Check by backdriving the steering gear by the pitman arm.
Failure to backdrive indicates binding.
Input shaft or bearings worn. When checking worm bearing preload, torque wrench will
give an erratic reading. Correct as required.
Output shaft binding. Felt as a drag when input shaft is driving output shaft in
the backlash area. Drag also felt by oscillating output shaft
in the backlash area.
Bent worm gear. Felt as en erratic torque reading every 360 through mesh.
Steering gear bottoming. Turn steering wheel lock-to-lock and check for bottoming.
Adjust wheel stops to limit turns before steering gear
bottoms.
Control valve sticking and not centering. Repair or replace as necessary.
Steering Wheel, Shaft, Splines, U-Joints and Column
Binding. Inspect for proper lubrication, binding and excessive
looseness.
Steering Gear Mounting
Steering gear mounting causing a bind in gear housing. Check preloads while gear is mounted on frame.
Systematically loosen fasteners to detect uneven mounting
surface.
Drag Link Ends
Binding. If horizontal type, check ball for flat spot. If vertical type,
rotate stud to detect for binding.
Wheel Lug Nuts Loose Torque to specification.

24
Group 61 Volvo 5.7, 6.7 Ton Front Axle Troubleshooting

D
Excessive Front Wheel Brake Drag Adjust brakes.
Front Axle
Wheel bearings worn. Replace as necessary.
Kingpin or thrust bearing loose, binding or seized. Repair or replace as necessary.
Bent. Replace axle.
Toe adjustment improper. Set toe to specification.

Shimmy at High Speed Troubleshooting Chart

Possible Cause Correction

Front Wheels and Tires
Out of balance. Have balanced by specialist.
Shock Absorbers Worn Inspect and replace as necessary.
Tandem
Out of alignment. Check and align to specification. (For the most current
alignment specifications, see Wheel Alignment, Group 1.)
Worn wheel bearings. Replace and adjust as necessary.
Frame
Twisted, sprung, diamond-shaped. Have frame checked by specialist.

25
Group 61 Volvo 5.7, 6.7 Ton Front Axle Troubleshooting

D
Shimmy at Low Speed Troubleshooting Chart

Possible Cause Correction

Front Tires
Improper air pressure. Inflate to specification.
Unequal size or type. Match tires.
Poor condition or uneven wear. Replace as necessary. (Refer to manufacturer
recommendations for front end corrections.)
Caster
Too high. Set caster to specification.
Steering Gear Adjustment
Worm bearing preload too low, permitting end play. Check and adjust worm bearing preload.
Total mesh preload too low, resulting in gear backlash. Check and adjust total mesh preload (center gear as
specified).
Air in hydraulic system. Bleed system and check pump seal.
Steering Gear Problems The following items require dismantling and repair of the
steering gear. Refer to the manufacturer’s service manual.
Input shaft or bearings worn. When checking worm bearing preload, torque wrench will
give an erratic reading. Correct as required.
Defective control valve. Replace control valve as necessary.
Steering Wheel, Shaft, Splines, U-Joints and Column
Loose. Inspect for proper lubrication, binding and excessive
looseness. Replace as specified by the manufacturer.
U-joints worn, felt every 180 degrees. Replace.
Steering Gear Mounting
Loose at frame or pitman arm, loose at output shaft. Torque fasteners to specification.
Drag Link Ends
Loose. If horizontal type, check ball for flat spot. If vertical type,
rotate stud to detect for binding or looseness.
Drag Link Length
Too long or too short causing steering gear to operate off Center steering gear, set front wheels straight ahead,
center. adjust drag link length. Note: Non-adjustable drag links
are used on certain Volvo chassis.
Axle U-Bolts
Loose axle shifts on front springs. Check spring center tie bolt to make sure it enters axle.
Torque U-bolts to specification.
Wheel Lug Nuts Loose Torque to specification.
Loose Ball Socket (Tie Rod) Joints, Cross Steering Replace as required. Torque to specification.
Lever, Steering Lever
Tandem
Worn wheel bearings. Replace and adjust as required.

26
Group 61 Volvo 5.7, 6.7 Ton Front Axle Troubleshooting

D
Front Axle
Wheel bearings worn. Replace as necessary.
Kingpin or thrust bearing loose, binding or seized. Repair or replace as necessary.
Bent. Replace axle.
Toe adjustment improper. Set toe to specification.

Knotty Feel Troubleshooting Chart

Possible Cause Correction

Lack of Lubrication
Steering gear. Inspect lubricant for metal shavings, water or excessive
thickness. Fill or replace with proper lubricant.
Axle, steering system and chassis. Thoroughly lubricate all points.
Steering Gear Problems The following items require dismantling and repair of the
steering gear. Refer to the manufacturer service manual.
Input shaft or bearings worn. When checking worm bearing preload, torque wrench will
give an erratic reading. Correct as required.
Bent worm gear. Felt as en erratic torque reading every 360 through mesh.
Steering Wheel, Shaft, Splines, U-Joints and Column
Binding. Inspect for proper lubrication, binding and excessive
looseness
U-joints worn, felt every 180 degrees. Replace as necessary.
U-joints out of phase, felt every 90 degrees. Rephase. (Align arrows on male and female splines.)
Steering Gear Mounting
Loose at frame or pitman arm, loose at output shaft. Torque fasteners to specification.
Steering gear mounting causing a bind in gear housing. Check preloads while gear is mounted on frame.
Systematically loosen fasteners to detect uneven mounting
surface.
Drag Link Ends
Binding. If horizontal type, check ball for flat spot. If vertical type,
rotate stud to detect for binding.

27
Group 61 Volvo 5.7, 6.7 Ton Front Axle Troubleshooting

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Miscellaneous Conditions Troubleshooting Chart

Condition Possible Cause Correction

Lines connected incorrectly. Check for proper line connections.
Direction of Steering Reversed Incorrect steering gear used (if just Check for use of proper steering gear.
replaced).
Lack of Assist When Turning Inadequate output from pump, Check and replace pump as
Steering Wheel Rapidly particularly at idle speed (flow). necessary.
Fluid level low. Fill power steering reservoir with
approved fluid.
Intermittent Power Steering Air in system. Bleed system and check pump seal.
Relief valve sticking. Repair and replace valve assembly as
necessary.
Pump inlet restricted. Investigate to relieve restriction.
Fluid level low. Fill power steering reservoir with
approved fluid.
Noisy Pump Air in system. Bleed system and check pump seal.
Relief valve sticking. Repair or replace valve assembly as
necessary.
Pump worn. Replace pump.
Fluid level low. Fill power steering reservoir with
approved fluid.
Oil Foaming Air in system. Bleed system and check pump seal.
Sucking air. Check pump seals and replace as
necessary.
Power Steering in One Direction Control valve malfunction. Adjust or replace control valve
Only assembly as necessary.

28
Group 61 Volvo 5.7, 6.7 Ton Front Axle Service Procedures

Service Procedures

D
6010-06-02-03
Front End Wear, Check
You must read and understand the precautions and
guidelines in Service Information, group 60, "General
Safety Practices" before performing this procedure.
If you are not properly trained and certified in this
procedure, ask your supervisor for training before
you perform it.

Hub End Play Inspection

1
Chock rear wheels and apply the parking brakes.

2
Remove the hubcap from the wheel hub.

3
Raise the front tire off the ground, then place proper size
jack stands to support the weight.

4
Attach the magnetic base for the dial indicator to the
end of the spindle.

5
Position the dial indicator against the flat surface of
the rim and "0" the dial.

W6001531

6
Grasp the tire at 3 and 9 o’clock and push inward, then
pull outward while watching the dial indicator.

Note: Wheel hub end play should be between 0.0–0.1

mm (0.000–0.004 in.)

0.0–0.1 mm (0.000 –0.004 in.)

7
Remove the dial indicator from the wheel and spindle.

8
Raise the front axle up, then remove the jack stands and
lower tire to the ground.

29
Group 61 Volvo 5.7, 6.7 Ton Front Axle Service Procedures

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9
Install a new O-ring on the hubcap.

W6001532

10
Install the hubcap and torque to 215–285 Nm (159-210
ft-lb).

215–285 Nm (159–210 ft-lb)

Steering (Turning) Angle and Turning Radius

Correct setting of the turning angle is important. A
steering angle that is too large can cause interference
between the tires and the chassis or steering linkage.
In some cases, excessive steering angle can cause a
dangerous steering linkage toggle condition that can lock
the steering and cause a loss of vehicle control. If the
steering angle is too small, the maneuverability of the
vehicle is reduced and the turning radius increases.

Note: On all vehicles, the front axle wheel stops must be

adjusted to provide a minimum of one-inch clearance
between the tires and chassis components, and a
minimum of one-half inch between any moving steering
component (pitman arm, drag link, steering lever, etc.)
and any other steering component.

Check the turning angle whenever the wheels are aligned

or if new springs or front axle have been installed, or if
tire size has been changed. The turning angle must be
adjusted for both right- and left-hand turns. The angle for
a right-hand turn may not be the same as for a left-hand
turn. See Group1 for wheel alignment specifications and
Group 6 for steering pressure and flow checks.

30
Group 61 Volvo 5.7, 6.7 Ton Front Axle Service Procedures

Springs

D
Vehicle stability suffers if the springs do not keep the
front and rear axles in alignment. Check for broken or
sagging springs, loose spring clips or rebound clips, loose
axle clamping plates, and front spring center bolt wear
(indicated by the loose fit of the bolt).

W6001533

W6001534

Excessive side clearance on the shackle end of the spring

may result in shimmy. Be sure that the pin and bushing
at the fixed end of the spring are a good fit. Clearance
should not exceed 0.8 mm (0.030 in). Looseness in this
area contributes to increased tire wear and tramp.

W6001535

Steering Linkage (Cross Steering Tube, Drag Link and Steering Levers)
Inspect all steering linkage for cracks, dents or bends.
Also make sure that the cross steering tube clamp bolts,
steering lever and cross steering lever bolts are tightened
to specification. Repair or replace as necessary.

31
Group 61 Volvo 5.7, 6.7 Ton Front Axle Service Procedures

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W6001537
1 Drag Link
2 Cross Steering Tube Clamp Plates
3 Cross Steering Tube

Ball Sockets (Tie Rod Ends)

When inspecting ball sockets, the front of the vehicle
must be raised off the ground. Support the vehicle weight
with jackstands of adequate capacity.

DANGER
Never work on a vehicle that is supported only by
a hydraulic jack. The jack could fail unexpectedly,
resulting in severe personal injury or death.

1
Place blocks at the rear wheels and set the parking
brakes to prevent the vehicle from moving.

2
Raise the front of the chassis and support on jackstands.

3
Start the engine, then have an assistant turn the wheels
from full left to full right and then return the wheels to the
straight-ahead position. While the wheels are turning,
check for looseness in any threaded joint, or unintended
movement of any ball socket stud or stud nut. Any
movement requires that the ball socket be replaced.

WARNING
Avoid placing hands or fingers in an area where they
could be pinched while performing this test.

32
Group 61 Volvo 5.7, 6.7 Ton Front Axle Service Procedures

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4
Shut the engine off.

5
Check all ball socket boots. Replace any ball sockets that
have missing, cracked or damaged boots.

W6001538

1. Socket Boot

6
Check that the ball socket nut is installed and secured
with a cotter pin.

DANGER
A cotter pin must be installed through the threaded end
of the ball socket stud and the nut must be tightened to
proper specification. A missing cotter pin can allow the
ball socket stud and nut to loosen and possibly result
in a total loss of steering control, which can lead to
serious personal injury or death.

7
If a cotter pin is missing, check the ball socket nut to
make sure it is tightened to specification. Always tighten
the nut to the specified torque. If the nut does not align
with the cotter pin hole, continue tightening until the cotter
pin can be inserted through both the nut and the end
of the ball socket stud. Do not loosen the nut in order
to install the cotter pin.

8
Inspect the ball socket to ensure that the socket is
threaded correctly into the cross steering tube and that
threaded engagement is deeper than the slot in the tube.
Threads of the ball socket must be visible for the entire
length of the cross steering tube slot.

DANGER
The ball socket must have adequate thread
engagement with the cross steering tube or it could
separate from the cross steering tube. This could
cause component failure or steering system failure
resulting in severe personal injury or death.
W6001539
1 Cross Steering Tube
2 Tie Rod Threads Visible Entire Length of Slot
3 Cross Steering Tube Slot

33
Group 61 Volvo 5.7, 6.7 Ton Front Axle Service Procedures

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9
Grasp the ball socket with both hands, as close as
possible to the socket (no further than approximately 6
inches). Apply pressure vertically (up and down) in a
push/pull motion several times. Check for any movement
or looseness of any ball socket. Any movement (other
than rotational) greater than 3 mm (1/8 in) between any
linkage member and its attachment point, requires that
the ball socket be replaced.

10
Lubricate the ball sockets. For more information see
Group 1 for Preventive Maintenance and lubrication
intervals.

Frame
Front and rear wheels must track correctly. To accomplish
this, the front axle must be parallel to the rear axle and
at right angles to the center line of the chassis. For
more information, see Group 1 for wheel alignment
specifications.

Steering Knuckle
Wear can occur between the knuckle bushing and/or roller
bearing and kingpin. If, during inspection or adjustment, it
is determined that wear between the knuckle bushing
and/or roller bearing and kingpin is excessive, or proper
clearances cannot be obtained, the steering knuckle must
be overhauled. Excessive clearance affects steering and
increases tire wear. Repairs must be made by replacing
the kingpin, bushings or bearings as required.
The knuckle assemblies on the Volvo 5.7, 6.7 and 9 Ton
axles use presized bushings, so reaming the bushings
will not be necessary.

34
Group 61 Volvo 5.7, 6.7 Ton Front Axle Service Procedures

Axle Center Section

D
The axle must be without bends or twists. For
kingpin inclination, see Group 1 for wheel alignment
specifications. The axle straightness is checked with the
axle and knuckles removed from the chassis. No service
is required, or possible.

Front End Alignment

For information on wheel alignment specifications,
see Group 1. Total chassis alignment is the basis for
vehicle stability, ease of steering, improved tire life, and
satisfied drivers.

35
Group 61 Volvo 5.7, 6.7 Ton Front Axle Service Procedures

6010-06-02-01

D
Wheel Angles, Check-Measure (All)

Knuckle Stop Bold Adjustment (Turning Circle)

1
Drive the vehicle straight into the service bay and make
sure the front wheels are facing straight ahead.

2
Block the rear wheels to prevent the vehicle from moving.

3
Raise the front of the chassis.

4
Place turning angle plates under each front wheel,
centered below each front tire. Make sure the gauges on
both plates are set to zero.

5
Lower the front of the vehicle so that the front tires and
weight of the vehicle are resting on the turning plates.

6
Start the engine and let it run at idle.

7
Use the treadle valve to apply the service brakes.

Note: It is important that the service brakes be applied

during this procedure, to prevent the front wheels from
rotating while being turned.

8
Turn the steering wheel fully to the right until the knuckle
stop bolt contacts the axle.

9
Read the amount of turn in degrees on the gauge of
the right-hand turning angle plate.

10
Turn the steering wheel fully to the left until the knuckle
stop bolt contacts the axle.

36
Group 61 Volvo 5.7, 6.7 Ton Front Axle Service Procedures

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11
Read the amount of turn in degrees on the gauge of
the left-hand turning angle plate.

Turning angle may be changed per customer preference.

Turning angle is changed by adjusting the knuckle stop
bolts. Adjust the stop bolts as necessary until the desired
turning angle is achieved.
When the desired turning angle is obtained, verify that
there is a minimum of one inch (25.4 mm) of clearance
between the tire and chassis components, and a
minimum of 1/2 inch (12.7 mm) of clearance between any
movable steering and axle components and any other
chassis components. Additionally, knuckle stops must be
adjusted so that contact with the axle is made at least one
full thread before the steering gear bottoms.
W6001540
1 Axle Boss Note: After the knuckle stop bolts have been adjusted,
2 Steel Block adjust the power steering gear internal pressure
3 Stop Screw relief poppets. Steering gear relief poppets must be
adjusted so that at least 2±1mm clearance between the
axle/knuckle stops is maintained as pressure relief
occurs. Refer to TR 8145055 for more information.

37
Group 61 Volvo 5.7, 6.7 Ton Front Axle Service Procedures

6010-06-02-13

D
Curve Angles, One Axle, Checking
With camera

Kingpin Play
Upper Bearing Vertical Play
Lower Bushing Lateral Play
Before replacing kingpins, bushings/bearings on Volvo
front axles, kingpin play must first be checked with a dial
indicator to verify replacement of these components is
actually necessary. Kingpins, bushings and bearings
should be replaced only when vertical or lateral play
exceeds the specification. Kingpin lateral and vertical
play must be checked at each C and D inspection.
Procedures for measuring kingpin play are as follows:

Vertical Play
1
Place blocks at the rear wheels to prevent the vehicle
from moving.

2
Raise the front of the vehicle off the ground and support
on jackstands of adequate capacity.

DANGER
Do not work under a vehicle that is supported only on
a hydraulic jack, as a hydraulic jack could fail suddenly
and unexpectedly, resulting in severe personal injury
or death. Always use jackstands of adequate capacity
to support the weight of the vehicle.

38
Group 61 Volvo 5.7, 6.7 Ton Front Axle Service Procedures

D
3
Measure kingpin vertical play at the upper bearing
as follows:

Note: For the most accurate measurements, mount the

dial indicator on a surface of the axle beam that is as
flat as possible.
1 Position the tip of dial indicator J-7872, or equivalent,
against the upper or lower kingpin (knuckle) covers or
steering levers of the steering knuckle as shown in Fig.
1: Measuring Kingpin Upper Bearing Vertical Play
(Kingpin Cover), page 39 or Fig. 2: Measuring Kingpin
Upper Bearing Vertical Play (Steering Lever), page 39.
It is acceptable to position the dial indicator tip right
on top of the cover, if necessary.

W6001541

Fig. 1: Measuring Kingpin Upper Bearing Vertical Play

(Kingpin Cover)
2 Zero the dial indicator.

W6001542

Fig. 2: Measuring Kingpin Upper Bearing Vertical Play

(Steering Lever)

39
Group 61 Volvo 5.7, 6.7 Ton Front Axle Service Procedures

D
3 Pry the front tire up by placing a 2 x 4 inch block of
wood on the floor next to the front tire and apply
upward pressure by placing a large pry bar over the
wood block and under the tire. Push the pry bar down
to move the wheel assembly and knuckle while
observing the dial indicator.
Note: To ensure accurate measurements, do not allow
the steering knuckle to turn to the left or right while
moving the tire/wheel assembly. Having an assistant
apply the brakes will lock the wheel in position and aid in
preventing the steering knuckle from turning.

A reading of greater than 0.254 mm (0.010 in) on the dial

indicator indicates that the upper kingpin nut may be loose
or the upper bearing may be worn or damaged. If vertical
play is greater than 0.254 mm (0.010 in), remove the
upper cover and tighten the kingpin nut to specifications,
670–770 Nm (465–568 ft-lb). If vertical play is still not
within specifications, overhaul of the steering knuckle is
required. If examination reveals that the knuckle cannot
be overhauled, it must be replaced as an assembly.
W6001543

Lateral Play
1
Chock the rear wheels and apply the parking brakes.

2
Raise the front wheel and tire off the ground and place
proper jack stands under the axle to support the weight.

DANGER
Do not work under a vehicle that is supported only on
a hydraulic jack, as a hydraulic jack could fail suddenly
and unexpectedly, resulting in severe personal injury
or death. Always use jackstands of adequate capacity
to support the weight of the vehicle.

3
Note: For the most accurate measurements, mount the
dial indicator on a surface of the axle beam that is as
flat as possible.
Attach the dial indicator magnetic base to the bottom of
the front axle. Position the dial indicator on the lower
portion of the kingpin-knuckle, then "0" the dial.

W6001554

40
Group 61 Volvo 5.7, 6.7 Ton Front Axle Service Procedures

D
4
Note: To ensure accurate measurements, do not allow
the steering knuckle to turn to the left or right while
moving the tire/wheel assembly. Having an assistant
apply the brakes will lock the wheel in position and aid in
preventing the steering knuckle from turning.
Place a wooden block beside the tire, then using a pry
bar on top of the block and under the tire, pry up on tire
while another person reads the gauge (requires 2).

Note: Reading should be 0.381 mm (0.015 in) or less.

W6001543

5
Remove the dial indicator.

6
Raise the front axle, remove the jack stands, then
lower tire to the ground.

6010-05-03-08
Curve Angles, One Axle, Adjustment
With camera

1
Apply the parking brake and chock rear wheels.

2
Place a jack under the center of the front axle, jack tires
off the floor, position proper jack stands under axle on
each side, then lower axle on to stands.

3
Remove the wheel and tire.

4
Back off on slack adjuster to allow clearance for brake
drum to be removed.

5
Remove the brake drum, using a drum dolly or hoist.

W5001546

41
Group 61 Volvo 5.7, 6.7 Ton Front Axle Service Procedures

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6
Remove the ABS wheel sensor.

W5001547

7
Place a wooden block on top of a jack stand and place
underneath a wheel stud to lock the hub to allow the
hubcap to be removed

8
After loosening hubcap, remove jack stand from under
wheel stud.

W6001545
1 Tool J45996
2 Jackstand with Wood Block

9
Remove the snap ring and locking plate from spindle.

W6001546

42
Group 61 Volvo 5.7, 6.7 Ton Front Axle Service Procedures

D
10

W6001547 Remove the spindle nut and "D" washer.

W6001548

11
Disconnect the brake air hose at brake chamber, then
remove the hub from spindle.

W7001387

12
Remove the brake shoe backing plate assembly.

W7001388

43
Group 61 Volvo 5.7, 6.7 Ton Front Axle Service Procedures

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13
Remove the tie rod ball socket from spindle.

W6001550

14
Remove the steering assist cylinder ball socket.

15
Remove the grease fittings from the top kingpin cover.

16
Remove the top kingpin cover.

W6001552

17
Remove the bottom kingpin cover.

W6001554

18
Remove the kingpin shaft nut.

44
Group 61 Volvo 5.7, 6.7 Ton Front Axle Service Procedures

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19
Install the kingpin removal tool and turn tool until it
bottoms on kingpin.

Note: There will still be space between the tool and

upper bearing.

W6001556

20
Use a sledge hammer to drive down on the end of the
tool to loosen kingpin.

21
Remove the tool from the kingpin.

22
Using a hammer and a brass punch, drive the kingpin and
lower seal out the bottom side of knuckle.

W6001559

23
Remove the knuckle from the axle.

24
Remove the bearing cone from the upper side of knuckle
using a hammer and brass punch.

25
Remove the nylon bushing from the lower side of the
knuckle using a hammer and punch.

W6001560

45
Group 61 Volvo 5.7, 6.7 Ton Front Axle Service Procedures

D
26
Remove the upper bearing cup and seal using a hammer
and a drift punch.

27
Measure the bearing seat using a micrometer.

Note: Should be 0.392-0.394 mm (0.015–0.016 in)

0.392-0.394 mm (0.015–0.016 in)

W6001561

28
Install a new lower bushing; drive bushing down until
shoulder of tool rests on surface of the knuckle.

W6001562
1 Tool J45943
2 Lower Bushing

29
Apply a layer of grease to the underneath side of upper
bearing bore.

W6001564

30
Clean all grease and dirt from axle eye and kingpin using
proper solvent and cloth.

46
Group 61 Volvo 5.7, 6.7 Ton Front Axle Service Procedures

D
31
Position the lower seal, nylon insert facing down.

W6001565
1 Seal Nylon Insert (Must face down)
2 Lower Seal
3 Positioning Lower Seal

32
Position the knuckle assembly on the axle. Make sure
that the lower seal stays in position. Insert kingpin by
hand aligning pin with seal and axle eye. Push up firmly.

Note: Pin should stay in place.

33
Position a bottle jack under kingpin. Lift up until truck is
supported by the jack.

W6001569

34
Using a sledge hammer, strike down on axle directly
behind the knuckle. This will wedge the pin into the
taper in axle eye.

47
Group 61 Volvo 5.7, 6.7 Ton Front Axle Service Procedures

D
35
Pack upper bearing with grease, then assemble bearing,
cup and seal.

W6001570
1 Upper Bearing Seal
2 Upper Bearing Cup
3 Upper Bearing Cone

36
Install the bearing assembly over kingpin, then, using a
suitable bearing driver, tap bearing down on kingpin until
shaft is out enough to install kingpin nut.

W6001571

37
Install the kingpin nut and torque to 200-300 Nm
(148-221 ft-lb)

200-300 Nm (148-221 ft-lb)

38
Remove the bottle jack from under the kingpin and pivot
knuckle from side to side to insure it will move freely.

39
Retorque kingpin nut to 670-770 Nm (465-568 ft-lb)

670-770 Nm (465-568 ft-lb)

48
Group 61 Volvo 5.7, 6.7 Ton Front Axle Service Procedures

D
40
Position a magnetic stand on the steering arm and locate
the dial indicator on the top of the kingpin. Check end play.

W6001573
1 Tool J7872 Magnetic Base Dial Indicator
2 Kingpin Nut Top Surface

41
Install a new O-ring on the top kingpin cover. Install cover
and torque to 130-170 Nm (111-125 ft-lb).

130-170 Nm (111-125 ft-lb).

42
Install grease fittings in top cover.

43
Install a new O-ring on the lower kingpin cover. Install
cover and torque to 130-170 Nm (111-125 ft-lb).

130-170 Nm (111-125 ft-lb).

44
Apply grease to both top and bottom grease fittings on
knuckle, moving knuckle from side to side until grease
purges past upper and lower seals.

45
Connect the tie rod to the lower steering arm and torque
to 200 Nm (148 ft-lb). Install new cotter pin.

Note: If cotter pin will not line up, turn to next slot

200 Nm (148 ft-lb)

46
Install the steering assist cylinder to upper steering arm
and torque to 200 Nm (148 ft-lb). Install new cotter pin.

Note: If cotter pin will not line up, turn to next slot.

200 Nm (148 ft-lb)

47
Secure the brake assembly, then with proper lifting device
positioned on knuckle, align and start all mounting bolts.

49
Group 61 Volvo 5.7, 6.7 Ton Front Axle Service Procedures

D
48
Secure all mounting bolts, alternating from side to side.
Torque to 205-245 Nm (151-181 ft-lb).

205-245 Nm (151-181 ft-lb)

49
Apply a light coat of grease to the spindle.

50
Install a new O-ring on the back of the hub.

W6001579

51
Position hub on spindle. Install the "D" washer and
spindle nut (hand tighten only).

52
Rotate hub approximately 20 revolutions, then torque hub
nut to 900-1100 Nm (664-811 ft-lb).

900-1100 Nm (664-811 ft-lb)

53
Position the lock plate over the hub nut. Rotate until
lock fits over nut and aligns with tab on "D" washer,
then install the snap ring.

54
Install a new O-ring on the hubcap. Coat O-ring with
grease, install the hubcap and torque to 215-285 Nm
(159-210 ft-lb)
Note: Place a wooden block on top of a jack stand
and place underneath a wheel stud to prevent hub
from turning.

215-285 Nm (159-210 ft-lb)

55
Apply “never seize” to the ABS sensor retaining clip.
Install sensor and connect "P" clamp, securing sensor
harness to backing plate.

56
Connect and secure air hose to brake chamber.

57
With proper lifting device, position brake drum over
wheel studs.

50
Group 61 Volvo 5.7, 6.7 Ton Front Axle Service Procedures

D
58
Using a wheel dolly, install and secure the wheel and tire.

59
Raise front axle and remove jack stands. Lower tires to
ground and remove wheel chocks.

51
 D

52
 Operation Numbers

D
6010-06-02-03 Front End Wear, Check ............................................................................................................................ 29
6010-06-02-01 Wheel Angles, Check-Measure (All) ........................................................................................................ 36

6010-06-02-13 Curve Angles, One Axle, Checking .......................................................................................................... 38

6010-05-03-08 Curve Angles, One Axle, Adjustment ....................................................................................................... 41

 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

PV776-20176980 (1000) 6.2006 © Volvo Trucks North America, Inc., 2006